Techniques for mixing in additive fabrication and related systems and methods

Patent metadata

Field	Value
Publication number	US-10987873-B2
Application number	US-202016817522-A
Country	US
Kind code	B2
Filing date	Mar 12, 2020
Priority date	Mar 15, 2019
Publication date	Apr 27, 2021
Grant date	Apr 27, 2021

Abstract

According to some aspects, a mixer for detection and/or removal of material in an undesired location of an additive fabrication device is provided. For instance, in an inverse stereolithography device, liquid photopolymer may adhere and cure or partially cure to a surface of the additive fabrication device in a location that may interfere with the additive fabrication process and/or cause the additive fabrication process to be unsuccessful. The mixer may be coupled to a movable structure within the additive fabrication device so that the mixer, when coupled to the movable structure, may be moved along at least one axis within the additive fabrication device. The mixer may be configured to detect and/or remove undesired material from a surface within the additive fabrication device.

First claim

What is claimed is:

1. An additive fabrication device configured to form layers of solid material on a build platform, the additive fabrication device comprising:
a container;
a mixer disposed within the container and configured to move along at least a first axis;
a sensor configured to produce sensor data indicative of a state of the mixer;
at least one processor; and
at least one computer readable medium comprising instructions that, when executed by the at least one processor:
operate one or more actuators to move the mixer along the first axis; and
detect a failure of an additive fabrication process based at least in part on the sensor data produced by the sensor during movement of the mixer along the first axis.

2. The additive fabrication device of claim 1 , wherein the mixer comprises an elongated body with a first end and a second end and at least one edge member extending along the elongated body from the first end to the second end.

3. The additive fabrication device of claim 2 , wherein the at least one edge member is configured to remove debris from a surface proximate to the edge member.

4. The additive fabrication device of claim 3 , wherein the at least one edge member is wedge-shaped.

5. The additive fabrication device of claim 3 , wherein the instructions, when executed by the at least one processor, further comprise, upon detection of the failure, moving the mixer along the first axis to remove the detected failure.

6. The additive fabrication device of claim 1 , wherein the instructions, when executed by the at least one processor, further comprise alerting the user upon detection of the failure.

7. The additive fabrication device of claim 1 , wherein the sensor is a force sensor configured to measure forces applied to the mixer.

8. The additive fabrication device of claim 7 , wherein the failure comprises material adhered to a surface of the container, and wherein detecting the failure comprises detecting an increase in force measured by the sensor during movement of the mixer along the first axis.

9. The additive fabrication device of claim 1 , further comprising a movable structure disposed below the container, the movable structure being coupled to the mixer and the one or more actuators, wherein operating the one or more actuators causes motion of the mixer along the first axis as a result of said coupling to the movable structure.

10. The additive fabrication device of claim 1 , wherein the sensor comprises a first sensor and a second sensor, each being configured to produce sensor data indicative of a state of the mixer.

11. An additive fabrication device configured to form layers of solid material on a build platform, the additive fabrication device comprising:
a build platform;
a mixer disposed below the build platform and configured to move along a first axis;
at least one sensor configured to produce sensor data indicative of a state of the mixer;
at least one processor; and
at least one computer readable medium comprising instructions that, when executed by the at least one processor:
lower the build platform iteratively whilst operating one or more actuators to move the mixer along the first axis underneath the build platform until the build platform contacts the mixer; and
detect a failure of an additive fabrication process based at least in part on the sensor data produced by the sensor during movement of the mixer along the first axis.

12. The additive fabrication device of claim 11 , wherein the mixer comprises an elongated body with a first end and a second end and at least one edge member extending along the elongated body from the first end to the second end.

13. The additive fabrication device of claim 12 , wherein the at least one edge member is configured to remove debris from a surface proximate to the edge member.

14. The additive fabrication device of claim 13 , wherein the at least one edge member is wedge-shaped.

15. The additive fabrication device of claim 11 , wherein the instructions, when executed by the at least one processor, further comprise moving the mixer along the first axis while the build platform is in contact with the mixer to remove the detected failure.

16. The additive fabrication device of claim 11 , wherein the instructions, when executed by the at least one processor, further comprise alerting the user upon detection of the failure.

17. The additive fabrication device of claim 11 , wherein the sensor is a force sensor configured to measure forces applied to the mixer.

18. The additive fabrication device of claim 17 , wherein the failure comprises material adhered to the build platform, and wherein detecting the failure comprises detecting an increase in force measured by the sensor during movement of the mixer along the first axis.

19. The additive fabrication device of claim 11 , further comprising a movable structure disposed below the container, the movable structure being coupled to the mixer and the one or more actuators, wherein operating the one or more actuators causes motion of the mixer along the first axis as a result of said coupling to the movable structure.

20. The additive fabrication device of claim 1 , wherein the sensor comprises a first sensor and a second sensor, each being configured to produce sensor data indicative of a state of the mixer.

Assignees

• Formlabs Inc

Inventors

• Moldave Jack
• Bennedsen Sarah
• Reed Christian
• Oikonomopoulos Konstantinos
• Joachim Robert
• Hill Geoff
• Lobovsky Maxim

Classifications

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y40/10

  Pre-treatment · CPC title

• B29C64/393 Primary

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/314

  Preparation · CPC title

• B29C64/129 Primary

  characterised by the energy source therefor, e.g. by global irradiation combined with a mask · CPC title