Forming microstructures in 3D printing by fusing and sintering using a fusing agent

Patent metadata

Field	Value
Publication number	US-11077612-B2
Application number	US-201616097822-A
Country	US
Kind code	B2
Filing date	Jul 20, 2016
Priority date	Jul 20, 2016
Publication date	Aug 3, 2021
Grant date	Aug 3, 2021

Abstract

In an example implementation, a method of printing a three-dimensional (3D) object includes, applying a layer of build powder onto a printing platform and depositing a deliberate micropattern of liquid agent onto the powder within a macropattern that defines a cross-section of a 3D object to be printed. The method includes forming a microstructure from the deliberate micropattern by applying fusing energy to the powder, the microstructure comprising fused areas and sintered areas between the fused areas.

First claim

What is claimed is:

1. A method of printing a three-dimensional (3D) object comprising:
receiving object data that represents a model of a 3D object;
modifying the object data to generate patterned object data;
from the patterned object data, generating print data to control a 3D printer to deposit a deliberate micropattern of liquid fusing agent onto a layer of build material within a macropattern that comprises a cross-section of a 3D object being printed, the deliberate micropattern comprising agent areas that have liquid fusing agent and gap areas that lack liquid fusing agent; and,
forming a deliberate microstructure that corresponds with the deliberate micropattern by applying fusing energy to simultaneously fully melt build material in the agent areas from heat generated in the agent areas by absorbing fusing energy with the fusing agent, while binding without fully melting, build material in the gap areas with indirect heat that disperses into the gap areas from the agent areas.

2. A method as in claim 1 , wherein modifying the object data comprises integrating the deliberate micropattern with the object data.

3. A method as in claim 1 , further comprising:
depositing a liquid colorant onto the layer of build material within the macropattern; and,
capturing the liquid colorant within the gap areas when forming the microstructure.

4. A method as in claim 3 , wherein:
depositing a deliberate micropattern of liquid fusing agent comprises depositing an infrared (IR) radiation-absorbing fusing agent; and,
applying fusing energy comprises applying IR radiation to heat build material according to the deliberate micropattern while not heating the liquid colorant.

5. A method as in claim 1 , wherein depositing a deliberate micropattern comprises depositing multiple different micropatterns onto the layer of build material at different areas within the macropattern.

6. A method as in claim 1 , wherein forming a microstructure comprises forming a microstructure on a layer of the 3D object selected from the group consisting of a surface layer of the 3D object, an inner layer of the 3D object, and combinations thereof.

7. A non-transitory machine-readable storage medium storing instructions that when executed by a processor of a three-dimensional (3D) printer cause the 3D printer to:
deposit a powder layer onto a printing platform;
form on the powder layer, a deliberate micropattern comprising fusible areas on which fusing agent is deposited separated by sinterable areas in between the fusible areas on which fusing agent is not deposited; and,
expose the powder layer to infrared radiation to simultaneously fully melt powder in the fusible areas with heat generated by the fusing agent absorbing infrared radiation and bind powder without fully melting powder in the sinterable areas into a microstructure with indirect heat that disperses into the sinterable areas from the fusible areas.

8. A storage medium as in claim 7 , wherein forming a deliberate micropattern comprises depositing fusing agent, the instructions further causing the 3D printer to deposit a colorant while depositing the fusing agent.

9. A storage medium as in claim 8 , wherein exposing the powder layer to infrared radiation comprises capturing the colorant within the sinterable areas.

10. A method of printing a three-dimensional (3D) object comprising:
applying a layer of build powder onto a printing platform;
depositing a deliberate micropattern of liquid fusing agent onto the powder within a macropattern that defines a cross-section of a 3D object to be printed; and,
forming simultaneously, sintered areas and fused areas of a microstructure from the deliberate micropattern by applying fusing energy to the powder, the microstructure comprising fused areas of the powder that are solidified after fully melting from heat generated by the absorption of fusing energy by the fusing agent and sintered areas of the powder between the fused areas that are bound together without fully melting from indirect heat that disperses into the sintered areas from the fused areas.

11. A method as in claim 10 , wherein depositing a deliberate micropattern of liquid agent comprises:
forming liquid agent areas on which liquid fusing agent is deposited; and,
forming in between the liquid agent areas, gap areas that are devoid of liquid fusing agent.

12. A method as in claim 11 , wherein:
depositing liquid fusing agent comprises depositing an infrared (IR) radiation-absorbing agent; and,
applying fusing energy comprises applying IR radiation.

13. A method as in claim 10 , further comprising:
depositing a liquid colorant onto the powder within the cross-section; and,
capturing the colorant within the sintered areas.

14. A method as in claim 13 , wherein depositing liquid fusing agent and liquid colorant comprises scanning a liquid agent dispenser over the printing platform and depositing the liquid fusing agent and liquid colorant from the liquid agent dispenser in a same scanning motion.

15. A method as in claim 10 , wherein forming a microstructure comprises forming a lattice structure in which the fused areas and the sintered areas are evenly spaced from one another in a regular pattern.

Assignees

• Hewlett Packard Development Co

Inventors

• Lebron Hector
• Wright Jake
• Kabalnov Alexey S

Classifications

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B29C67/00

  Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 · CPC title

• B33Y50/00

  Data acquisition or data processing for additive manufacturing · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title