Fusing three dimensional (3D) parts

Patent metadata

Field	Value
Publication number	US-11780170-B2
Application number	US-201816637663-A
Country	US
Kind code	B2
Filing date	May 29, 2018
Priority date	May 29, 2018
Publication date	Oct 10, 2023
Grant date	Oct 10, 2023

Abstract

In an example implementation, a method of fusing layers of 3D parts includes forming a layer of build material, and selectively applying a liquid agent onto the layer of build material to define a part layer of a 3D part and a sacrificial layer of a sacrificial part. The method includes, in a single pass of a thermal energy source over the layer of build material, applying fusing energy to the sacrificial layer, sensing a temperature of the sacrificial layer, adjusting a power level of the thermal energy source based on the sensed temperature, and applying fusing energy to the part layer with the adjusted power level of the thermal energy source.

First claim

What is claimed is:

1. A method of fusing layers of three-dimensional (3D) parts comprising:
forming a layer of build material;
selectively applying a liquid agent onto the layer of build material to define a part layer of a first 3D part being formed and a sacrificial layer of a sacrificial part being formed; and,
in a single pass of a thermal energy source over the layer of build material:
applying fusing energy to the sacrificial layer; then
sensing a temperature of the sacrificial layer of the sacrificial part being formed;
comparing the sensed temperature to a first target temperature of the part layer of the first 3D part being formed;
adjusting a power level of the thermal energy source to a first adjusted power level based on the comparison of the sensed temperature; and,
applying fusing energy to the part layer of the first 3D part being formed with the first adjusted power level of the thermal energy source.

2. The method as in claim 1 , wherein adjusting a power level comprises:
increasing the power level when the sensed temperature is below the first target temperature; and,
decreasing the power level when the sensed temperature is above the first target temperature.

3. The method as in claim 2 , wherein comparing the sensed temperature to a first target temperature of the part layer of the first 3D part being formed comprises:
receiving a material property selection for the part layer of the first 3D part being formed;
and, determining the first target temperature based on the material property selection.

4. The method as in claim 3 , wherein determining the first target temperature comprises:
associating in a look-up table, the first target temperature with the material property selection and with a material type specified for the part layer of the first 3D part being formed.

5. The method as in claim 2 , wherein selectively applying a liquid agent defines a part layer of a second 3D part being formed within the layer of build material, the method further comprising:
in the single pass of the thermal energy source over the layer of build material:
comparing the sensed temperature to a second target temperature of the part layer of the second 3D part being formed;
increasing the power level to a second adjusted power level when the sensed temperature is below the second target temperature;
decreasing the power level to a second adjusted power level when the sensed temperature is above the second target temperature; and,
applying fusing energy to the part layer of the second 3D part being formed with the second adjusted power level.

6. The method as in claim 1 , further comprising:
forming a next layer of build material;
selectively applying a liquid agent onto the next layer of build material to define a next part layer of the first 3D part being formed and a next sacrificial layer of the sacrificial part being formed; and,
in a single pass of the thermal energy source over the next layer of build material:
applying fusing energy to the next sacrificial layer; then sensing a temperature of the next sacrificial layer of the sacrificial part being formed;
comparing the sensed temperature to a first target temperature of the part layer of the first 3D part being formed;
adjusting a power level of the thermal energy source based on the comparison of the sensed temperature of the next sacrificial layer; and,
applying fusing energy to the next part layer of the first 3D part being formed with the adjusted power level of the thermal energy source.

7. A 3D printing system for fusing layers of 3D parts, comprising:
a dispensing assembly to spread a layer of build material over a build surface and to dispense a fusing agent onto the layer of build material;
a thermal energy source;
a thermal sensor; and,
a controller programmed to:
control the dispensing assembly to form a layer of build material;
control the dispensing assembly to selectively apply the fusing agent onto the layer of build material to define a part layer of a first 3D part being formed and a sacrificial layer of a sacrificial part being formed; and,
in a single pass of the thermal energy source over the layer of build material:
control the thermal energy source to apply fusing energy to the sacrificial layer; then
receive a temperature of the sacrificial layer of the sacrificial part being formed sensed by the thermal sensor;
compare the received temperature to a first target temperature of the part layer of the first 3D part being formed;
adjust a power level of the thermal energy source to a first adjusted power level based on the comparison of the sensed temperature; and,
control the thermal energy source to apply fusing energy to the part layer of the first 3D part being formed with the first adjusted power level.

8. The 3D printing system as in claim 7 , wherein the controller programmed to adjust a power level to a first adjusted power level comprises the controller programmed to:
increase the power level when the sensed temperature is below the first target temperature; and,
decrease the power level when the sensed temperature is above the first target temperature.

9. The 3D printing system as in claim 8 , wherein the controller is programmed to:
control the dispensing assembly to selectively apply the fusing agent to define a part layer of a second 3D part being formed within the layer of build material; and,
in the single pass of the thermal energy source over the layer of build material:
comparing the sensed temperature to a second target temperature of the part layer of the second 3D part being formed;
increasing the power level to a second adjusted power level when the sensed temperature is below the second target temperature;
decreasing the power level to a second adjusted power level when the sensed temperature is above the second target temperature; and,
applying fusing energy to the part layer of the second 3D part being formed with the second adjusted power level.

10. The 3D printing system as in claim 7 , wherein the dispensing assembly comprises:
a build material spreading device to spread the layer of build material over the build surface; and,
a printhead to selectively deposit the fusing agent onto the layer of build material to define the sacrificial layer, and the part layer of the first 3D part being formed.

11. A method of fusing layers of three-dimensional (3D) parts comprising:
accessing 2D data slices, each 2D data slice defining a part layer of a 3D part being formed and a sacrificial layer of a sacrificial part being formed;
forming layers of build material, and for each layer of build material:
selectively applying a fusing agent onto the layer of build material to define a part layer and a sacrificial layer;
heating the sacrificial layer with a thermal energy source;
sensing a temperature of the heated sacrificial layer of the sacrificial part being formed;
comparing the sensed temperature to a first target fusing temperature of the part layer of the 3D part being formed;
adjusting a power level of the thermal energy source based on the comparison of the sensed temperature; and,
heating the part layer with the adjusted power level of the thermal energy source.

12. The method as in claim 11 , wherein adjusting a power level of the thermal energy source comprises:
obtaining material properties of the 3D part being formed that specify a material property for each part layer of the 3D part being formed; and
determining from the material properties, a target fusing temperature for the part layer.

13. The method as in claim 12 , wherein obtaining material propertie

Assignees

• Hewlett Packard Development Co

Inventors

• Barnes Arthur H
• Ewe Michael

Classifications

• B29C64/393 Primary

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