Powder Distribution System for Three-Dimensional Printer

Patent metadata

Field	Value
Publication number	US-2024165872-A1
Application number	US-202318210047-A
Country	US
Kind code	A1
Filing date	Jun 14, 2023
Priority date	Jun 12, 2017
Publication date	May 23, 2024
Grant date	—

Abstract

The present invention relates to powder-layer three-dimensional printers ( 2 ) having a discrete supply hopper ( 340 ) and a recoater ( 20 ). The discrete supply hopper ( 340 ) is configured to transfer a build powder to the recoater ( 20 ) in a manner that enhances the uniformity of build powder layers that are dispensed from the recoater ( 20 ). In some embodiments, at least one of the discrete supply hopper and the powder hopper of the recoater is adapted to selectively contact the other, seal against the other, and/or have one partially inserted inside the other so as to diminish or prevent powder pluming during the transfer of build powder from the discrete supply hopper to the recoater.

First claim

1 . A powder-layer three-dimensional printer ( 2 ) comprising:
a recoater ( 20 ) and a build material discrete supply hopper ( 340 ), the discrete powder hopper ( 340 ) having (a) a build powder reservoir ( 342 ) having a bottom opening ( 355 ); (b) a planar mesh ( 352 ), the planar mesh ( 352 ) being selectively permeable to a build powder and being located so as to permeably close off the bottom opening ( 355 ); and (c) a selectively operable vibrator ( 362 , 364 ) in vibrational communication with the planar mesh ( 352 ) and/or the build powder; wherein at least one of the recoater ( 20 ) and the discrete supply hopper ( 340 ) is adapted to vertically align the recoater ( 20 ) below the discrete supply hopper ( 340 ) for the build powder dispensed by the planar mesh ( 352 ) during the operation of the vibrator ( 362 , 364 ) to be received by the recoater ( 20 ).

2 . The powder-layer three-dimensional printer ( 2 ) of claim 1 wherein the recoater ( 20 ) has (a) a sheet screen ( 28 ) having a plurality of perforations ( 126 ) and a first side and a second side; (b) a first ultrasonic transducer ( 30 ) in vibrational communication with the sheet screen ( 28 ); and (c) a build powder supply hopper ( 26 ) adapted to provide the build powder to the first side of the sheet screen ( 28 );
wherein when the first ultrasonic transducer ( 30 ) vibrates the sheet screen ( 28 ) the build powder from the build powder supply hopper ( 26 ) is dispensed from the sheet screen second side via the perforations ( 126 ).

3 . The powder-layer three-dimensional printer ( 2 ) of claim 1 wherein the vibrator ( 362 , 364 ) of the discrete supply hopper ( 340 ) comprises at least one of a second ultrasonic transducer ( 362 ) and a low frequency vibrator ( 364 ).

4 . The powder-layer three-dimensional printer ( 2 ) of claim 3 wherein the ultrasonic transducer ( 362 ) is adapted to sweep across a frequency range during its operation.

5 . The powder-layer three-dimensional printer ( 2 ) of claim 1 wherein the discrete supply hopper ( 340 ) is movably located within the powder-layer three-dimensional printer ( 2 ).

6 . The powder-layer three-dimensional printer ( 2 ) of claim 1 wherein the planar mesh ( 352 ) comprises a wire mesh.

7 . The powder-layer three-dimensional printer ( 2 ) of claim 1 wherein the planar mesh ( 352 ) comprises a metal sheet having a plurality of perforations.

8 . The powder-layer three-dimensional printer ( 2 ) of claim 7 wherein the plurality of perforations include a first perforation having a first shape and a second perforation having a second shape wherein the first shape is different from the second shape.

9 . The powder-layer three-dimensional printer ( 2 ) of claim 7 wherein at least one of the size, shape, and distribution of the perforations of the plurality is varied to reduce any tendency the planar mesh ( 352 ) otherwise would have to dispense build powder non-uniformly due to local vibration variances.

10 . The powder-layer three-dimensional printer ( 2 ) of claim 1 wherein the build powder reservoir ( 342 ) is adapted to provide mass flow of the build powder to the planar mesh ( 352 ).

