Material jetting printer with pressure-assisted fluid extraction

Abstract

A three-dimensional (3D) inkjet printer is configured to build an object by printing a series of layers and stacking them to form the object. To speed printing, the drying of each layer is accelerated by using a pressure differential to remove the liquid carrier from the ink and transferring the printed layer away from the inkjet print head before drying to enable the inkjet print head to print the next layer. The dried printed layer can also be conditioned and / or cured. The dried printed layers are stacked at a build station to assemble the finished object.

Description

Technical Field

[0001] The present invention relates to three-dimensional (3D) printing using an inkjet printer, and more particularly to utilizing vacuum to extract a liquid carrier from printed layers for assembly. Background Art

[0002] Since the first patents were granted over 30 years ago, three-dimensional (3D) printing has garnered significant attention as a potentially faster and more economical manufacturing method. However, to date, this potential has remained largely unrealized. Today, the vast majority of 3D printers are used to create demonstration parts or non-functional samples, most of which are made from plastic materials chosen primarily for compatibility with the printer rather than to meet the material requirements of the final part.

[0003] While binder jet 3D printers are arguably the most efficient technology for creating 3D printed objects, one of their attributes, the ability to deposit relatively thick layers, limits their effectiveness when precise thin layers are required. Inkjet printing can quickly deposit ink over large areas, but its layer thickness is limited to a few microns. The trade-off is that the print resolution is much finer than binder jet printing.

[0004] While inkjet-based 3D printers have been the subject of research and development, the approach has yet to see widespread commercial adoption. As mentioned above, inkjet technology in 3D printing applications offers limited deposition rates, which limits its economic viability. Although printing speeds can be slow with pure inkjet technology, inkjet-based 3D printers offer major advantages. Specifically, inkjet printers are easily adaptable to printing multiple different materials (colors) into a single printed layer. Inkjet printers can easily control the amount of material in each droplet and can achieve pixel sizes as small as 0.010 mm. Furthermore, inkjet printers can print a complete layer very quickly, taking as little as 1 second for an "A4" size sheet of paper.

[0005] The downside is that while inkjet printers can cover a large area per second, the volume per unit time, especially in the case of 3D printers, is very low. Currently available 3D printers based on inkjet technology are capable of depositing several hundred cubic centimeters of active material per hour, which can be compared to the deposition rate of jetted binders, which can reach tens of liters per hour.

[0006] Therefore, there is still a need for a 3D printing system that can maintain the fine resolution of inkjet technology and significantly increase the printing speed. Summary of the Invention

[0007] In one aspect, a three-dimensional (3D) printer comprises: a receiver device comprising a substrate; an inkjet print head configured to deposit ink on the substrate to form a printed layer, wherein the ink comprises a suspension of a particulate material in a liquid carrier; a removal system configured to remove a portion of the liquid carrier from the printed layer using a pressure differential to form a dried layer; and a transfer system configured to transfer the dried layer to a build station.

[0008] On the other hand, a three-dimensional (3D) printing method includes: depositing ink onto a substrate using an inkjet print head to form a printed layer, the ink including a particulate material and a liquid carrier; transferring the printed layer from the inkjet print head, removing a portion of the liquid carrier from the printed layer using a pressure difference to form a dried printed layer; and transferring the dried printed layer to a building station to form a stacked printed layer.

[0009] In another aspect, an inkjet printer includes: a receiver device including a substrate, an inkjet print head configured to deposit ink on the substrate to form a printed layer, wherein the ink includes a suspension of particulate material in a liquid carrier; and a removal system configured to remove a portion of the liquid carrier from the printed layer using a pressure differential.

[0010] The above summary introduces in simplified form some concepts that will be further described in the detailed description below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter. Furthermore, the claimed subject matter is not limited to implementations that solve any or all deficiencies noted in any part of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The accompanying drawings illustrate one or more embodiments of the present invention by way of example and not limitation. In the accompanying drawings, the same reference numerals refer to the same or similar elements. In addition, it should be understood that the accompanying drawings are not necessarily drawn to scale.

