Cartridge-based 3D printing system

Abstract

Embodiments of the invention are directed to a 3D printing system that directs projected light at tunable wavelengths to cure a polymer resin from monomers or oligomers which floats on a dense liquid platform in which the curing occurs within a prepackaged vessel which facilitates the layer is printed at any given time.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS[0001]This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61 / 815,603 filed Apr. 24, 2013, and U.S. Provisional Patent Application No. 61 / 815,607 filed Apr. 24, 2013 which are incorporated herein by reference in its entirety as if fully set forth herein.FIELD OF THE INVENTION[0002]Embodiments of the invention are directed to systems, apparatuses and business models for rapidly building custom products out of polymers using 3D printing systems.BACKGROUND OF THE INVENTION[0003]3D printing or additive manufacturing is a process of making a three-dimensional solid object of virtually any shape from a digital model. 3D printing is achieved using an additive process, where successive layers of material are laid down in different shapes. 3D printing is also considered distinct from traditional machining techniques, which mostly rely on the removal of material by methods such as cutting or drilling (su...

AI Technical Summary

Benefits of technology

[0007]An embodiment of the invention is directed to a 3D printing system that directs projected light at tunable wavelengths to cure a polymer resin from monomers or oligomers that is floating on a more dense liquid platform, wherein the curing occurs within a prepackaged vessel that facilitates the printing of specific layers are any given time.

[0012]The system described uses a cartridge-based system to get around these issues. Because the resin is packaged and contained within a pre-sealed cartridge, when used properly, there will be no exposure to uncured resin. The system uses a so-called ‘z-fluid’ to control height and move the resin relative to the build table inside, allowing clean, efficient prints. This means that the machine will not be exposed to resin and thus never be subject to purge cycles. There are other innovations that readily follow, such as the printing of multiple parts at the same time using different resins. A further advantage is the limited stock required for purchase. Currently, materials are usually sold in large quantities at fairly high prices. This system would enable sale of much smaller amounts of resin in a single batch, also eliminating waste. These lower volumes of stock would also amount to a larger variety of stock.

[0013]Cartridges that are sealed and packaged with the resin can be bought and sold individually following a business models similar to the Keurig K-cup model in which users and customers buy cartridges that fit into a system. The processing occurs in a standardized disposable (or refillable) container in which the contents are variable and chosen by the user. Attachments for the system can allow advanced users self-filling capabilities. This limits cleaning, waste of the resin, purging steps, and allows 24 / 7 use of the equipment to select rapidly from among different color parts, and parts made from different materials.

[0014]The self-contained nature of this system allows for ease in the supply chain and distribution and facilitated standardized packaging in large scale manufacturing facilities. Due to the scale of this system, extremely low cost cartridge packaging can be amortized over large numbers of cartridges. This allows for the potential to produce the system at a very competitive price point to encourage system use.

Problems solved by technology

The first of these is the powdered, sinter-able material used in Selective Laser Sintering (SLS) machines—all of which are currently very high in cost.

These printers tend to have a fairly proportional cost vs quality curve—e.g. low cost printers tend to be of poor resolution and variable build quality.

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