11 . The powder-layer three-dimensional printer ( 2 ) of claim 1 wherein the planar mesh ( 352 ) is mounted in a holder ( 354 ).

12 . The powder-layer three-dimensional printer ( 2 ) of claim 11 wherein the planar mesh ( 352 ) is bonded to the holder ( 354 ) by an adhesive.

13 . The powder-layer three-dimensional printer ( 2 ) of claim 1 wherein the discrete supply hopper ( 340 ) further comprises a selectively operable gate ( 356 ) located below the planar mesh ( 352 ).

14 . The powder-layer three-dimensional printer ( 2 ) of claim 1 wherein the discrete supply hopper ( 340 ) further comprises a cyclonic receiver ( 348 ) located above the build powder reservoir ( 342 ).

15 . The powder-layer three-dimensional printer ( 2 ) of claim 14 wherein the discrete supply hopper ( 340 ) further comprises a valve ( 350 ) interposed between the cyclonic receiver ( 348 ) and the build powder reservoir ( 342 ).

16 . The powder-layer three-dimensional printer ( 2 ) of claim 1 wherein the recoater ( 20 ) has a powder receiving area ( 372 ) and the planar mesh ( 352 ) has a powder discharge portion ( 370 ), the powder discharge portion ( 370 ) having a center which is vertically aligned with the powder receiving area ( 372 ) during transfer of the build powder from the discrete supply hopper ( 340 ) to the recoater ( 20 ).

17 . The powder-layer three-dimensional printer ( 2 ) of claim 1 wherein the planar mesh ( 352 ) has a powder discharge portion ( 370 ), the powder discharge portion ( 370 ) having at least one of the geometric shape and dimensions of the powder receiving area ( 372 ) of the recoater ( 20 ).

18 . The powder-layer three-dimensional printer ( 2 ) of claim 17 wherein the powder discharge portion ( 370 ) of the planar mesh ( 352 ) has a span (S 1 ) and a width (Wi) and at least one of the span (S 1 ) and width (W 1 ) is the same as the width (W 2 ) of the recoater's powder receiving area.

19 . The powder-layer three-dimensional printer ( 2 ) of claim 1 wherein the recoater ( 20 ) has (a) a wire mesh screen ( 366 ) having a first side and a second side; (b) a third ultrasonic transducer ( 367 ) in vibrational communication with the wire mesh screen ( 366 ); and (c) a hopper ( 365 ) adapted to provide the build powder to a first side of the wire mesh screen ( 366 );
wherein when the third ultrasonic transducer ( 367 ) vibrates the wire mesh screen ( 366 ) the build powder from the hopper ( 365 ) is dispensed from the wire mesh screen second side.

20 . A method comprising:
(a) providing a powder-layer three-dimensional printer having a recoater ( 20 ) and a build material discrete supply hopper ( 340 ), the discrete powder hopper ( 340 ) having (1) a build powder reservoir ( 342 ) having a bottom opening ( 355 ); (2) a planar mesh ( 352 ), the planar mesh ( 352 ) being selectively permeable to a build powder and being located so as to permeably close off the bottom opening ( 355 ); and (3) a selectively operable vibrator ( 362 , 364 ) in vibrational communication with the planar mesh ( 352 ) and/or the build powder; (b) vertically aligning the discrete supply hopper ( 340 ) below the discrete supply hopper ( 340 ); (c) operating the vibrator ( 362 , 264 ) to dispense the build powder from the planar mesh ( 352 ) during the operation of the vibrator ( 362 , 364 ); and (d) receiving the dispensed build powder in the recoater ( 20 ).

21 .- 32 . (canceled)

Assignees

• Desktop Metal Inc

Inventors

• Flick Jake
• Mccoy Michael John
• Bolt Joseph J
• Hydock Alec
• Inks Travis Maxwell
• Dugan Anthony S
• Lizzi Thomas

Classifications

• B29C64/153 Primary

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title

• B07B1/40

  Resonant vibration screens · CPC title

• B22F12/52

  Hoppers · CPC title

• B22F12/67

  Blades · CPC title

• B29C64/205

  Means for applying layers · CPC title