IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0624513
(2012-09-21)
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등록번호 |
US-8718522
(2014-05-06)
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발명자
/ 주소 |
- Chillscyzn, Steven A.
- Comb, James W.
- Hanson, William J.
- Sanders, J. Randolph
- Bacus, Michael W.
|
출원인 / 주소 |
|
대리인 / 주소 |
|
인용정보 |
피인용 횟수 :
18 인용 특허 :
41 |
초록
▼
An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto
An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.
대표청구항
▼
1. An additive manufacturing system for printing a thermoplastic part, the additive manufacturing system comprising: an imaging engine configured to develop imaged layers of a thermoplastic-based powder having a fusion temperature;a movable build platform;a transfer medium having a transfer surface
1. An additive manufacturing system for printing a thermoplastic part, the additive manufacturing system comprising: an imaging engine configured to develop imaged layers of a thermoplastic-based powder having a fusion temperature;a movable build platform;a transfer medium having a transfer surface configured to sequentially receive and convey the imaged layers from the imaging engine to the build platform, and having an opposing contact surface;a heater configured to heat the imaged layers on the transfer medium to at least the fusion temperature;a heater configured to heat a previously transfused layer of a thermoplastic part being printed on the build platform to at least the fusion temperature;a heated layer transfusion element configured to transfuse a heated imaged layer conveyed by the transfer medium onto the heated previously fused layer by engaging the contact surface of the transfer medium so that the transfer medium and the heated imaged layer are pressed between the transfuse element and the build platform, and to disengage therefrom without releasing the transfer medium from the transfused layer; anda cooling unit configured to actively cool the transfused layer to below the fusion temperature while it remains on the transfer medium, so as to transfix the transfused layer before delaminating it from the transfer medium. 2. The additive manufacturing system of claim 1, wherein the layer transfusion element is heated to the fusion temperature. 3. The additive manufacturing system of claim 1, wherein the layer transfusion element comprises a press plate. 4. The additive manufacturing system of claim 3, wherein the moveable build platform is configured to release the transfer medium from the transfused layer by moving away from the transfer medium. 5. The additive manufacturing system of claim 1, wherein the transfer medium comprises a rotatable belt, and wherein the rotatable belt revolves in a rotational path from the imagine engine, past the heater, in between the layer transfusion element and build platform, and past the cooling unit. 6. The additive manufacturing system of claim 1, wherein the layer transfusion element comprises a fusion roller. 7. The additive manufacturing system of claim 6, wherein the transfer medium comprises a rotatable belt that revolves in a rotational path from the imagine engine, past the heater, in between the layer transfusion element and build platform, and past the cooling unit, and wherein the moveable built platform is configured to move at a synchronized rate and direction with the rotatable belt while the fusion roller presses the heated layer to previously fused layers of the printed three-dimensional part. 8. The additive manufacturing system of claim 7, and further comprising a release roller disposed downstream of the cooling unit in the rotational path of the rotatable belt and configured to engage the contact surface of the rotatable belt so as to assist in delaminating the transfused layer from the transfer medium after it is transfixed. 9. The additive manufacturing system of claim 1, wherein the heater comprises a non-contact radiant heater. 10. An additive manufacturing system for printing a thermoplastic part, the additive manufacturing system comprising: an imaging engine configured to develop imaged layers of a thermoplastic-based powder having a fusion temperature;a movable build platform;a transfer medium having a transfer surface configured to sequentially receive and convey the imaged layers from the imaging engine to the build platform, and having an opposing contact surface;a heater configured to heat the imaged layers on the transfer medium to at least the fusion temperature;a heater configured to heat a previously transfused layer of a thermoplastic part being printed on the build platform to at least the fusion temperature;a heated fusion roller configured to be heated to a transfer temperature and further configured to transfuse a heated imaged layer conveyed by the transfer medium onto the heated previously fused layer by engaging and rolling across the contact surface of the transfer medium, and to disengage therefrom without releasing the transfer medium from the transfused layer;a cooling unit configured to actively cool the transfused layer to below the fusion temperature while it remains on the transfer medium so as to transfix the transfused layer; anda release roller disposed downstream of the cooling unit and configured to engage the contact surface of the transfer medium so as to assist in delaminating the transfused layer from the transfer medium. 11. The additive manufacturing system of claim 10, wherein the transfer medium is a rotatable belt that follows a rotational path from the imagine engine, past the heater configured to heat the imaged layers, in between the fusion roller and build platform, past the cooling unit and the release roller, and returning to the imaging engine. 12. The additive manufacturing system of claim 11, wherein the moveable built platform is configured to move at a synchronized rate and direction with the rotatable belt while the fusion roller is engaged to transfuse a heated imaged layer. 13. The additive manufacturing system of claim 10, wherein one or more heaters comprise a non-contact radiant heater. 14. The additive manufacturing system of claim 10, wherein the cooling unit comprises at least one air knife, at least one air jet, or a combination thereof. 15. A method for printing a three-dimensional part with an additive manufacturing system, the method comprising: imaging a layer of the three-dimensional part from a thermoplastic-based powder;transferring the imaged layer to a transfer medium;heating the imaged layer while the imaged layer is retained on the transfer medium;heating a top surface of the three-dimensional part;transfusing the heated layer to the heated top surface of the three-dimensional part;cooling the transfer medium and at least a portion of the transfused layer; andreleasing the transfused layer from the cooled transfer medium such that the transfused layer remains adhered to the three-dimensional part. 16. The method of claim 15, wherein imaging the layer comprises developing the layer with an electrophotography engine. 17. The method of claim 15, and further comprising further cooling the transfused layer to hold the printed three-dimensional part at about an average part temperature that is below a deformation temperature of the three-dimensional part. 18. The method of claim 15, wherein the transfer medium comprises a rotatable belt, and wherein the method further comprises: rotating the rotatable belt at a rotational rate; andmoving the three-dimensional part at a rate that is synchronized with the rotational rate of the rotatable belt. 19. The method of claim 15, wherein heating the imaged layer comprises heating the imaged layer to at least a fusion temperature of the thermoplastic-based powder, and wherein heating the top surface of the three-dimensional part comprises heating the top surface of the three-dimensional part to at least the fusion temperature of the thermoplastic-based powder. 20. The method of claim 15, wherein the transfused layer defines a new top surface of the three-dimensional part, and wherein the method further comprises: imaging a subsequent layer of the three-dimensional part from the thermoplastic-based powder;transferring the subsequent imaged layer to the transfer medium;heating the subsequent imaged layer while the subsequent imaged layer is retained on the transfer medium;heating the new top surface of the three-dimensional part; andtransfusing the heated subsequent layer to the heated new top surface of the three-dimensional part.
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