Debinding of 3D objects

Patent metadata

Field	Value
Publication number	US-11413684-B2
Application number	US-201916561628-A
Country	US
Kind code	B2
Filing date	Sep 5, 2019
Priority date	Dec 15, 2017
Publication date	Aug 16, 2022
Grant date	Aug 16, 2022

Abstract

3D-printed parts may include binding agents to be removed following an additive manufacturing process. A debinding process removes the binding agents by immersing the part in a solvent bath causing chemical dissolution of the binding agents. The time of exposure of the 3D-printed part to the solvent is determined based on the geometry of the part, wherein the geometry is applied to predict the diffusion of the solvent through the 3D-printed part. The 3D-printed part is then immersed in the solvent bath to remove the binding agent, and is removed from the solvent bath after the time of exposure.

First claim

What is claimed is:

1. A method of determining a debinding time of a printed part or a model of a part, the method comprising:
receiving data about the printed part or the model of the part;
determining an effective thickness of the printed part or the model of the part by defining a series of shells within the printed part or the model of the part;
calculating a debinding time based on the effective thickness; and
debinding the printed part for the debinding time.

2. The method of claim 1 , wherein defining the series of shells within the printed part or the model of the part comprises:
producing a geometry of a shell corresponding to a displacement of an exterior surface of the printed part or the model of the part inward along a local normal vector of the exterior surface relative to a geometry of the printed part or the model of the part or any preceding reduced part.

3. The method of claim 2 , further comprising:
repeating the steps of defining the series of shells within the printed part or the model of the part until an innermost reduced part, having either no interior volume or an interior volume below a threshold, is produced.

4. The method of claim 3 , further comprising
calculating a distance from an exterior surface of the part or the model of the part to an exterior surface of one of the shells; and
determining the effective thickness based on the distance.

5. The method of claim 4 , wherein calculating the distance from the exterior surface of the part or the model of the part to an exterior surface of one of the shells includes calculating distances from the exterior surface of the part or the model of the part to exterior surfaces of each of the reduced parts.

6. The method of claim 5 , wherein a maximum of the calculated distances is equal to the effective thickness of the printed part or the model of the part.

7. The method of claim 5 , wherein the distance from the innermost shell to the exterior surface of the printed part or the model of the part is a deepest point of the part or the model of the part, and
wherein a distance from the deepest point to the exterior surface of the part or the model of the part is equal to the effective thickness of the printed part or the model of the part.

8. The method of claim 3 , wherein intersecting or missing portions of the one or more shells are trimmed from the shell.

9. The method of claim 3 , wherein, if a shell has a discontinuous geometry with two or more shapes that are not connected, the method includes repeating the steps of defining the series of shells within the printed part or the model of the part for the two or more shapes.

10. The method of claim 9 , wherein the steps of defining the series of shells within the printed part or the model of the part for the two or more shapes are repeated until only one shape having an internal volume remains, and then further reducing the remaining shape with the internal volume until the remaining shape has no internal volume.

11. The method of claim 9 , wherein the steps of defining the series of shells within the printed part or the model of the part for the two or more shapes are repeated until each of the two or more shapes are reduced to having no internal volume in a same cycle.

12. The method of claim 1 , wherein calculating the debinding time based on the effective thickness includes raising the effective thickness to an exponent greater than or equal to 1 and less than or equal to 2.4.

13. The method of claim 1 , wherein the printed part or the model of the part includes a plurality of printed parts or a plurality of models of parts, and wherein the effective thickness is determined for each of the plurality of parts or each of the plurality of models of parts, and wherein the debinding time is based on a greatest effective thickness.

14. A system for debinding a printed part, comprising:
a chamber configured to receive the printed part;
a storage chamber fluidly connected to the chamber and configured to store a debinding solution; and
a controller configured to calculate a debinding time for the printed part or a model of a part, wherein calculating the debinding time includes:
determining an effective thickness of the printed part or the model of the part by defining a series of shells within the printed part or the model of the part, wherein the effective thickness is a distance from an innermost shell, having no internal volume or an internal volume below a threshold, to an exterior surface of the printed part or the model of the part; and
calculating a debinding time based on the effective thickness.

15. The system of claim 14 , wherein defining the series of reduced parts within the printed part or the model of the part comprises:
producing a geometry corresponding to a displacement of the exterior surface inward along a local normal vector of the exterior surface relative to a geometry of a preceding reduced part; and
repeating the steps of defining the series of shells within the printed part or the model of the part until the innermost reduced part shell, having either no interior volume or an interior volume below a threshold, is produced.

16. The system of claim 14 , wherein the printed part or the model of the part includes a plurality of printed parts or a plurality of models of parts, and wherein the controller is configured to determine the debinding time by determining a longest debinding time of the debinding times for each of the printed parts or the models of the parts.

17. The system of claim 14 , further comprising:
a user interface, wherein the controller is configured to signal the user interface to display one or more indications of the debinding.

18. A non-transitory computer readable medium for use on a computer system containing computer-executable programming instructions for performing a method of determining a debinding time of a printed part or a model of a part, the method comprising:
receiving data about the printed part or the model of the part;
determining an effective thickness of the printed part or the model of the part by defining a series of shells within the printed part or the model of the part, wherein the effective thickness is equal to a distance from an innermost reduced part, having no internal volume or an internal volume below a threshold, to an exterior surface of the printed part or the model of the part; and
calculating a debinding time based on the effective thickness.

19. The non-transitory computer readable medium of claim 18 , wherein defining the series of shells within the printed part or the model of the part comprises:
producing a geometry corresponding to a displacement of the exterior surface inward along a local normal vector of the exterior surface relative to a geometry of a preceding shell; and
repeating the steps of defining the series of shells within the printed part or the model of the part until the innermost reduced part, having either no interior volume or an interior volume below a threshold, is produced.

20. The non-transitory computer readable medium of claim 18 , further comprising:
raising the effective thickness to a power having an exponent greater than or equal to 1 and less than or equal to 2.4; and
calculating a time proportional to the effective thickness raised to the exponent.

Assignees

• Desktop Metal Inc

Inventors

• Gibson Michael A
• Barbati Alexander C

Classifications

• B22F3/1025 Primary

  not by heating only · CPC title

• B22F3/1021 Primary

  Removal of binder or filler (removal of binder from ceramics C04B35/638) · CPC title

• B22F12/55

  Two or more means for feeding material · CPC title

• B22F10/43

  characterised by material · CPC title

• B22F10/30

  Process control · CPC title