Devices, systems and methods for printing three- dimensional objects
The present disclosure provides systems and methods for printing three-dimensional objects. A method for printing a three-dimensional object may comprise alternately and sequentially applying a stream comprising a binding substance to an area of a layer of powder material in a powder bed, and generating at least one perimeter of the three-dimensional object in the area. The stream may be applied in accordance with a model design of the three-dimensional object. The at least one perimeter may generated in accordance with the model design.
1 . A system for simultaneously printing a plurality of three-dimensional objects, comprising:
an enclosure comprising a plurality of three-dimensional printing systems, wherein a printing system of said plurality of three-dimensional printing systems comprises:
a container configured to hold a powder bed comprising powder material;
a binder application unit comprising a spray head, wherein the binder application unit is configured to apply, layer by layer, a binding substance to the powder material in said powder bed; and
at least one perimeter generator comprising a cutting tool, wherein the at least one perimeter generator is configured to generate one or more perimeters in the powder bed by removing, layer by layer, one or more portions of the powder material bound by the binding substance, wherein the container, the binder application unit, and the at least one perimeter generator are positioned to perform a method for simultaneously generating the plurality of three-dimensional objects located within an environment of the enclosure, the method including alternately:
applying, by the binder application unit, the binding substance to an area of a layer of the powder material in the powder bed to form an intermediate three-dimensional object held within the enclosure; and
generating, by the at least one perimeter generator, at least one perimeter of one of the plurality of three-dimensional objects, which is supported by the container, by removing one or more portions of the area of the layer of the powder material in the intermediate three-dimensional object bound by the binding substance;
an environmental control unit operably coupled to the enclosure, wherein said environmental control unit comprises an air conditioner configured to regulate temperature of the environment in the enclosure; and
one or more computer processors operatively coupled to the binder application unit and the at least one perimeter generator of each of the three-dimensional printing systems, the one or more computer processors being individually or collectively programmed to control each of the three-dimensional printing systems to perform the method.
2 . The system of claim 1 , wherein the binding substance is applied based on a model design of said one of the plurality of three-dimensional objects, and wherein said at least one perimeter is in accordance with said model design.
3 . The system of claim 1 , further comprising an energy source that is configured to provide an energy beam directed to at most a portion of said layer of the powder material.
4 . The system of claim 3 , wherein the method further comprises directing said energy source to provide said energy beam directed to at most a portion of said layer of the powder material.
5 . The system of claim 3 , wherein said energy source comprises at least one laser.
6 . The system of claim 1 , further comprising a feedback control unit for regulating a level of the binding substance in said binder application unit.
7 . The system of claim 1 , wherein said environmental control unit is configured to regulate humidity in said enclosure.
8 . The system of claim 1 , wherein said environmental control unit is configured to regulate an oxygen level in said enclosure.
9 . The system of claim 1 , wherein said environmental control unit further comprises a control panel configured to allow a user to control an environmental parameter of the environment within the enclosure.
10 . The system of claim 1 , further comprising a cleaning unit, wherein the cleaning unit comprises a cleaning tool configured to remove powder material from said plurality of three-dimensional objects subsequent to printing.
11 . The system of claim 10 , wherein said cleaning unit is external to the enclosure.
12 . The system of claim 1 , further comprising a powder dispenser configured to dispense said powder material.
13 . The system of claim 1 , further comprising a roller configured to remove excess powder material from said powder bed and/or adjust a top surface of said powder bed.
14 . The system of claim 1 , wherein said at least one perimeter generator is a multi-axis machine unit, a computer numeric control (CNC) spindle, a cutting tool bit, or a blade.
15 . The system of claim 7 , wherein said environmental control unit further comprises a dehumidifier configured to control said humidity in said enclosure.
16 . The system of claim 1 , further comprising a sensor configured to detect one or more of a humidity, temperature, or oxygen level in the enclosure.
17 . A system for printing a plurality of three-dimensional objects, comprising:
a manufacturing apparatus including
a powder dispenser configured to supply powder material to a powder bed,
a binder application unit comprising a spray head and configured to apply a binding substance, and
a plurality of cutting devices configured to generate one or more perimeters in the powder bed by removing, layer by layer, one or more portions of the powder material bound by the binding substance, wherein the powder dispenser, the binder application unit, and the plurality of cutting devices are positioned to perform a method for generating the plurality of three-dimensional objects located within an environment of an enclosure; and
one or more computer processors operatively coupled to the manufacturing apparatus and configured to control the manufacturing apparatus to perform the method, wherein the one or more computer processors are individually or collectively programmed to:
(i) direct the binder application unit to apply the binding substance to a first area of a first layer of the powder material of the powder bed,
(ii) direct a first set of cutting devices of the plurality of cutting devices to generate a plurality of perimeters in the first layer in the powder bed by removing, in accordance with a model design of each of the plurality of three-dimensional objects held within the enclosure, one or more portions of the first layer of the powder material bound by the binding substance,
(iii) direct the powder dispenser to supply the powder material to deposit a second layer of the powder material,
(iv) direct the binder application unit to apply the binding substance to a second area of the second layer of the powder material of the powder bed, and
(v) direct a second set of cutting devices of the plurality of cutting devices to generate a plurality of perimeters in the second layer by removing, in accordance with the model design of each of the plurality of three-dimensional objects held within the enclosure, one or more portions of the second layer of the powder material bound by the binding substance, thereby simultaneously generating at least a portion of each of the plurality of three-dimensional objects within the enclosure.
18 . The system of claim 1 , wherein the area of the layer of the powder material is a first area of a first layer of the powder material, and the method further comprises:
applying the binding substance to a second area of a second layer of the powder material to form the intermediate three-dimensional object; and
generating at least one perimeter of one of the plurality of three-dimensional objects comprises removing one or more portions of the first area of the first layer and one or more portions of the second area of the second layer of the powder material in the intermediate three-dimensional object bound by the binding substance.
19 . The system of claim 1 , wherein the spray head is an ultrasonic mist generator.
20 . The system of claim 10 , wherein the cleaning unit comprises a stage configured to vibrate to aid in removal of the powder material.