Granted Patent B2

US 9,517,592 · App. 15/077,112 · Granted Dec 13, 2016

Abstract

Claims (86)

1. A method for the preparation of three-dimensionally printed articles with an equipment assembly, the method comprising:

a) initiating operation of a three-dimensional printing build system comprising:

a modular conveyor system adapted to conduct plural build modules along a circuitous path;

the plural build modules engaged with the modular conveyor system, wherein the plural build modules are adapted to receive and temporarily retain powder from a powder layering system, and the plural build modules comprise respective incrementally height adjustable platforms and removable build plates; and

at least one build station comprising: 1) at least one powder layering system adapted to form incremental powder layers on respective removable plates within the plural build modules; and 2) at least one printing system adapted to apply a liquid according to one or more predetermined patterns to the incremental powder layers;

b) with the modular conveyor system, repeatedly transporting the plural build modules from the at least one powder layering system to the at least one printing system to form three-dimensionally printed beds comprising one or more three-dimensionally printed articles in the plural build modules; and

c) transferring the three-dimensionally printed beds and respective removable plates, one or more at a time, away from the plural build modules and respective incrementally height adjustable platforms.

2. The method of claim 1 further comprising:

a) harvesting the one or more three-dimensionally printed articles from the three-dimensionally printed beds with at least one harvesting system adapted to separate loose powder from the one or more three-dimensionally printed articles.

3. The method of claim 2 further comprising removing liquid from the incremental powder layers or from the three-dimensionally printed beds with at least one liquid removal system.

4. The method of claim 3 further comprising dedusting the one or more three-dimensionally printed articles that have been harvested from respective three-dimensionally printed powder beds to remove loose particles of powder from the one or more three-dimensionally printed articles.

5. The method of claim 3 further comprising:

a) packaging the one or more three-dimensionally printed articles with at least one packaging system;

b) recovering loose powder generated during the process with a powder recovery system;

c) detecting the presence, amount or concentration of liquid present in the one or more three-dimensionally printed articles with a liquid detector; or

d) inspecting the three-dimensionally printed beds or the one or more three-dimensionally printed articles with at least one inspection system.

6. The method of claim 5 , wherein: a) the at least one inspection system is a printed powder inspection system that determines the integrity of printing in incremental powder layers or the one or more three-dimensionally printed articles, or determines whether or not powder was applied in one or more incremental layers; b) the at least one inspection system is a printed article inspection system that determines whether or not the one or more three-dimensionally printed articles have the correct size, shape, weight, appearance, density, content or color; c) the at least one inspection system is a liquid application inspection system that monitors liquid applied to the incremental powder layers; or d) the at least one inspection system comprises one or more cameras.

7. The method of claim 6 , wherein: a) determining the integrity of printing comprises at least one of determining whether or not the liquid has been correctly applied to the one or more incremental powder layers according to the one or more predetermined patterns, or determining whether or not the liquid has been correctly applied to the one or more incremental powder layers according to a predetermined amount; or b) the one or more cameras is independently selected at each occurrence from the group consisting of a visible wavelength camera, an UV wavelength camera, a near infrared wavelength camera, an x-ray camera and an infrared wavelength camera.

8. The method of claim 1 wherein: a) the bed transfer system transfers the three-dimensionally printed beds to one or more liquid removal systems or one or more harvesting systems; or b) the bed transfer system is integrated or synchronized with the modular conveyor system.

9. The method of claim 3 , wherein: a) the at least one liquid removal system processes two or more of the three-dimensionally printed beds at a time; or b) the at least one liquid removal system processes two or more three-dimensionally printed articles at a time.

10. The method of claim 1 further comprising controlling operation of the equipment assembly with a control system comprising one or more computerized controllers, one or more computers, and one or more user interfaces for one or more computers.

11. The method of claim 10 , wherein one or more of the modular conveyor system, the at least one powder layering system, or the at least one printing system are computer controlled.

12. The method of claim 10 , wherein the at least one printing system is computer controlled and the process further comprises providing to the printing system one or more image files comprising pixels, wherein the one or more image files define the one or more predetermined patterns.

13. The method of claim 1 , wherein: a) the plural build modules further comprise respective bodies comprising upper surfaces with respective cavities within which the respective incrementally height adjustable platforms are disposed, respective height adjusters engaged with the bodies and the incrementally height adjustable platforms, and engagement mechanism; b) the plural build modules are removably engaged with the modular conveyor system; or c) the plural build modules further comprises respective one or more sidewalls surrounding respective incrementally height adjustable platforms and being adapted to retain powder on the incrementally height adjustable platforms.

14. The method of claim 13 further comprising raising or lowering the incrementally height adjustable platforms by one or more increments after placing respective incremental powder layers thereon.

15. The method of claim 1 , wherein: a) the modular conveyor system conducts the plural build modules along a planar circuitous path, a horizontal circuitous path, a vertical circuitous path, or a combination thereof; b) the modular conveyor system transports the plural build modules along a path in a counterclockwise direction; or c) the modular conveyor system transports the plural build modules along a path in a clockwise direction.

16. The method of claim 1 , wherein: a) the at least one build station is incrementally height adjustable with respect to the plural build modules, whereby the vertical space between the plural build modules and the at least one build station can be adjusted by one or more increments; or b) the at least one build station is vertically fixed with respect to the plural build modules so that the vertical distance between the at least one build station and the plural build modules remains the same during a print lap or print cycle.

17. The method of claim 1 , wherein the at least one powder layering system comprises at least one powder fill head that does not move either longitudinally or transversely, with respect to the plural build modules, when forming incremental powder layers.

18. The method of claim 1 , wherein the at least one printing system comprises at least one print head that does not move either longitudinally or transversely, with respect to the plural build modules, when applying liquid to the incremental powder layers.

