Three-dimensional printing system and method of three-dimensional printing

Patent metadata

Field	Value
Publication number	US-11260449-B2
Application number	US-202016808285-A
Country	US
Kind code	B2
Filing date	Mar 3, 2020
Priority date	Mar 3, 2020
Publication date	Mar 1, 2022
Grant date	Mar 1, 2022

Abstract

A three-dimensional printing system includes a build platform comprising a build surface. The printing system also includes an enclosure system having a side portion extending entirely around the build surface, a top plate portion that abuts the side portion, and a bottom portion. The side portion, the top plate portion and the bottom portion form an enclosed space surrounding the build surface. The top plate portion is moveable so as to adjust a volume of the enclosed space. A 3D printer printhead is disposed adjacent to the enclosure system for depositing a print material onto the build surface. The printing system also includes a heating system for heating the enclosed space.

First claim

What is claimed is:

1. A three-dimensional printing system, the system comprising:
a build platform comprising a build surface;
an enclosure system having a side portion extending entirely around the build surface, a top plate portion that abuts the side portion, and a bottom portion, the side portion, the top plate portion and the bottom portion forming an enclosed space surrounding the build surface, the top plate portion being moveable so as to adjust a volume of the enclosed space, the bottom portion comprising a heat shield that extends from the build platform and abuts the side portion;
a 3D printer printhead disposed adjacent to the enclosure system for depositing a print material onto the build surface; and
a heating system for heating the enclosed space,
wherein the heat shield comprises two or more separate plates comprising a central opening, the plates being stacked vertically in a stack so that the opening of the plates align to form an orifice in the heat shield through which the build platform extends, each plate in the stack having a smaller dimension than the plate on which it is stacked so as to allow the orifice and the build platform to move together in any direction within an XY plane.

2. The system of claim 1 , wherein a position of the printhead and the top plate portion are both adjustable along a z-axis.

3. The system of claim 1 , further comprising a printhead mount plate positioned within a region of the top plate portion, the printhead being attached to the printhead mount plate.

4. The system of claim 1 , wherein the heating system comprises at least one heat source chosen from a radiant heating system, a conductive heating system and a convection heating system.

5. The system of claim 1 , wherein the heating system comprises a radiant heating system.

6. The system of claim 1 , wherein the heating system comprises a convection heating system.

7. The system of claim 1 , wherein the top plate portion comprises a seal disposed at the position where top plate portion abuts the side portion.

8. The system of claim 1 , wherein the plates are sized to avoid formation of gaps between the plates in an x or y direction of the XY plane, thereby forming a continuous shield surrounding the build platform.

9. The system of claim 1 , wherein the printhead is configured for ejecting drops of a conductive liquid print material onto the build platform.

10. The system of claim 9 , wherein the printhead comprises an electromagnetic coil for applying a DC pulse for ejecting the drops.

11. A method of three-dimensional printing, the method comprising:
enclosing a build surface of a build platform in an enclosure system, the enclosure system having a side portion extending entirely around the build surface, a top plate portion that abuts the side portion, and a bottom portion, the side portion, the top plate portion and the bottom portion forming an enclosed space surrounding the build surface, the top plate portion being moveable so as to adjust a volume of the enclosed space;
heating the build surface in the enclosed space;
adjusting the position of the build surface along an x-axis, a y-axis or both the x-axis and the y-axis,
during the adjusting of the position of the build surface, a heat shield moving within an XY plane, the heat shield comprising two or more separate plates comprising a central opening, the plates being stacked vertically in a stack so that the opening of the plates align to form an orifice in the heat shield through which the build platform extends, each plate in the stack having a smaller dimension than the plate on which it is stacked so as to allow the orifice and the build platform to move together in any direction within the XY plane; and
depositing a print material onto the build surface with a 3D printer printhead to form a 3D object.

12. The method of claim 11 , wherein depositing the print material comprises ejecting a first drop of a molten metal from the printhead so as to deposit the first drop on a preheated drop contact point at a first deposition temperature.

13. The method of claim 11 , further comprising adjusting the position of the top plate portion and the printhead along a z-axis.

14. The method of claim 11 , wherein the plates are sized to avoid formation of gaps between the plates in an x or y direction of the XY plane, thereby forming a continuous shield surrounding the build platform during the adjusting of the position of the build surface.

15. A three-dimensional printing system, the system comprising:
a build platform comprising a build surface;
an enclosure system having a side portion extending entirely around the build surface, a top plate portion that abuts the side portion, and a bottom portion, the side portion, the top plate portion and the bottom portion forming an enclosed space surrounding the build surface, the bottom portion comprising a heat shield that extends from the build platform and abuts the side portion;
a 3D printer printhead disposed adjacent to the enclosure system for depositing a print material onto the build surface; and
a heating system for heating the enclosed space,
wherein the heat shield comprises: a first plate and a second plate, the first plate comprising a first central opening and a first width dimension, the second plate comprising a second central opening and being disposed on the first plate, the second plate having a second width dimension that is smaller than the first width dimension, the first plate and the second plate being stacked vertically so that the first central opening and the second central opening align to form an orifice through which the build platform extends, the first plate and the second plate being slidable relative to each other so as to allow the orifice and the build platform to be moveable together in any direction within an XY plane when the first plate is held stationary.

16. The system of claim 15 , wherein the heat shield further comprises a third plate comprising a third central opening and being disposed on the second plate so that the third central opening aligns with the first central opening and the second central opening to form the orifice, the third plate having a width dimension that is smaller than the width dimension of the second plate, the third plate slidable relative to the first plate and the second plate.

17. The system of claim 16 , wherein the first plate, the second plate and the third plate comprise a material chosen from ceramics, metals, high temperature polymers and mixtures thereof.

18. The system of claim 16 , wherein the shield system includes one or more additional plates, each additional plate including a central opening, each additional plate having a width dimension that is smaller than the width dimension of the plate on which it is disposed.

19. The system of claim 16 , wherein the plates are sized to avoid formation of gaps between the plates in an x or y direction of the XY plane, thereby forming a continuous shield surrounding the orifice.

Assignees

• Xerox Corp

Inventors

• Herrmann Douglas K
• Ruiz Erwin
• Dergham Ali R
• Atwood Christopher D
• Knopp Daniel R
• Bryl Derek A
• Hoover Linn C

Classifications

• B22F2003/1053

  by induction · CPC title

• B22F3/003 Primary

  Apparatus, e.g. furnaces (in general F27B) · CPC title

• B22F3/14

  simultaneously · CPC title

• B22F12/38

  Housings, e.g. machine housings · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title