[0012] Figure 1 The control flow of a 3D inkjet printer is shown;

[0013] Figure 2 shows a schematic diagram of a 3D inkjet printer;

[0014] Figure 3 Shown Figure 2 a diagram of the layers of the receiver / carrier arrangement shown;

[0015] Figure 4 Shown Figure 3 a top view of a receiver assembly including a plurality of apertures as shown;

[0016] Figure 5 Shown Figure 3 a top view of a receiver device including a fiber material as shown;

[0017] Figure 6 shows a schematic diagram of a pressure-assisted system for removing solvent;

[0018] Figure 7 A schematic diagram showing a pressure plate for removing solvent;

[0019] Figure 8 A schematic diagram showing a pressure belt for removing solvent is shown;

[0020] Figure 9 A schematic diagram showing a roller transfer device;

[0021] Figure 10 shows a schematic diagram of an articulated transfer device;

[0022] Figure 11 shows a schematic diagram of a planar pressure transfer device;

[0023] Figure 12 shows a schematic diagram of a bending pressure transfer device;

[0024] Figure 13 A schematic diagram of a multi-method 3D printer system is shown;

[0025] Figure 14 A schematic diagram of a computer system for controlling a 3D inkjet printer is shown;

[0026] Figure 15 A schematic diagram of a print station controller for use with a 3D inkjet printer is shown;

[0027] Figure 16 A block diagram illustrating an exemplary computing device that may be used to implement the systems and methods described herein;

[0028] Figure 17 A block diagram illustrating components of an example machine configured to read instructions from a machine-readable medium is shown. DETAILED DESCRIPTION

[0029] In the detailed description that follows, numerous specific details are presented by way of example to facilitate a more comprehensive understanding of the relevant technical teachings. However, it will be apparent that the present technical teachings can be practiced without such details. In other instances, well-known methods, procedures, components, and / or circuits are described in relatively general terms without detailed description to avoid unnecessarily obscuring aspects of the present invention.

[0030] Inkjet printheads operate most efficiently with low-viscosity inks, for example, those with viscosities of approximately 40 centipoise (cP) or less, which can require very low levels of insoluble materials such as metals, ceramics, or polymers. Typically, the volume content of insoluble materials in inkjet inks is 20% or less. The binder may comprise 5% to 20% of the total ink volume, leaving 60% to 75% or more as liquid carrier, most of which needs to be removed to achieve a practical green density of at least 40% active material by volume.

[0031] Material jetting printers can be used with inks containing materials that polymerize into a solid substance after deposition, a method that can be used to manufacture parts composed primarily of organic materials. While it is theoretically possible to formulate jettable, nearly 100% polymerizable materials, it is unlikely that inks containing solutions of inorganic materials will exceed approximately 20% of the volume of the persistent material. Therefore, if material jetting printers are to be suitable for high-speed 3D printing, a device must be provided that can remove the majority of the liquid carrier deposited during a printing cycle faster than by evaporation alone. The printer described herein provides just such a tool, utilizing an applied pressure differential drying technique to enhance or replace evaporation, and in some embodiments, is capable of printing subsequent layers while drying previous layers.

[0032] The 3D inkjet printers described herein are designed to create printed objects, layers, and parts using combinations of materials not typically associated with inkjet printing. These materials can be high-performance engineered materials specifically designed to meet the engineering requirements of the final printed part and contained within inks designed for use in inkjet printheads. These materials can include ceramics and metals as particles suspended in a liquid carrier, as well as organic materials.

[0033] Printing process

[0034] The basic process for manufacturing 3D printed parts typically starts with a CAD file that fully defines the structure, materials, and specifications of the desired part. The part described in the CAD file can be sliced ​​into print pattern layers, with the thickness of each layer determined by the specifications of each position within the printed part, such as the final thickness and pattern tolerance. Each layer is then divided into areas that may require different materials. The printer control instructions for each area with different material requirements are then sent from the design file to the appropriate print station control unit of the jetting material printer system via an input device and a central processing unit and an interface bus. As used herein, a "printed part" includes any combination of printed sub-parts or layers that can be fused together to form a part. Such an assembly may be referred to as a "printed part" before or after its components are fused together. As used herein, a "printed layer" includes a layer of one or more materials of one unit thickness that may have a horizontal design that meets the design requirements at a preset position within the desired printed part.

