Three-dimensional printer

Patent metadata

Field	Value
Publication number	US-11072088-B2
Application number	US-201615765088-A
Country	US
Kind code	B2
Filing date	Jan 29, 2016
Priority date	Jan 29, 2016
Publication date	Jul 27, 2021
Grant date	Jul 27, 2021

Abstract

According to an example, a three-dimensional (3D) printer may include a spreader to spread build material granules into a layer on a build area platform, a pressing die positioned above the layer of spread build material granules, in which the pressing die is to apply pressure onto the layer of build material granules to fragment the build material granules into primary particles to increase the density of the layer of build material granules, and a printhead to selectively deposit a fusing agent between the primary particles of the spread layer of build material granules.

First claim

What is claimed is:

1. A three-dimensional (3D) printer comprising:
a spreader to spread build material granules into a layer on a build area platform;
a pressing die positioned above the layer of spread build material granules;
a controller to operate the pressing die, wherein the controller is programmed to control the pressing die to apply pressure onto the layer of build material granules sufficient to fragment a majority of the build material granules into primary particles to increase the density of the layer of build material granules; and
a printhead to selectively deposit a fusing agent between the primary particles of the spread layer of build material granules.

2. The 3D printer according to claim 1 , wherein the controller is to control the build area platform, the spreader, and the pressing die to iteratively form multiple layers of build material granules which are spread by the spreader, pressed by the pressing die, and have received the deposited fusing agent.

3. The 3D printer according to claim 1 , further comprising:
a heater to apply heat at a first temperature to the multiple layers of build material granules to cause the primary particles upon which the fusing agent has been deposited to have a higher level of bonding with each other as compared to the primary particles upon which the fusing agent has not been deposited.

4. The 3D printer according to claim 1 , wherein the build material granules comprise ceramic build material granules and wherein the pressing die is to apply a sufficient level of pressure to fragment a majority of the ceramic build material granules into primary ceramic particles.

5. A method comprising:
a) spreading build material granules into a layer on a build area platform;
b) applying pressure onto the layer of spread build material granules to fragment the build material granules into primary particles to increase the density of the layer of build material granules; and
c) depositing a fusing agent into selected areas of the layer of spread build material granules, wherein the fusing agent is to facilitate binding of the primary particles in the selected areas to each other.

6. The method according to claim 5 , further comprising:
repeating a)-c) until a green body formed of a predetermined number of layers of build material granules has been spread, pressed, and received the deposited fusing agent.

7. The method according to claim 6 , further comprising:
applying heat at a first temperature to the layers of build material granules to cause the primary particles upon which the fusing agent has been deposited to have a higher level of bonding with each other as compared to the primary particles upon which the fusing agent has not been deposited;
removing the primary particles that have not received the fusing agent from the primary particles that have received the fusing agent; and
applying heat at a second temperature to the primary particles that have received the fusing agent, wherein the second heat is to enable sintering and densification of the primary particles between which the fusing agent has been deposited.

8. The method according to claim 6 , further comprising:
lowering the build area platform and supplying additional build material granules between successive performances of a) through c).

9. The method according to claim 5 , further comprising:
performing c) prior to performing b).

10. The method according to claim 5 , wherein spreading the layer of build material granules further comprises spreading a layer of ceramic build material granules onto the build area platform.

11. The method according to claim 10 , wherein applying pressure onto the layer of spread build material granules further comprises causing a pressing die having a flat surface to be pressed onto a top section of the layer of ceramic build material granules such that the layer of ceramic build material granules receives compressive force between the pressing die and the build area platform.

12. The method according to claim 11 , wherein causing the pressing die to be pressed onto the top section of the layer of ceramic build material granules further comprises causing the pressing die to be pressed with a sufficient level of force to cause a majority of the ceramic build material granules in the layer of ceramic build material granules to be fragmented.

13. The method according to claim 5 , wherein depositing the fusing agent further comprises depositing the fusing agent via an inkjet delivery mechanism.

14. The method according to claim 5 , wherein the build material granules have a size of 10 μm or more and applying the pressure to fragment the build material granules results in primary particles of 0.5 μm or less that have been fragmented from the granules.

15. The method according to claim 5 , wherein the build material granules comprise primary ceramic particles and a thermally-decomposable organic binder, the method further comprising:
repeatedly spreading build material, applying the pressure and depositing the fusing agent to selected areas to form a cake that comprises multiple layers of build material, some of the build material treated with fusing agent and a remainder of the build material not receiving fusing agent;
heating the cake to remove the thermally-decomposable organic binder from the cake; and
removing build material from the cake that has not received the fusing agent.

16. The method according to claim 15 , wherein heating the cake is performed so as to form bonds between the primary particles upon which the fusing agent has been deposited as well as removing the organic binder.

17. The method according to claim 15 , further comprising sintering remaining build material that received fusing agent in a furnace.

18. The method according to claim 15 , where removing the build material from the cake that has not received the fusing agent comprises sandblasting the cake to remove the build material that has not received the fusing agent.

19. The method according to claim 15 , where removing the build material from the cake that has not received the fusing agent comprises applying mechanical vibration to the cake to remove the build material that has not received the fusing agent.

20. A management apparatus comprising:
a controller; and
machine readable instructions that are to cause the controller to:
control a spreader to spread ceramic build material granules into a layer onto a build area platform;
control a pressing die to apply a sufficient level of pressure onto the layer of ceramic build material granules to cause a majority of the ceramic build material granules to be fragmented and thereby increase a density of the layer of ceramic build material granules; and
control a printhead to deposit a fusing agent at predetermined locations between the crushed ceramic build material granules.

21. The management apparatus according to claim 20 , wherein the machine readable instructions are further to cause the controller to:
one of:
control the pressing die to apply pressure onto the layer of ceramic build material granules prior to control of the printhead to deposit the fusing agent; and
control the printhead to deposit the fusing agent onto the layer of ceramic build material granules prior to control the pressing die to apply pressure onto the layer of ceramic build material granules.

Assignees

• Hewlett Packard Development Co

Inventors

• Monroe Michael G
• Kasperchik Vladek
• Kornilovich Pavel
• Champion David A

Classifications

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B28B11/243

  Setting, e.g. drying, dehydrating or firing ceramic articles (B28B11/242 takes precedence) · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B28B1/001 Primary

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B29C64/205

  Means for applying layers · CPC title