Material supply systems and methods for using the same
A system ( 100 ) includes a build area positioned along a working surface ( 102 ), a supply receptacle ( 110 ) spaced apart from the build area and defining one or more supply receptacle sidewalls and an upwardly-facing receptacle opening ( 114 ), a dosing hopper ( 240 ) positioned above and in selective communication with the supply receptacle, where the dosing hopper is structurally configured to deliver build material to an interior space ( 116 ), and a conveyance hopper ( 260 ) in communication with the dosing hopper ( 240 ).
1 . A system, comprising:
a build area positioned along a horizontal working surface that defines a plurality of openings therethrough;
one or more supply receptacle sidewalls extending vertically under the working surface at a first opening of the plurality of openings and spaced apart from the build area, the one or more supply receptacle sidewalls defining an elongate supply receptacle;
a dosing hopper positioned above the working surface at a location horizontally spaced a distance from and in selective communication with the supply receptacle, the supply receptacle continuously positionally fixed relative to the dosing hopper, wherein the dosing hopper defines an opening that is aligned with a second opening of the plurality of openings in the working surface to deliver build material to an interior space of the supply receptacle;
an excess return disposed horizontally between the dosing hopper and the supply receptacle, the excess return defining a third opening of the plurality of openings in the working surface and in selective flowing communication with the supply receptacle; and
a conveyance hopper in communication with the dosing hopper.
2 . The system of claim 1 , further comprising a build material conveyance system coupled to the conveyance hopper, wherein the build material conveyance system is structurally configured to move build material to a conveyance inlet of the conveyance hopper.
3 . The system of claim 2 , wherein:
the build material conveyance system comprises a build material reservoir in communication with the conveyance inlet of the conveyance hopper; and
the build material conveyance system comprises a conveyance pump in communication with the conveyance hopper, and/or
the build material conveyance system comprises a filter positioned between the pump and the conveyance hopper.
4 . The system of claim 1 , wherein the conveyance hopper is positioned above the dosing hopper.
5 . The system of claim 1 , further comprising one or more of:
a conveyance agitation device coupled to the conveyance hopper; or
one or more conveyance hopper level sensors structurally configured to detect a level of build material within the conveyance hopper.
6 . The system of claim 1 , further comprising a build enclosure that at least partially encloses the build area, the supply receptacle, and a recoat assembly.
7 . The system of claim 6 , wherein the conveyance hopper and/or the dosing hopper is positioned outside of the build enclosure.
8 . The system of claim 1 , further comprising a recoat assembly structurally configured to move build material from the supply receptacle to the build area.
9 . The system of claim 8 , further comprising one or more of:
a recoat build material reclamation system in communication with the dosing hopper and the recoat assembly; or
a separation unit positioned between the dosing hopper and the recoat assembly, wherein the separation unit is structurally configured to separate build material in gas passed to the separation unit from the recoat assembly.
10 . The system of claim 9 , wherein the recoat build material reclamation system further comprises a reclamation pump in communication with the recoat assembly.
11 . The system of claim 10 , further comprising one or more of:
a build enclosure that at least partially encloses the build area, the supply receptacle, and the recoat assembly; or
a cooling unit in communication with and positioned between the reclamation pump and the build enclosure, wherein the cooling unit is structurally configured to cool gas passing from the reclamation pump to the build enclosure.
12 . The system of claim 1 , further comprising one or more of:
a dosing vent coupled to the dosing hopper; or
a vent filter coupled to the dosing hopper.
13 . The system of claim 1 , further comprising a dosing level sensor coupled to the dosing hopper, wherein the dosing level sensor is structurally configured to detect an amount of build material within the dosing hopper.
14 . The system of claim 1 , wherein the conveyance hopper defines a build material portion and a gas portion separated from the build material portion by a conveyance hopper bulkhead.
15 . The system of claim 1 , further comprising a pressurized gas source in selective communication with the conveyance hopper.
16 . The system of claim 1 , further comprising a recoat assembly movable relative to the supply receptacle, wherein a horizontal distance between the dosing hopper and the supply receptacle is such that the recoat assembly is horizontally positionable along the working surface over the third opening between the dosing hopper and the supply receptacle.
17 . The system of claim 1 , wherein the excess return comprises one or more return sidewalls extending between the third opening and the supply receptacle, the one or more return sidewalls being downwardly sloped from the third opening to the supply receptacle.
18 . The system of claim 1 , further comprising a supply chute positioned under the working surface and in selective flowing communication between the supply receptacle and the dosing hopper at the second opening.
19 . The system of claim 18 , wherein the supply chute comprises one or more supply chute sidewalls that extend from the second opening to a supply intersection at the one or more supply receptacle sidewalls, and wherein the dosing hopper is positioned vertically above the supply intersection such that the supply chute is downwardly sloped between the dosing hopper and the supply intersection.