[0035] Figure 1 A method 100 for creating a 3D printed part at a high level of generalization is shown. The details of each step of the illustrated method will be expanded upon in the subsequent figures described below. Method 100 begins by depositing inkjet ink onto a substrate in a patterned layer using an inkjet printhead as described below (step 104). The deposited patterned layer is then transferred away from the inkjet printhead (step 106), and a pressure differential is applied to facilitate rapid drying of the printed layer (step 108). Optionally, the printed layer may be conditioned, cured, and / or further dried (step 110). Once the processing steps for a single printed layer are completed, the printed layer is transferred to a build station where it is transferred to the stack of previously printed layers (or, for the first layer printed, a new stack is started at the build station) (step 112). This process is repeated until all layers of the desired printed part have been transferred to the build station (conditioning step 114). For some embodiments, after all layers have been stacked at the build station, post-processing of the printed part can be completed (step 116), for example, by sintering the stacked layers together or by applying heat or another energy input to activate the binder of the conditioning step. Finally, the finished printed part is removed from the build station (step 118).

[0036] 3D jetting printer

[0037] refer to Figure 2 and Figure 3 The deposition of the patterned layer (step 104) begins by providing an inkjet ink suitable for each of the plurality of inkjet print heads 202 of the 3D inkjet printer 200 to a receiver device (also referred to herein as a carrier 204 or receiver 204) which is provided at Figure 22 is shown as a continuous strip. In other embodiments, the receiver device 204 may take other forms, such as individual carrier sheets or extended lengths of carrier material that may be cycled through the printer once before being repaired or processed. Each of the plurality of inkjet print heads 202 deposits ink in a preset pattern of printed layers according to instructions received from a control system that communicates with a computer, as will be described below in conjunction with Figure 14 and Figure 15 The deposited ink forms a printed layer 304, Figure 3 As can be seen in the figure, it is located on top of the receiver device 204 and the permeable membrane 302, which will be further described below. Each of the multiple inkjet material print heads 202 is supplied with inkjet ink containing the same or different building materials, and each material meets the preset physical specifications. Each of the multiple inkjet print heads can be of a type known in the art and provided by companies such as Xaar, Hewlett Packard and Konica Minolta (for example, a piezoelectric head, a thermal head or a valve-based head). The multiple print heads can all be of the same type, or each of the multiple print heads can be a type different from one or more other print heads in the multiple print heads. The print head 202 can be configured to print directly onto the receiver device 204 to create a 3D printed layer thereon or on the permeable membrane 302 located on the receiver device 204, as discussed further below.

[0038] As shown below, combined Figure 15 As directed by the print station controller depicted, each printhead 202 deposits a predetermined amount of inkjet ink in a predetermined voxel pattern onto the receiver device 204. The predetermined pattern of voxels for any one of the plurality of printheads 202 may be separate from all voxel patterns for any other printhead in the plurality of printheads 202, or it may partially or completely overlap with the voxel patterns for any or all of the other printheads in the plurality of printheads 202. The result is a complete printed layer 304 of the predetermined pattern of multiple ink types on the receiver device 204. It should be understood that the "complete" pattern of ink may not provide 100% coverage of the receiver device 204, depending on the part to be printed and any subsequent processing of the layer.

[0039] The receiver device 204 can be moved in the direction of travel using the printer drive motor 256 (step 106) so that the printed layer 304 can be placed in juxtaposition with the vacuum liquid extraction device 206. The vacuum liquid extraction device 206 is then evacuated to partially or completely remove the low viscosity components of the ink constituting the printed layer 304 from the printed layer 304, thereby drying the layer. Figure 6-Figure 8 As further discussed, fluid pressure may be applied to an optional upper portion of the liquid extraction device 206 to assist in removing liquid.

