Generating a three-dimensional object

Patent metadata

Field	Value
Publication number	US-2019299535-A1
Application number	US-201916442363-A
Country	US
Kind code	A1
Filing date	Jun 14, 2019
Priority date	Jan 16, 2014
Publication date	Oct 3, 2019
Grant date	—

Abstract

According to one aspect there is provided an apparatus for generating a three-dimensional object. The apparatus may include a first agent distributor to selectively deliver a coalescing agent onto portions of a layer of build material, a second agent distributor to selectively deliver a coalescence modifier agent onto portions of the layer of build material, and a controller to control the first and second distributors to selectively deliver each of the agent and the coalescence modifier onto the layer of build material in respective patterns derived from data representing a slice of a three-dimensional object to be generated, in which when energy is applied to the layer of build material, the build material coalesces and solidifies to form a slice of the three-dimensional object in accordance the patterns and the three-dimensional object has mechanical object properties that are related to the patterns.

First claim

1 . An apparatus for generating a three-dimensional object, comprising:
a first distributor to selectively deliver an agent onto portions of a layer of build material; a second distributor to selectively deliver a coalescence modifier onto portions of the layer of build material; and a controller to control the first and second distributors to selectively deliver each of the agent and the coalescence modifier onto the layer of build material in respective patterns derived from data representing a slice of a three-dimensional object to be generated, wherein, when energy is applied to the layer of build material, the build material solidifies in accordance with the patterns and the three-dimensional object has mechanical object properties that are related to the patterns.

2 . The apparatus of claim 1 , wherein the controller is to control the first and second distributors to selectively deliver each of the agent and the coalescence modifier onto the layer of build material in respective patterns to cause a first portion has first mechanical object properties and a second portion has second mechanical object properties.

3 . The apparatus of claim 1 , wherein the build material comprises a powdered metal build material.

4 . The apparatus of claim 3 , wherein the coalescence modifier comprises at least one of a colloidal ink, a dye-based ink, a polymer-based ink, or a salt solution.

5 . The apparatus of claim 4 , wherein at least one of the first and second distributors is a drop on demand thermal printhead.

6 . The apparatus of claim 4 , wherein at least one of the first and second distributors is a drop on demand piezo inkjet printhead.

7 . The apparatus of claim 1 , further comprising a build material distributor to provide a first layer of build material on a build material support, and to provide subsequent layers of build material on a previously provided layer of build material.

8 . The apparatus of claim 7 , wherein the first and second distributors have a length to enable the first and second distributors to span the support and wherein at least one of the support and the distributors is moveable relative to the other to enable the agent and the coalescence modifier to be selectively deliverable to a surface of any portion of the layer of build material.

9 . The apparatus of claim 7 , wherein the coalescence modifier acts to produce a mechanical separation between particles of the build material.

10 . The apparatus of claim 7 , further comprising a carriage movable bi-directionally across the support on which are mounted, or on which are mountable, the first distributor to selectively deliver the agent, the second distributor to selectively deliver the coalescence modifier, and the build material distributor, the first and second distributors and the build material distributor being arranged to allow delivery of build material, agent, and coalescence modifier whilst the carriage is moving in either direction.

11 . The apparatus of claim 7 , further comprising a carriage movable bi-directionally across the support on which are mounted, or on which are mountable, the first distributor to selectively deliver the agent, the second distributor to selectively deliver coalescence modifier, and a pair of build material distributors, the first and second distributors and the pair of build material distributors being arranged to allow delivery of build material, the agent, and the coalescence modifier whilst the carriage is moving in either direction.

12 . The apparatus of claim 1 , wherein the first distributor is a first printhead, and wherein the second distributor is a second, different, printhead.

13 . The apparatus of claim 1 , wherein the first distributor comprises a first array of nozzles of a printhead, and wherein the second distributor comprises a second array of nozzles of the printhead.

14 . The apparatus of claim 1 , wherein the controller is to control the first and second distributors to selectively deliver the agent and the coalescence modifier onto a surface of the layer of build material in accordance with control data derived from a combination of data representing a slice of a three-dimensional object to be generated and data representing at least one desired object property of at least one portion of the three-dimensional object to be generated.

15 . The apparatus of claim 1 , wherein at least one of the first distributor or the second distributor is to eject drops of the agent or coalescence modifier in the order of about 10 pico liters per drop.

16 . The apparatus of claim 1 , wherein:
the first distributor is to deliver drops of agent that are larger than drops of coalescence modifier to be delivered from the second distributor; the first distributor is to deliver drops of agent that are about the same size as the drops of coalescence modifier to be delivered from the second distributor; or the first distributor is to deliver drops of agent that are smaller than the drops of coalescence modifier to be delivered from the second distributor.

17 . The apparatus of claim 1 , wherein the controller is to generate control data from data representing a three-dimensional object and mechanical object property data.

18 . The apparatus of claim 1 , further comprising an unfocused energy source to apply energy to build material to cause a portion of the build material to solidify to form a slice of the three-dimensional object in accordance with where the agent and the coalescence modifier was delivered.

19 . A method of controlling a system to generate a three-dimensional object, comprising:
obtaining control data, the control data being derived from data representing a portion of a three-dimensional object to be generated; depositing a layer of build material; selectively depositing an agent and a coalescence modifier on the layer of deposited build material in respective patterns derived from the obtained control data; and applying energy to the layer of deposited build material to cause portions of the build material to solidify in accordance with the patterns to cause the three-dimensional object to have mechanical object properties that are related to the patterns.

20 . An apparatus for generating a three-dimensional object, comprising:
a first distributor to selectively deliver an agent onto portions of a layer of build material; a second distributor to selectively deliver a coalescence modifier onto portions of the layer of build material; and a controller to control the first and second distributors to selectively deliver each of the agent and coalescence modifier onto the layer of build material in respective patterns derived from data representing a slice of a three-dimensional object to be generated, wherein when energy is applied to the layer of build material, the build material coalesces in accordance with the patterns and the three-dimensional object has mechanical object properties that are related to the patterns.

Assignees

• Hewlett Packard Development Co

Inventors

• De Pena Alejandro Manuel
• Comas Cespedes Esteve
• Baldez Luis

Classifications

• B29C64/393 Primary

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y30/00

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

• B29C64/165 Primary

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title