Electrophotographic additive manufacturing with moving platen and environmental chamber

Patent metadata

Field	Value
Publication number	US-2017192382-A1
Application number	US-201615386853-A
Country	US
Kind code	A1
Filing date	Dec 21, 2016
Priority date	Dec 31, 2015
Publication date	Jul 6, 2017
Grant date	—

Abstract

A method of printing a part in an electrophotographic additive manufacturing system includes printing a part and associated support structure in a layer by layer manner, and providing a chamber in which printing is performed. The chamber is supported by a movable platform and the chamber is positioned about a movable platen. The movable platen is supported by the movable build platform. The movable platen is movable within the chamber on the movable build platform. An electrophotography-based additive manufacturing system for printing a three-dimensional part includes a transfer medium configured to receive and transfer imaged layers of a three-dimensional part, and a support from one or more imaging engines. The system includes a heater configured to heat the imaged layers on the transfer medium to at least a fusion temperature, and a layer transfusion assembly configured to transfuse the imaged layers to the build platen or a previously printed layer.

First claim

1 . A method of printing a part in an electrophotography-based additive manufacturing system, comprising:
providing a movable build platform; providing a chamber supported by the build platform, wherein printing is performed within the chamber; providing a movable platen within the chamber and carried on the movable build platform, the movable platen movable within the chamber on the movable build platform such that imaged layers of part material and support material can be transfused on the build platen or previously printed layers of the part material and support material in a layer by layer manner.

2 . The method of claim 1 , wherein providing the chamber comprises providing a chamber having walls at least partially surrounding the movable platen carried on the movable build platform, the movable platen movable within the chamber on the movable build platform.

3 . The method of claim 1 , and further comprising heating an internal environment within the movable chamber.

4 . The method of claim 3 , wherein heating comprises providing a heater in at least one wall of the movable chamber.

5 . The method of claim 4 , and further comprising controlling temperature of the part in the movable chamber along a height of the movable chamber.

6 . The method of claim 1 , and further comprising providing at least one temperature sensor in at least one wall of the chamber, the at least one temperature sensor configured to monitor a temperature of the internal environment of the chamber, and to control the heater to maintain a desired temperature profile within the movable chamber.

7 . The method of claim 1 , and further comprising printing a layer of the part on the movable platen with a transfusion assembly, wherein printing a layer comprises transfusing a layer to be printed at a top of the movable chamber, and wherein a top of the movable chamber accepts shear loading of the transfusion assembly.

8 . The method of claim 1 and further comprising moving the chamber relative to the movable platen and/or the movable build platform.

9 . An electrophotography-based additive manufacturing system for printing a three-dimensional part, the additive manufacturing system comprising:
a transfer medium configured to receive and transfer imaged layers of a thermoplastic-based powder for a three-dimensional part, and a thermoplastic-based powder for a soluble support from one or more imaging engines; a heater configured to heat the imaged layers on the transfer medium to at least a fusion temperature of the thermoplastic-based powder; and a layer transfusion assembly comprising:
a movable build platform;
a movable platen carried on the movable build platform and configured to accept imaged layers from the transfer medium; and
a chamber supported by the build platform, the movable chamber having one or more walls at least partially surrounding the movable platen, the movable platen movable within the chamber on the movable build platform.

10 . The additive manufacturing system of claim 9 , wherein the chamber further comprises at least one heater.

11 . The additive manufacturing system of claim 9 , wherein the chamber comprises walls at least partially surrounding the movable platen carried on the movable build platform.

12 . The additive manufacturing system of claim 11 , wherein the at least one heater comprises a heater for each of the exterior walls of the chamber.

13 . The additive manufacturing system of claim 11 , wherein each wall of the chamber includes at least one heater, wherein the at least one heater comprises a multi-zone heater.

14 . The additive manufacturing system of claim 9 , and further comprising at least one temperature sensor, the at least one temperature sensor mounted to a wall of the chamber.

15 . The additive manufacturing system of claim 9 , and further comprising at least one position sensor, the at least one position sensor mounted to the one or more walls of the chamber and configured to sense a position of the platen.

16 . An electrophotographic additive manufacturing system comprising:
a platform; a platen supported by the platform, the platen configured to move relative to the platform; and a chamber supported by the platform, the chamber comprising a plurality of sidewalls, the plurality of sidewalls at least partially surrounding the movable platen, the plurality of sidewalls defining an environment therein, wherein the chamber is configured to control a temperature profile within the environment.

17 . The electrophotographic additive manufacturing system of claim 16 , wherein the chamber comprises a plurality of substantially vertical walls arranged substantially around a perimeter of the movable platen.

18 . The electrophotographic additive manufacturing system of claim 16 , wherein the chamber further comprises at least one temperature modifying element disposed in one of the sidewalls of the plurality of sidewalls.

19 . The electrophotographic additive manufacturing system of claim 18 , wherein the at least one temperature modifying element comprises a heater for each of the walls of the chamber.

20 . The electrophotographic additive manufacturing system of claim 16 , wherein each wall of the chamber includes at least one temperature modifying element

21 . The electrophotographic additive manufacturing system of claim 18 and wherein the at least one temperature modifying element comprises a multi-zone heater.

22 . The electrophotographic additive manufacturing system of claim 16 , and further comprising at least one position sensor configured to sense a position of the platen relative to the platform, the at least one position sensor mounted to a wall of the chamber.

23 . The electrophotographic additive manufacturing system of claim 16 and wherein the chamber is configured to move relative to the platform and the platen.

Assignees

• Stratasys Inc

Inventors

• Baecker James

Classifications

• B33Y30/00 Primary

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• G03G15/6585

  by using non-standard toners, e.g. transparent toner, gloss adding devices · CPC title

• G03G2215/1695

  at the second or higher order transfer point · CPC title

• G03G15/24

  whereby at least two steps are performed simultaneously · CPC title

• G03G15/224

  Machines for forming tactile or three dimensional images by electrographic means, e.g. braille, 3d printing · CPC title