[0040] like Figure 1 As shown in step 110 of FIG. 1 , the receiver device 204 can be moved in the direction of travel so that the printed layer 304 is juxtaposed with the conditioning device 208, as will be further described below. Before, after, or in lieu of conditioning the printed layer 304, the receiver device can also move the printed layer 304 adjacent to a curing device 210, which can be used to cure the printed layer 304, as described below. Before or after any of these steps, the printed layer 304 can be moved to an additional fluid removal device 212, which can further remove carrier fluid that was not extracted in the previous steps.

[0041] After printed layer 304 has dried, and optionally conditioned and / or cured, receiver device 204 can move it to build plate 214, where it can be transferred to build plate 214 using transfer device 216. As used herein, "transfer device" includes any device for moving printed layers to an assembly device. First printed layer 304 can be transferred directly to build plate 214, and subsequent layers can be placed thereon to form stack 218 of printed layers.

[0042] The receiver device 204 may be equipped with a printer drive motor 256 so that the receiver device 204 can be moved in the direction of travel (under the control of the print station control unit). The plurality of print heads 202 may be positioned such that the nozzles of each of the plurality of print heads 202 form one or more substantially straight lines, and the lines of nozzles in all of the plurality of print heads 202 are parallel to each other and juxtaposed. In an embodiment of the present application, the plurality of print heads may be aligned such that the parallel rows of nozzles are aligned perpendicular to the direction of travel of the receiver device 204, and the nozzles may extend substantially across the entire width of the receiver device 204. The plurality of print heads 202 may be equipped with a transport device to move the plurality of print heads 202 across the length of the receiver device 204, thereby creating a predetermined voxel pattern on the receiver device 204.

[0043] In some embodiments of the present application, multiple printheads can be fixed across the width of receiver device 204, and receiver device 204 can be moved in the direction of travel, so that the multiple printheads can deposit a predetermined ink pattern in the form of voxels across the length of receiver device 204. In other embodiments, the parallel rows of nozzles can be aligned parallel to the direction of movement of receiver device 204. In this case, multiple printheads 202 can be equipped with a transport device to allow multiple printheads 202 to traverse the width of receiver device 204, thereby creating multiple predetermined ink patterns in the form of voxels on receiver device 204. Regardless of the configuration of the printheads 202, they can collectively deposit an ink layer, which will be referred to as a print layer 304.

[0044] The receiver device 204 may include a permeable membrane 302, such as Figure 3 As shown, the permeable membrane 302 is at least partially permeable to low viscosity liquids, such as liquids having a viscosity of less than about 2 cP, 4 cP, 6 cP, 8 cP, 10 cP, or 12 cP. Figure 4 As shown, the permeable membrane 302 may comprise a metal, metal alloy, or other material, further comprising an array of permeable pores 402 communicating between the two major surfaces of the permeable membrane 302. In the following description, for convenience, the surface of the membrane 302 on which the ink is deposited will be referred to as the "top," while the opposite surface will be referred to as the "bottom," but it will be understood that the receiver device 204 and the permeable membrane 302 may be oriented in any convenient direction. The permeable pores 402 may be positioned in the bottom of the membrane 302. Figure 4 It is shown as a cylinder, but may have other regular or irregular shapes.

[0045] In other embodiments, the permeable membrane 302 may also include a woven or non-woven fiber material that may exhibit porous properties to liquids having lower viscosities, but exhibit non-porous properties to higher viscosity liquids and particles. For example, in one embodiment, liquids having a viscosity of less than about 12 cP may pass through the membrane 302, while liquids having higher viscosities may be substantially unable to pass through the membrane. It should be understood that another threshold value of liquid viscosity as described above may be used. The receiver device 204 may also include, for example, Figure 5The support frame 502 shown can provide mechanical support for the permeable membrane 302. The support frame 502 can include a metal, such as an iron alloy or a copper alloy. The support frame 502 can also include a polymer material or a composite material of a polymer material and a fiber material, and the fiber material is, for example, a carbon fiber, a glass fiber, or an organic fiber. The support frame 502 can include a composite material of a polymer material and a metal or a metal alloy. In some embodiments, the support frame 502 can present a continuous sheet structure, which can be provided with holes in which the permeable membrane 302 can be installed. In other embodiments, the support frame 502 can be a discrete window frame-like structure surrounding the permeable membrane 302. In any one of these embodiments, the support frame 502 can be a separate structure, or it can be fixed to the permeable membrane 302.

