Apparatus for continuous high-speed 3D printing

Patent metadata

Field	Value
Publication number	US-11279084-B2
Application number	US-201816237464-A
Country	US
Kind code	B2
Filing date	Dec 31, 2018
Priority date	Dec 31, 2018
Publication date	Mar 22, 2022
Grant date	Mar 22, 2022

Abstract

A method for providing high-speed three dimensional (3D) printing is provided. The method includes producing at least one three dimensional (3D) printed part. Producing the 3D part includes continuously constructing to extend outwardly a diameter of a rotating cylindrical core via continuous deposition of a layer, and defining a first pattern in the continuously deposited layer corresponding to a cross-section of the at least one 3D printed part.

First claim

What is claimed is:

1. A printing system for producing at least one three dimensional (3D) printed part, comprising:
a deposition system configured to continuously deposit a layer onto a cylinder to outwardly extend a diameter of the cylinder, wherein the layer comprises a first pattern, wherein the first pattern defines one or more cut-lines to enable removal of a plurality of parts including the at least one 3D printed part from the cylinder;
a rotating system configured to rotate the cylinder; and
a control system configured to synchronize the deposition system with the cylinder.

2. The printing system of claim 1 , wherein the deposition system comprises a first subsystem configured to move radially with respect to the cylinder to continuously deposit a first portion of the layer on a curved outer surface of the rotating cylinder.

3. The printing system of claim 2 , wherein the deposition system comprises a second subsystem configured to move radially with respect to the diameter of the cylinder to deposit a second portion of the layer on the curved outer surface of the rotating cylinder.

4. The printing system of claim 3 , wherein the first portion comprises a first material and wherein the second portion comprises a second material.

5. The printing system of claim 4 , wherein the rotating system comprises a support plate, wherein an axis of rotation of the cylinder is perpendicular to the support plate and the axis is oriented parallel to the direction of gravity.

6. The printing system of claim 1 , wherein the deposition system uses a jetting process to continuously deposit the first pattern onto the cylinder and wherein the jetting process is performed using one or more of a piezoelectric based print-head, a thermal based print-head, and an aerosol spray head.

7. The printing system of claim 1 , wherein the deposition system comprises a first subsystem configured to continuously deposit an active material to be 3D printed and a second subsystem configured to continuously deposit a support material.

8. The printing system of claim 1 , wherein the deposition system comprises a first subsystem configured to a continuously deposit an active material to be 3D printed and a second subsystem configured to continuously deposit at least one of an anti-sintering material and a de-binding agent.

9. The printing system of claim 1 , further comprising a sintering subsystem that includes a heating element.

10. The printing system of claim 1 , wherein the printing system is configured to decompose a target construction of the at least one 3D printed part into concentrically cylindrical and spiral layers.

11. The printing system of claim 1 , further comprising an optical device, wherein the first pattern is defined via the optical device.

12. The printing system of claim 1 , wherein the layer comprises a second pattern and wherein the second pattern does not correspond to a cross-section of the at least one 3D printed part.

13. The printing system of claim 1 , wherein the deposition system comprises an intermediate transfer belt and wherein an axis of rotation of the rotating cylinder is dynamically positioned to maintain the transfer of the layer between the intermediate transfer belt and an outer curved surface of the rotating cylinder.

14. The printing system of claim 1 , wherein the deposition system comprises a plurality of subsystems, wherein the layer comprises multiple patterns, and wherein the plurality of subsystems is configured to:
deposit multiple portions of the layer on the curved outer surface of the rotating cylinder as a diameter of the rotating cylinder grows outward, based on the multiple patterns, wherein at least one portion of the multiple portions comprises a different material than at least one other portion of the multiple portions.

15. The printing system of claim 11 , wherein the first pattern is defined in the continuously deposited layer by the optical device.

16. The printing system of claim 15 , wherein the optical device defines the first pattern by projecting patterned light of wavelength between 200 nanometers to 10 micrometers onto the continuously deposited layer.

17. The printing system of claim 15 , wherein the optical device defines the first pattern through an oxygen permeable membrane.

18. The printing system of claim 12 , wherein the second material comprises at least one of: an anti-sintering agent, and a de-binding agent.

Assignees

• Xerox Corp
• Palo Alto Res Ct Inc

Inventors

• Pattekar Ashish V
• Jackson Warren
• Plochowietz Anne
• Lu Jengping
• Kalb Jamie
• Chua Christopher L
• Moorlag Carolyn
• Beh Eugene

Classifications

• B33Y30/00

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

• B29C64/209

  Heads; Nozzles · CPC title

• B29C64/245

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

• B33Y40/00

  Auxiliary operations or equipment, e.g. for material handling · CPC title

• B29C64/386

  Data acquisition or data processing for additive manufacturing · CPC title