Generating three-dimensional objects

Patent metadata

Field	Value
Publication number	US-10220564-B2
Application number	US-201415110754-A
Country	US
Kind code	B2
Filing date	Jan 31, 2014
Priority date	Jan 16, 2014
Publication date	Mar 5, 2019
Grant date	Mar 5, 2019

Abstract

A three-dimensional object may be generated. Energy may be applied to a layer of build material to cause a first portion of the layer to coalesce and solidify in a first pattern. A cooling agent may be selectively delivered on a second portion of the layer of the build material to reduce a temperature of the second portion in a second pattern, the first and second patterns being independent of each other.

First claim

The invention claimed is:

1. An apparatus for generating a three-dimensional object, the apparatus comprising:
an energy source to apply energy to a layer of build material to cause a first portion of the layer to coalesce and solidify;
a first agent distributor to selectively deliver a coalescing agent onto the first portion of the layer of build material;
a second agent distributor to selectively deliver a cooling agent onto a second portion of the layer of build material; and
a controller to:
control the energy source to apply energy to the layer to cause the first portion to coalesce and solidify;
control the first agent distributor to selectively deliver the coalescing agent to the first portion of the layer of build material in a first pattern; and
control the second agent distributor to selectively deliver the cooling agent onto the second portion of the layer in a second pattern, the first and second patterns being independent of each other;

wherein the selective delivery of the cooling agent in the second pattern includes selecting portions to deliver the cooling agent from portions of the build material where the coalescing agent is not delivered, and delivering the cooling agent to the selected portions;
and wherein the cooling agent delivered to portions of the build material where the coalescing agent is not delivered prevents the build material from coalescing in response to the application of energy.

2. The apparatus of claim 1 further comprising a temperature sensor to obtain temperature feedback representing a measured temperature distribution from the layer of build material prior to delivering the cooling agent, wherein the cooling agent is selectively delivered based on the measured temperature distribution.

3. The apparatus of claim 1 wherein the controller is to determine, prior to controlling the agent distributor to deliver the cooling agent, a temperature distribution of the layer of build material based on a thermal process model, wherein the controller is to control the agent distributor to selectively deliver the cooling agent based on the temperature distribution.

4. The apparatus of claim 1 wherein the controller is to determine, based on a temperature distribution of the build material prior to the selective delivery of the cooling agent, an amount of and location of the cooling agent to selectively deliver to achieve a target temperature distribution.

5. The apparatus of claim 1 wherein:
the first agent distributor is to selectively deliver additional coalescing agent onto a third portion of the layer; and
the controller is to control the first agent distributor to selectively deliver the coalescing agent onto the third portion of the layer to cause the third portion to warm when the energy is applied without causing coalescence of the third portion due to a combination of the additional coalescing agent and the build material.

6. The apparatus of claim 1 wherein the cooling agent comprises water.

7. The apparatus of claim 1 wherein the controller is to control the second agent distributor to selectively deliver the cooling agent before controlling the energy source to apply the energy.

8. The apparatus of claim 1 wherein the controller is to control the second agent distributor to selectively deliver the cooling agent after controlling the energy source to apply the energy.

9. A method of generating a three-dimensional object, the method comprising:
selectively delivering a coalescing agent on a first portion of the layer of the build material in a first pattern;
applying energy to a layer of delivered build material to cause the first portion of the layer to coalesce and solidify in the first pattern; and
selectively delivering a cooling agent on a second portion of the layer of the build material to reduce a temperature of the second portion in a second pattern derived from data representing a measured temperature distribution from the layer or representing a temperature distribution predicted by a thermal process model;
wherein the selective delivery of the cooling agent in the second pattern includes selecting portions to deliver the cooling agent from portions of the build material where the coalescing agent is not delivered and delivering the cooling agent to the selected portions;
and wherein the cooling agent delivered to portions of the build material where the coalescing agent is not delivered prevents the build material from coalescing in response to the application of energy.

10. The method of claim 9 further comprising obtaining temperature feedback representing the measured temperature distribution from the layer of build material prior to delivering the cooling agent.

11. The method of claim 9 further comprising determining, prior to delivering the cooling agent, a temperature distribution of the layer of build material based on the temperature distribution predicted by the thermal process model.

12. The method of claim 9 further comprising selectively delivering the cooling agent to control mechanical properties of the build material where coalescence is desired.

13. A method of generating a three-dimensional object, the method comprising:
delivering a layer of build material;
selectively depositing coalescing agent to a first portion of the layer;
applying energy to the layer to cause the first portion having the coalescing agent to coalesce and solidify in a first pattern; and
selectively delivering a cooling liquid to a second portion of the layer to reduce a temperature of a second portion of the build material in a second pattern based on data representing a location to which the cooling liquid is to be selectively delivered;
wherein the first and second patterns are independent of each other;
wherein the selective delivery of the cooling agent in the second pattern includes selecting portions to deliver the cooling agent from portions of the build material where the coalescing agent is not delivered and delivering the cooling agent to the selected portions;
and wherein the cooling agent delivered to portions of the build material where the coalescing agent is not delivered prevents the build material from coalescing in response to the application of energy.

14. The method of claim 13 wherein the cooling agent delivered to portions of the build material where the coalescing agent has been delivered reduces a temperature of the build material without preventing the build material from coalescing in response to the application of energy.

15. The apparatus of claim 1 wherein the cooling agent delivered to portions of the build material where the coalescing agent has been delivered reduces a temperature of the build material without preventing the build material from coalescing in response to the application of energy.

16. The method of claim 9 wherein the cooling agent delivered to portions of the build material where the coalescing agent has been delivered reduces a temperature of the build material without preventing the build material from coalescing in response to the application of energy.

Assignees

• Hewlett Packard Development Co

Inventors

• Nauka Krzysztof
• Comas Esteve
• De Pena Alejandro Manuel
• Tom Howard S
• Ng Hou T

Classifications

• B29C35/0805 Primary

  using electromagnetic radiation · CPC title

• B29C64/165 Primary

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B29C35/16

  Cooling {(cooling extruded material B29C48/911; cooling preforms for blow moulding B29C49/6427; cooling blown articles B29C49/66; cooling tyres during post cure inflation B29D30/0643)} · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B29C2035/1616

  using liquids · CPC title