[0046] The receiver device 204 can be configured to move the permeable membrane 302 away from the print head 202 after the printed layer 304 has been deposited on the permeable membrane 302, for example, by the action of the printer drive motor 256. The printed layer 304 can be moved to the solvent extraction device 206, which can use a pressure differential to dry the printed layer 304. By moving the printed layer 304 away from the print head 202 before drying, the 3D printer can print another printed layer in parallel with the drying process.

[0047] The solvent extraction apparatus 206 may include a vacuum chamber 310, which may include a vacuum-tight housing and a liquid-permeable support 312. In some embodiments, the solvent extraction apparatus 206 may also be provided with a connection to a vacuum source (not shown). In some embodiments, for example, Figure 6-Figure 8 As shown, instead of or in addition to applying a vacuum to the bottom of the printed layer 304, the solvent extraction system can apply a pressure differential by applying a positive pressure to the top surface of the printed layer 304.

[0048] Immediately after the printed layer 304 has been deposited onto the permeable membrane 302, it may include a substantial amount of low-viscosity liquid, for example, up to 90% by volume. After the printed layer 304 (on the permeable membrane 302) has been positioned in contact with the vacuum liquid extraction device 206, the vacuum chamber 310 may be evacuated by a vacuum source connected thereto to create a pressure differential across the printed layer 304. The pressure differential across the printed layer 304 may cause a substantial amount (for example, up to 90%) of the low-viscosity liquid in the layer to be forced through the permeable support 312 and into the vacuum chamber 310, thereby converting the printed layer 304 into a dry layer for subsequent processing, as described below.

[0049] refer to Figure 6-Figure 8In certain embodiments of the present invention, liquid extraction may be enhanced by a pressure device 602, 700, 800 located on top of the printed layer 304, opposite the permeable membrane 302, relative to the liquid extraction device 206.

[0050] Pressure chamber assisted fluid extraction

[0051] Figure 6 A fluid pressure device 602 is shown, which applies fluid pressure to the surface of the printed layer 304 opposite the permeable membrane 302 to enhance the extraction of low-viscosity liquids from the printed layer 304. The fluid pressure device 602 may include a pressure chamber wall 604 and a compliant seal 606 to contain a pressure above ambient pressure within the pressure chamber 608. After the printed layer 304 on the permeable membrane 302 has been positioned in contact with the vacuum liquid extraction device 206 and a seal has been formed by the compliant seal 606, the pressure within the pressure chamber 608 can be increased above ambient pressure while the pressure within the vacuum chamber 310 drops below ambient temperature, thereby increasing the overall force required to remove the low-viscosity liquid from the printed layer 304. The fluid used to apply pressure to the printed layer 304 in the fluid pressure device 602 may include a gas, such as air, nitrogen, argon, oxygen, steam, or a gaseous compound or combination of gases. In some embodiments, the fluid used to apply pressure to the printed layer 304 in the fluid pressure device 602 may include a liquid rather than a gas. Whether a liquid, gas, or mixture, the fluid used to apply pressure to the printed layer 304 in the fluid pressure device 602 can also promote changes in the composition of the printed layer 304 in order to, for example, adjust the final properties of the printed material by reacting with materials on or below the surface of the printed layer 304.

[0052] Pressure plate assisted fluid extraction

[0053] In another embodiment of the present application, Figure 7 , to enhance the removal of low-viscosity liquids from the printed layer 304. When the printed layer 304 is positioned in contact with the vacuum liquid extraction device 206, the pressurizing device 702 can cooperate with the evacuation of the vacuum chamber 310 to apply pressure to the printed layer 304 to enhance the force applied to extract the low-viscosity liquid from the printed layer 304.

