Method for creating structures of two or more materials using a multi-material three-dimensional printer

Patent metadata

Field	Value
Publication number	US-11806937-B2
Application number	US-202217970347-A
Country	US
Kind code	B2
Filing date	Oct 20, 2022
Priority date	Jun 7, 2018
Publication date	Nov 7, 2023
Grant date	Nov 7, 2023

Abstract

A multi-material three-dimensional printing apparatus is provided. The provided apparatus includes two or more print stations. Each of the print stations includes a substrate, a transportation device, a dispersion device, a compaction device, a printing device, a fixing device, and a fluidized materials removal device. The apparatus also includes an assembly apparatus in communication with the two or more print stations via the transportation device. The apparatus also includes one or more transfer devices in communication with the assembly apparatus. The apparatus also includes a computing and controlling device configured to control the operations of the two or more print stations, the assembly apparatus and the one or more transfer devices.

First claim

What is claimed is:

1. A method for creating structures of two or more materials using a multi-material three-dimensional printing apparatus, the method comprising:
receiving print instructions to direct and coordinate operation of the multi-material three-dimensional printing apparatus to print a three-dimensional part, the three-dimensional part made up of two or more materials and having at least two print thickness layers, each of the at least two print thickness layers having at least one single material pattern;
sending a first print instructions for a first single material pattern of the at least one single material pattern to a first print station within the multi-material three-dimensional printing apparatus;
dispersing material of the at least one single material pattern on a first substrate;
indexing the first substrate to move the dispersed material, via a first carrier device, to a first compaction apparatus where the material is compacted;
indexing the first substrate to move the compacted material, to a printing apparatus where a binder is dispersed in a predetermined pattern on the compacted material;
sending a second print instructions for a second single material pattern of the at least one single material pattern to a second print station within the multi-material three-dimensional printing apparatus;
dispersing material of the second single material pattern of the at least one single material pattern on a second substrate;
moving the dispersed material of the second single material pattern, via a second carrier device, to a second compaction apparatus where the material is compacted; and
transferring the at least two print thickness layers to a build substrate by using a transfer device, wherein the transfer device is positioned such that at any given time it has access to any one of the at least two print thickness layers, the transfer device configured to transfer the two print thickness layers in any desired order.

2. The method of claim 1 , wherein receiving print instructions comprises:
dividing a multi-material object design into at least two print thickness layers; and
separating each of the at least two print thickness layers into at least one single material pattern.

3. The method of claim 1 , further comprising:
indexing the first substrate to move the patterned material to a fixing apparatus where the binder pattern is fixed with fixing radiation;
indexing the first substrate to move the fixed pattern to a fluidized material removal apparatus, where the compacted material not fixed in position by a binder is removed; and
indexing the first substrate to move the patterned and fixed material to a transfer station, where at least one of the at least two print thickness layers is transferred to either a build substrate or to top a stack of previously positioned layers.

4. The method of claim 3 , further comprising:
determining whether or not the patterned and fixed material was a last layer, and if not, sending instructions to the print station within the multi-material three-dimensional printing apparatus to print a next printed layer.

5. The method of claim 3 , wherein moving the patterned and fixed material to the transfer station involves a pick-up assembly comprising an attachment apparatus configured to remove each of the at least two print thickness layers from the first substrate and the second substrate.

6. The method of claim 5 , wherein the attachment apparatus comprises at least one of a vacuum apparatus or an adhesive apparatus configured to overcome a force holding the each of the at least two print thickness layers to the first or second substrate.

7. The method of claim 3 , wherein moving the patterned and fixed material to the transfer station involves a translation apparatus configured to move the each of the at least two print thickness layers from the first substrate and the second substrate to an assembly apparatus in communication with the first print station and the second print station.

8. The method of claim 7 , wherein the assembly apparatus comprises a build substrate and position reference fiducials to facilitate accurate placement of each print thickness layer onto the build substrate.

9. The method of claim 3 , wherein the fluidized material removal apparatus comprises a vacuum apparatus, a disruptive apparatus, and an air knife.

10. The method of claim 3 , wherein the fixing apparatus is configured to provide at least one radiant energy source selected from a group of IR radiation, UV radiation, and electron beam.

11. The method of claim 1 , further comprising:
instructing, by central processing unit within the multi-material three-dimensional printing apparatus, the first and the second print stations to print a specific material based on the instructions.

12. The method of claim 1 , wherein the first compaction apparatus comprises a settling apparatus configured to provide vibration and at least one of a compliant pressure cuff or a roller.

13. The method of claim 12 , wherein the first compaction apparatus is configured to compact a fluidized material to a high density of at least 40% of a theoretical density of the fluidized material.

14. The method of claim 1 , wherein the first print instructions are either same as the second print instructions or the first print instructions are different from the second print instructions.

15. The method of claim 1 , wherein the first single material pattern is different from the second single material pattern.

16. A method for creating structures of two or more materials using a multi-material three-dimensional printing apparatus comprising a computer and a control device, the method comprising:
dividing a multi-material object design into at least two print thickness layers;
identifying different materials in one of the at least two print thickness layers;
for each of the identified materials in the one of the at least two print thickness layers:
sending at least one single material pattern to a print station within the multi-material three-dimensional printing apparatus;
creating a material object for the one of the at least two print thickness layers;
transferring the material object of the one of the at least two print thickness layers to a build substrate by using a transfer device; and
stacking each material object in a single layer on the build substrate;

determining if all material objects for the one of the at least two print thickness layers have been printed and transferred to the build substrate;
incrementing a build plate down a thickness of a next layer if all different materials within the single layer have been printed, wherein structure of the build substrate comprises two or more distinct materials in two or more printed layers; and
instructing, by a central processing unit of the computer, a print station control unit of the control device to print a specific material,
wherein the transfer device is positioned such that at any given time it has access to any one of the at least two print thickness layers, the transfer device configured to transfer the two print thickness layers in any desired order.

17. The method of claim 16 , wherein the print station control unit of the control device controls a plurality of devices.

18. The method of claim 17 , wherein the plurality of devices comprises at least one of a carrier device, dispensing device, compaction device, printing device, fixing device, fluidized material removal device, alignment device, transfer device, and assembly apparatus.

19.

Assignees

• Sakuu Corp

Inventors

• Rogren Philip Eugene
• Vatani Morteza

Classifications

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title

• B22F2999/00

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

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B22F7/062

  involving the connection or repairing of preformed parts · CPC title

• B22F7/02

  of composite layers {(B22F7/002 takes precedence)} · CPC title