Forming a layer of build material

Patent metadata

Field	Value
Publication number	US-11485077-B2
Application number	US-201716608453-A
Country	US
Kind code	B2
Filing date	Oct 23, 2017
Priority date	Oct 23, 2017
Publication date	Nov 1, 2022
Grant date	Nov 1, 2022

Abstract

According to one aspect, there is provided apparatus for forming a layer of build material for three-dimensional printing. The apparatus comprises a spreader to spread a volume of build material to form a layer of build material on a build platform, wherein at least one end of the spreader is to remain a constant distance from a build material retaining wall in proximity to at least one edge of the build platform as the spreader is moved over the surface of the build platform, and further wherein at least a portion of the spreader is below the top of the retaining wall.

First claim

What is claimed is:

1. Apparatus for forming a layer of build material for three-dimensional printing, comprising:
a spreader to spread a volume of build material to form a layer of build material on a build platform, wherein the build platform indexes downward for each subsequent layer of build material,
wherein at least one end of the spreader is to remain a constant distance from a build material retaining wall in proximity to at least one edge of the build platform as the spreader is moved over a surface of the build platform, and further
wherein at least a portion of the spreader is below a top of the retaining wall.

2. The apparatus of claim 1 , wherein the apparatus is a part of a 3D printing system, and wherein the retaining wall is one of: part of a build unit receiving housing; and part of a build unit.

3. The apparatus of claim 2 , wherein the build unit comprises four side walls forming an open-topped cuboidal-shaped build chamber and wherein the build platform is a rectangular build platform vertically movable within the build chamber.

4. The apparatus of claim 3 , wherein two opposite side walls comprise build material retaining walls extending above a base of the spreader to prevent build material from being displaced outside of the build chamber as the spreader is moved parallel to the retaining walls.

5. The apparatus of claim 2 , wherein the build unit receiving housing comprises build material retaining walls extending above a base of the spreader to prevent build material from being displaced outside of the build chamber as the spreader is moved parallel to the retaining walls.

6. The apparatus of claim 2 , wherein the build unit comprises a cylindrical build chamber within which a circular build platform is vertically movable and wherein the build unit comprises a circular retaining wall extending above a base of the spreader to prevent build material from being displaced outside of the build chamber as the spreader is rotated axially within the circular retaining wall.

7. The apparatus of claim 1 , wherein the build material retaining wall extends at least partially up a height of the roller.

8. The apparatus of claim 1 , wherein the spreader is a roller, and wherein the roller has a channel therein to be positioned over the retaining wall such that at least a portion of the retaining wall is within the channel as the roller is moved over the build platform.

9. The apparatus of claim 2 , further comprising an auxiliary platform on one side of the build platform to receive a pile of build material to be spread over the build platform by the spreader.

10. The apparatus of claim 1 , further comprising:
a build chamber, wherein the build platform is moveable within the build chamber; and
a lateral auxiliary platform positioned at one side of a top of the build chamber to receive a supply of build material for spreading by the spreader;
wherein the build material retaining wall extends above an upper surface of the lateral auxiliary platform and along a direction across the build chamber in which the spreader moves to form a build material layer.

11. The apparatus of claim 10 , wherein the build material retaining wall comprises a first retaining wall along a first side of the build chamber and a second retaining wall along an opposite side of the build chamber.

12. The apparatus of claim 1 , wherein the build material retaining wall extends along a direction across the build chamber in which the spreader moves to form a build material layer.

13. The apparatus of claim 12 , wherein a distance between an end of the spreader and the build material retaining wall remains constant as the spreader moves over the build platform.

14. The apparatus of claim 1 , wherein the spreader is a roller, and wherein the roller has a channel along a length thereof, the build material retaining wall extending into the channel such that a portion of the roller is disposed on either side of the retaining wall.

15. A method of forming a layer of build material on a build platform, comprising:
moving a spreader to spread a volume of build material to form a layer of build material on the build platform;
wherein moving the spreader comprises moving the spreader such that at least one end of the spreader remains a constant distance from a build material retaining wall and
wherein at least a portion of the spreader is below the top of the retaining wall as the spreader is moved over the surface of the build platform; and
indexing the build platform downward for each subsequent layer of build material to be formed.

16. The method of claim 15 , wherein the build platform is a rectangular-shaped build platform within a cuboidal-shaped build unit, the build unit having build material retaining walls on two opposite sides thereof, and wherein moving the spreader comprises moving the spreader in an axis parallel to the build material retaining walls.

17. The method of claim 15 , wherein the build platform is a circular-shaped build platform within a cylindrical-shaped build unit, the build unit having a circular build material retaining wall, and wherein moving the spreader comprises axially rotating the spreader within the circular retaining wall.

18. The method of claim 15 , wherein moving the spreader comprises moving the spreader such that at least a portion of the spreader is below the top of the retaining walls.

19. A three-dimensional printing system, comprising:
a roller to spread a volume of build material to form a layer of build material on a rectangular build platform within a cuboidal-shaped build unit, wherein the build platform indexes downward for each subsequent layer of build material;
a build unit, or a build unit receiver housing to receive a build unit, having a pair of build material retaining walls on two opposite edges thereof;
wherein the roller is to move between the build material retaining walls such that at least a portion of the roller is below the top of the build material retaining walls as the roller is moved to form a layer of build material on the build platform.

20. The three-dimensional printing system of claim 19 , wherein each end of the roller is in close proximity to its respective build material retaining wall to prevent build material from spreading out beyond the build material retaining walls as build material is spread by the roller.

Assignees

• Hewlett Packard Development Co

Inventors

• Ewald Brent
• Winters William
• Kaiser Pierre J

Classifications

• B29C64/25

  Housings, e.g. machine housings · CPC title

• B22F10/14

  by jetting of binder onto a bed of metal powder · CPC title

• B29C64/218 Primary

  Rollers · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B22F12/226

  for rotary motion · CPC title