[0054] Pressure band assisted fluid extraction

[0055] In another embodiment of the present application, Figure 8A pressure belt assembly 800 is shown to enhance the removal of low-viscosity liquids from the printed layer 304. The pressure belt assembly 800 may include an inflatable pressure belt 802 and a belt mount 804. When the printed layer 304 is positioned adjacent to the vacuum liquid extraction device 206 (opposite the receiver assembly 204), the pressure belt 802 may be inflated to apply pressure to the printed layer 304 in conjunction with evacuating the vacuum chamber 310 to enhance the force applied to extract the low-viscosity liquid from the printed layer 304.

[0056] Adjustment device

[0057] Back to Figure 2 After the liquid is partially or completely removed from the printed layer 304 by the action of the vacuum liquid extraction device 206, the receiver device 204 can be caused to transfer the printed layer 304 on the permeable membrane 302 in the direction of travel (driven by the printer drive motor 256) to the optional conditioning device 208. The exact steps for conditioning a particular material may vary depending on the physical and chemical properties of the powder components in the ink and the target properties of the material after any post-printing steps. In some embodiments, conditioning can include a compaction step, for example to increase the density of the printed layer to 30%-70% of the theoretical density. In some embodiments, compaction can include a sedimentation step, such as a vibration applied to the layer to cause the particles to settle and accumulate together. In another embodiment, compaction can include pressing the particles together with a force perpendicular to the surface of the layer.

[0058] Conditioning device 208 may include a compacting device, such as a calender roller as shown, or alternatively may include another device for applying pressure, such as a pressure belt device (not shown). Conditioning device 208 is configured to increase the compacted density of the material of dried printed layer 304, for example to at least 30% of theoretical density. Conditioning device 208 may also include devices for enhancing or enabling subsequent stages of the printing system to perform other processes, such as applying a coating to improve the effectiveness of curing device 210 described below. Conditioning device 208 may also perform a surface conditioning action on dried printed layer 304 to enhance the transfer of dried printed layer 304 to the stack of previously transferred layers 218, as described below in conjunction with Figures 9-12 The conditioning device 208 may also include a heater device, which in some embodiments can be used to evaporate the remaining portion of the liquid carrier of the printed layer.

[0059] Conditioning can also include actions that improve the properties of printed layer 304, such as robustness or uniformity, or the ability of printed layer 304 to adhere to build plate 214 or to the top of a stack of previously transferred layers 218. Conditioning can also include steps to reduce the packing density of particles in printed layer 304. This operation can include heating or cooling printed layer 304. In other embodiments, the properties of conditioning device 208 can be selected to suit the conditioning requirements of printed layer 304. For example, conditioning device 208 can apply radiation, such as RF radiation, X-ray radiation, or UV radiation, to alter the properties of the binder phase of unconditioned printed layer 304, thereby controlling the physical properties of printed layer 304. Printed layer 304 can be further conditioned by altering its electrostatic state to improve the ability of printed layer 304 to be transferred from receiver device 204 to build plate 214 or to the top of a stack of previously transferred layers 218. Such electrostatic exposure may cause the adhesion of printed layer 304 to be altered such that, when printed layer 304 contacts build plate 214, or contacts the top of a stack of previously transferred layers 218, the adhesion between printed layer 304 and receiver device 204 is lower than the adhesion between printed layer 304 and build plate 214, or lower than the adhesion between printed layer 304 and the top of a stack of previously transferred layers 218. Transferring printed layer 304 to build plate 214, or to the top of a stack of previously transferred layers 218, may thereby be facilitated.

