Methods and devices for counteracting stresses during 3d printing

Patent metadata

Field	Value
Publication number	US-2016136903-A1
Application number	US-201514942444-A
Country	US
Kind code	A1
Filing date	Nov 16, 2015
Priority date	Nov 14, 2014
Publication date	May 19, 2016
Grant date	—

Abstract

Methods of 3D printing an object with reduced curl on at least one surface that contacts a print plate are described herein. For example, in some embodiments, a method of 3D printing an object comprises depositing build material to form a first layer of a 3D printed object and depositing build material in a predetermined pattern to form a first layer of a skirt in contact with the 3D printed object. Depositing build material to form the first layer of the skirt comprises 3D printing a first layer of a sidewalk that substantially surrounds at least a portion of a perimeter of the 3D printed object and 3D printing a first layer of a perforated interface between the sidewalk and the perimeter of the skirt.

First claim

That which is claimed:

1 . A method of 3D printing an object, the method comprising:
depositing build material in a predetermined pattern to form a first layer of a 3D printed object; and depositing build material in a predetermined pattern to form a first layer of a skirt in contact with the 3D printed object, wherein depositing build material to form the first layer of the skirt comprises 3D printing a first layer of a sidewalk that substantially surrounds at least a portion of a perimeter of the 3D printed object and 3D printing a first layer of a perforated interface between the sidewalk and the perimeter of the skirt.

2 . The method of claim 1 further comprising depositing build material in a predetermined pattern to form a number of additional layers of the skirt beyond the first layer,
wherein the 3D printed object defines a geometry; and
wherein the number of additional layers of the skirt deposited is determined by at least one of the geometry and build material of the 3D printed object.

3 . The method of claim 1 , wherein:
the 3D printed object defines a geometry; and a width of the sidewalk is determined based upon at least one of the geometry and build material of the 3D printed object.

4 . The method of claim 1 , wherein depositing build material in a predetermined pattern to form the first layer of the 3D printed object is carried out prior to depositing build material in a predetermined pattern to form the first layer of the skirt.

5 . The method of claim 4 , wherein depositing build material in a predetermined pattern to form the first layer of the skirt comprises:
first, depositing build material to form a perimeter of the sidewalk of the skirt; and second, depositing build material to form a plurality of contacts to define the perforated interface between the sidewalk and the perimeter of the 3D printed object.

6 . The method of claim 1 , wherein:
depositing build material in a predetermined pattern to form the first layer of the skirt comprises:
depositing build material to form the sidewalk of the skirt; and
concurrent with depositing build material to form the sidewalk, depositing build material to form a plurality of connectors and a plurality of gaps along the perimeter of the 3D printed object.

7 . The method of claim 6 , wherein a connector-to-gap ratio is less than or equal to 2:1.

8 . The method of claim 6 , wherein the connector-to-gap ratio is less than or equal to 1:1.

9 . The method of claim 6 , wherein the connector-to-gap ratio is less than or equal to 0.5:1.

10 . The method of claim 6 , wherein the connector-to-gap ratio is less than or equal to 0.25:1.

11 . The method of claim 6 , wherein:
at least two of the connectors have sides that define an angle of 90 degrees or less relative to the perimeter of the 3D printed object adjacent the respective connector.

12 . The method of claim 1 , wherein:
the sidewalk comprises a sidewalk border; and the sidewalk border intermittently contacts the perimeter of the 3D printed object to define the perforated interface.

13 . The method of claim 1 , wherein 3D printing the first layer of the sidewalk comprises defining a tear-off starter in the first layer of the sidewalk.

14 . The method of claim 1 further comprising separating the sidewalk from the 3D printed object by pulling the sidewalk away from the 3D printed object in a direction that causes the perforated interface to separate from the 3D printed object.

15 . The method of claim 14 , wherein:
3D printing the first layer of the sidewalk comprises defining a tear-off starter in the first layer of the sidewalk; and separating the sidewalk from the 3D printed object by pulling the sidewalk away from the 3D printed object comprises applying a force to the tear-off starter.

16 . The method of claim 1 , wherein:
depositing build material to form the first layer of the sidewalk defines a fill pattern; and the fill pattern contacts the perimeter of the 3D printed object to define the perforated interface.

17 . The method of claim 16 , wherein the fill pattern defines at least one of a perpendicular hatch pattern, a diagonal hatch pattern, a perpendicular line pattern, an obtuse angle pattern, and an acute angle pattern.

18 . The method of claim 16 , wherein:
the fill pattern defined by depositing build material to form the first layer of the sidewalk is a first fill pattern; depositing build material to form the first layer of the 3D printed object defines a second fill pattern; and the first fill pattern differs from the second fill pattern.

19 . A method of 3D printing an object, the method comprising:
first, depositing build material to define at least a first layer of a fill portion of a 3D printed object; second, depositing build material to define at least a first layer of a fill portion of a sidewalk substantially surrounding at least a portion of the 3D printed object; third, depositing at least a first layer of a border portion of the 3D printed object; and fourth, depositing at least a first layer of a border portion of the sidewalk, wherein a perforated interface is defined between the sidewalk and the border of the 3D printed object.

Assignees

• 3D Systems Inc

Inventors

• Herran Leigh
• Moussa Khalil
• Johnson Martin Alan
• Podgursky Nickalaus K
• Manners Chris Robert

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• B29C64/40 Primary

  Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof · CPC title

• B29C67/0055

  Operations & Transport · mapped topic

• B29C67/0092 Primary

  Operations & Transport · mapped topic