Apparatuses, systems and methods for three-dimensional printing

Patent metadata

Field	Value
Publication number	US-10507549-B2
Application number	US-201715436558-A
Country	US
Kind code	B2
Filing date	Feb 17, 2017
Priority date	Jun 20, 2014
Publication date	Dec 17, 2019
Grant date	Dec 17, 2019

Abstract

The present disclosure provides three-dimensional (3D) objects, 3D printing processes, as well as methods, apparatuses and systems for the production of a 3D object. Methods, apparatuses and systems of the present disclosure may reduce or eliminate the need for auxiliary supports. The present disclosure provides three dimensional (3D) objects printed utilizing the printing processes, methods, apparatuses and systems described herein.

First claim

What is claimed is:

1. A method for printing a metallic three-dimensional object, comprising:
(a) receiving a request to generate the metallic three-dimensional object;
(b) printing the metallic three-dimensional object layerwise according to a model of the metallic three-dimensional object, which printing comprises utilizing a dispenser, wherein the metallic three-dimensional object comprises a material having at least one member selected from the group consisting of an elemental metal, and a metal alloy; and
(c) providing the metallic three-dimensional object for delivery to a user without trimming the metallic three-dimensional object, wherein the metallic three-dimensional object deviates from the model of the metallic three-dimensional object by at most about 100 micrometers plus a fundamental length scale of the metallic three-dimensional object divided by 2500.

2. The method of claim 1 , wherein printing the metallic three-dimensional object is performed without iterative printing and/or without corrective printing.

3. The method of claim 1 , wherein the metallic three-dimensional object comprises a plurality of layers, wherein the layers of the metallic three-dimensional object have a radius of curvature of at least 5 centimeters.

4. The method of claim 3 , wherein the metallic three-dimensional object comprises a plurality of layers, wherein one or more layers of the plurality of layers of the metallic three-dimensional object have a radius of curvature of at least 50 centimeters.

5. The method of claim 1 , wherein the metallic three-dimensional object comprises a surface having an arithmetic average of roughness profile (Ra) of at most 200 micrometers.

6. The method of claim 1 , wherein the metallic three-dimensional object comprises a cavity or a hanging plane.

7. The method of claim 1 , wherein the metallic three-dimensional object comprises at least one layer of hardened material, wherein the metallic three-dimensional object comprises a surface that faces a platform above which the metallic three-dimensional object is disposed during printing, and wherein during printing, an acute angle between a straight line on the surface of the metallic three-dimensional object and a direction normal to an average layering plane (N) of the at least one layer of hardened material, is from about 45 degrees to 90 degrees.

8. The method of claim 7 , wherein, with X and Y being points on the surface of the metallic three-dimensional object, (i) the surface of the metallic three-dimensional object that intersects a sphere of radius XY at positions X and Y is devoid of an auxiliary support feature, and (ii) X and Y are spaced apart by at least about two (2) millimeters.

9. The method of claim 1 , wherein in (c), the metallic three-dimensional object is provided for delivery to the user without polishing of the metallic three-dimensional object.

10. The method of claim 1 , further comprising receiving an item of value from the user in exchange for the metallic three-dimensional object.

11. The method of claim 1 , wherein printing the metallic three-dimensional object comprises utilizing an energy beam.

12. The method of claim 1 , wherein during printing, the metallic three-dimensional object is devoid of auxiliary support.

13. The method of claim 1 , wherein printing the metallic three-dimensional object is performed without iterative printing.

14. The method of claim 1 , wherein the user is a customer.

15. The method of claim 1 , wherein the metallic three-dimensional object comprises a cavity.

16. The method of claim 1 , wherein printing the metallic three-dimensional object layer wise comprises use of powder three-dimensional printing.

17. The method of claim 16 , wherein the powder three-dimensional printing comprises using a powder bed that is supported by a platform.

18. The method of claim 17 , wherein the powder three-dimensional printing comprises fusing a portion of powder material that forms the powder bed to print the metallic three-dimensional object.

19. The method of claim 18 , wherein fusing comprises melting, sintering, or bonding.

20. The method of claim 19 , wherein melting comprises entirely transforming powder material to a liquid state.

Assignees

• Velo3D Inc

Inventors

• Buller Benyamin
• Milshtein Erel
• Chua Thai Cheng

Classifications

• B29C64/35

  Cleaning · CPC title

• B29C64/214

  Doctor blades · CPC title

• B29C64/268

  using laser beams; using electron beams [EB] · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/245

  Platforms or substrates (support structures intended to be sacrificed after manufacture B29C64/40) · CPC title