[0060] Curing device

[0061] like Figure 2 As shown, an optional curing device 210 can be provided. The curing device 210 can be arranged downstream of the conditioning device 208 and / or downstream of the solvent extraction device 206 along the direction of travel. The curing device 210 can be configured to cure the binder material in the ink, thereby curing the ink into a functionally strong solid pattern. The curing device 210 may include a radiation energy source that can interact with the binder material to cause it to become a solid. In some embodiments, the radiation energy can be IR radiation, UV radiation, electron beam, or other known radiation types. Alternatively or in addition, the curing device 210 may include a heat source. It should be understood that the curing device 210 is not necessarily limited to the radiation types disclosed, as those listed here are given for exemplary embodiments and are not intended to be exhaustive.

[0062] Other fluid removal devices

[0063] like Figure 2 As shown, an optional fluid removal device 212 may be provided. The fluid removal device 212 may include a heating device or other fluid removal device, such as the one described above in conjunction with Figure 6 The vacuum chamber is used to completely or partially remove any remaining low-viscosity liquid from the dried printed layer.

[0064] exist Figure 2 Downstream of the fluid removal device 212 shown, a transfer device 216 may be provided. The transfer device 216 is used to transfer the dried print layer 304 from the receiver device 204 directly to the build plate 214 or to the top of a stack of previously transferred dried print layers 218, as described below in conjunction with Figures 9-12 further discussed.

[0065] Roller transfer device

[0066] In such Figure 9 In one embodiment of the transfer device 216 shown, the transfer device 216 includes a roller 902 and a carriage 904 for vertically supporting and moving the roller 902. In some embodiments, the carriage 904 may be a biaxial carriage that allows for vertical and horizontal movement of the roller 904 relative to the receiver device 204. Vertical movement of the biaxial carriage 904 can deflect the receiver device 204 and bring the printed object 304 into pressure contact with the build plate 214 or the top of a previously transferred stack of printed layers 218. Horizontal movement of the biaxial carriage 904 can then induce a line of contact that moves in a predetermined direction, from one end of the printed layer 304 to the other end. This moving line of contact across the printed layer 304 can transfer the printed layer 304 to the top of the build plate 214 or the stack of previously transferred printed layers 218.

[0067] Articulated transfer device

[0068] In another embodiment, Figure 10As shown, transfer apparatus 216 can be provided with a forming press 1002 and an articulation 1004. Transfer apparatus 216 can also be provided with a biaxial carriage 1006 that can provide horizontal and vertical movement of forming press 1002. Under the control of a print station control unit (described below), the vertical and horizontal movement of forming press 1002 can vertically deflect receiver assembly 204 and bring print layer 304 into contact under pressure with build plate 214 or the top of a stack of previously transferred print layers 218. Further vertical and horizontal movement of biaxial carriage 1006, in conjunction with articulation 1004, can gradually bring the entire forming surface of forming press 1002 into linear contact under pressure with receiver assembly 204. This progressive linear contact with receiver assembly 204 can deflect receiver assembly 204, thereby inducing progressive linear contact between print layer 304 and build plate 214 or the top of a stack of previously transferred print layers 218. The gradual line contact between printed layer 304 and build plate 214 or the top of the stack of previously transferred printed layers 218 is sufficient to transfer printed layer 304 to build plate 214 or the top of the stack of previously transferred printed layers 218.

[0069] Pressure device

[0070] In another embodiment, Figure 11 As shown, transfer device 216 can include a pressure device 1100. Pressure device 1100 can be provided with a single-axis bracket 1102 to provide vertical movement of pressure device 1100. Vertical movement of pressure device 1100 can vertically deflect receiver device 204 and cause print layer 304 to contact build plate 214 or a stack of previously transferred print layers 218 under pressure.