19. The method of claim 1 , wherein the liquid is applied using Cartesian coordinate based printing.

20. The method of claim 19 , wherein the liquid is not applied using polar coordinate based printing.

21. A method for the preparation of three-dimensionally printed articles with an equipment assembly, the method comprising:

a) initiating operation of a three-dimensional printing build system comprising:

a modular conveyor system adapted to conduct plural build modules along a circuitous path;

the plural build modules engaged with the modular conveyor system, wherein the plural build modules are adapted to receive and temporarily retain powder from a powder layering system and the plural build modules comprise respective sidewalls defining respective cavities, incrementally height adjustable platforms disposed within the cavities, and respective removable build plates disposed within the cavities;

at least one build station comprising: 1) at least one powder layering system adapted to form incremental powder layers within the plural build modules and on the removable build plates; and 2) at least one printing system adapted to apply a liquid according to one or more predetermined patterns to the incremental powder layers;

a build plate loading system; and

a bed transfer system;

b) with the build plate loading system, loading removable build plates onto the height adjustable platforms;

c) with the modular conveyor system, repeatedly transporting the plural build modules from the at least one powder layering system to the at least one printing system to form on the removable build plates respective three-dimensionally printed beds comprising one or more three-dimensionally printed articles;

d) with the bed transfer system, transferring the three-dimensionally printed beds and respective removable build plates away from the plural build modules and incrementally height adjustable platforms.

22. A method for the preparation of three-dimensionally printed articles with an equipment assembly, the method comprising:

a) providing a three-dimensional printing build system comprising:

a modular conveyor system adapted to conduct plural build modules along a circuitous path;

the plural build modules engaged with the modular conveyor system, the plural build modules comprising respective sidewalls defining respective cavities, and respective incrementally height adjustable platforms disposed within the cavities;

removable build plates;

at least one build station comprising: 1) at least one powder layering system; and 2) at least one printing system adapted;

one or more build plate loading systems; and

one or more bed transfer systems;

b) with the one or more build plate loading systems, loading removable build plates onto the height adjustable platforms;

c) with the modular conveyor system, repeatedly transporting the plural build modules from the at least one powder layering system to the at least one printing system to form on the removable build plates respective three-dimensionally printed beds comprising one or more three-dimensionally printed articles;

d) with the one or more bed transfer systems, transferring the three-dimensionally printed beds and respective removable build plates away from the plural build modules and incrementally height adjustable platforms.

23. The method of claim 22 , wherein the one or more bed transfer systems transfers the three-dimensionally printed beds and respective removable build plates to one or more liquid removal systems, one or more harvesting systems, one or more packaging systems, one or more dedusting systems, or a combination thereof.

24. The method of claim 22 further comprising:

transferring the three-dimensionally printed beds and respective removable build plates to one or more liquid removal systems; and

reducing the amount of liquid in the three-dimensionally printed beds.

25. The method of claim 24 further comprising:

transferring the three-dimensionally printed beds and respective removable build plates to one or more harvesting systems; and

harvesting the one or more three dimensionally printed articles from the three-dimensionally printed beds.

26. A method for the preparation of three-dimensionally printed articles with an equipment assembly, the method comprising:

a) providing a three-dimensional printing build system comprising:

a modular conveyor system adapted to conduct plural build modules along a circuitous path;

the plural build modules engaged with the modular conveyor system, the plural build modules comprising respective sidewalls defining respective cavities, and respective incrementally height adjustable platforms disposed within the cavities;

removable build plates;

at least one build station comprising: 1) at least one powder layering system; and 2) at least one printing system adapted;

one or more build plate loading systems;

one or more bed transfer systems;

one or more liquid removal systems; and

one or more harvesting systems;

b) with the one or more build plate loading systems, loading removable build plates onto the height adjustable platforms;

c) with the modular conveyor system, transporting the plural build modules from the at least one powder layering system to the at least one printing system to form printed incremental layers on the respective removable build plates;

d) lowering the incrementally height adjustable platforms;

e) with the modular conveyor system, transporting the plural build modules from the at least one powder layering system to the at least one printing system to form printed incremental layers on the respective removable build plates;

f) repeating steps d) and e) to form three-dimensionally printed beds comprising one or more three-dimensionally printed articles in the plural build modules;

g) with the one or more bed transfer systems, transferring the three-dimensionally printed beds and respective removable build plates away from the plural build modules and incrementally height adjustable platforms;

h) transferring the three-dimensionally printed beds and respective removable build plates to the one or more liquid removal systems and reducing the amount of liquid in the three-dimensionally printed beds; and

i) transferring the three-dimensionally printed beds and respective removable build plates to one or more harvesting systems and harvesting the one or more three dimensionally printed articles from the three-dimensionally printed beds.

27. A method for the preparation of three-dimensionally printed articles with an equipment assembly, the method comprising:

a) providing a three-dimensional printing build system comprising a modular conveyor system that conducts plural build modules, with respective height adjustable platforms, along a circuitous path;

b) loading removable build plates onto the respective height adjustable platforms;

c) forming printed incremental layers on the respective removable build plates by transporting the plural build modules from a powder layering system to a printing system;

d) repeating step c), if needed, to form three-dimensionally printed beds comprising one or more three-dimensionally printed articles in the plural build modules; and

e) transferring the three-dimensionally printed beds and respective removable build plates away from the plural build modules and height adjustable platforms.

28. The method of claim 27 further comprising:

f) transferring the three-dimensionally printed beds and respective removable build plates to the one or more liquid removal systems and reducing the amount of liquid in the three-dimensionally printed beds; and

g) transferring the three-dimensionally printed beds and respective removable build plates to one or more harvesting systems and harvesting the one or more three dimensionally printed articles from the three-dimensionally printed beds.

Assignments (10)