[0071] Shape adjustment device

[0072] In another embodiment, Figure 12As shown, transfer device 216 may be provided with a pressure device 1202 and a shape adjustment device 1204. Transfer device 216 may also be provided with a single-axis bracket 1206 that provides vertical movement of pressure device 1202. The vertical movement of pressure device 1202 may cause vertical deflection of receiver device 204 and bring printed layer 304 into contact with build plate 214 or the top of a stack of previously transferred printed layers 218 under pressure. Shape adjustment device 1204 may include a preformed molding structure that may include an elastic material that can be flattened by mechanical pressure applied perpendicular to the molding surface. As single-axis bracket 1206 brings the printed object into contact with build plate 214 or the top of a stack of previously transferred printed layers 218, shape adjustment device 1204 may gradually flatten, thereby gradually bringing printed object 304 into contact with build plate 214 or the top of a stack of previously transferred printed layers 218. The gradually moving contact between build plate 214 or the top of the stack of previously transferred print layers 218 may ensure uniform attachment between printed object 304 and build plate 214 or the top of the stack of previously transferred print layers 218 .

[0073] Adhesion adjustment device

[0074] Figures 9-12 Any of the aforementioned transfer devices 216 shown in FIG may further include an adhesion modulating device. The adhesion modulating device can adjust the adhesion strength between the printed layer 304 and the receiver device 204 to facilitate release of the printed layer 304 onto the build plate 214 or onto the top of the stack of previously transferred printed layers 218. The adhesion modulating device can further modify the adhesion of the printed layer 304 to the surface of the build plate 214 or onto the top of the stack of previously transferred printed layers 218, such that the adhesion between the printed layer 304 and the receiver device 204 is less than the adhesion between the printed layer 304 and the build plate 214 or onto the top of the stack of previously transferred printed layers 218. The adhesion modulating device can act on the interface between the receiver device 204 and the printed layer 304 by applying a stimulus to the receiver device 204 and / or the printed layer 304. Applying the stimulus can facilitate reducing the adhesion between the printed layer 304 and the receiver device 204. The stimulus that causes the adhesion modulating device to cause ...

[0075] Assembly device

[0076] Figure 22 shows a portion of an assembly apparatus 262, which includes an XY positioner apparatus 230 and a build station 260. As used herein, an "assembly apparatus" includes any system capable of receiving printed objects from a plurality of transfer modules in a manner that assembles printed layers and printed parts according to a predetermined design. Build station 260 may include a build plate 214. An AZ-axis positioning apparatus 264 may be provided that adjusts the vertical position of build plate 214 to maintain the layer on top of previously transferred printed layer 218 at a predetermined vertical position to facilitate proper transfer of printed layer 304 to build plate 214 or the top of a stack of previously transferred layers 218.

[0077] Build plate 214 may include an adhesion reducing device (not shown) to facilitate removal of the stack of completed printed objects from build plate 214 in step 118. The adhesion reducing device may be activated to reduce the adhesion of the stack of previously transferred layers 218 by applying a stimulus. The stimulus that causes the adhesion reducing device to release the stack of previously transferred layers 218 may be a thermal stimulus, a radiation stimulus, a magnetic stimulus, a chemical stimulus, an electrical stimulus, or a mechanical stimulus.

[0078] Alignment system

[0079] like Figures 9-12 As shown, build plate 214 may also include alignment sensors 906. Print layer 304 may include one or more alignment datums 908 that can interact with one or more alignment sensors 906 to precisely align printed object 304 with build plate 214 or with the top of a stack of previously transferred printed objects. Alignment sensors 906 can interact with alignment datums 908 magnetically or mechanically in the UV spectrum, visible spectrum, or IR spectrum. In some embodiments, in conjunction with computer system 1400, alignment sensors 906 can detect the position of alignment datums 908 to within 0.01 mm of the actual position and position build plate 214 relative to alignment datums 908 to within 0.01 mm of a preset position.

[0080] Assembly device positioner

[0081] like Figure 2 As shown, the assembly apparatus may include an XY positioning device 230 and a build station 260. Build station 260 may also include a Z positioning device and a build plate 214. In some embodiments, build station 260 may interact with build plate 214 and XY positioner apparatus 230 to position build plate 214 within 0.01 mm of a predetermined position relative to any one of a plurality of transfer devices 216 comprising a multi-material, multi-module printer system, under the instruction of computer system 1400.

[0082] The XY positioning device 230 may include a computer-controlled XY motion system. The motion system may be, but is not limited to, a pair of orthogonally connected linear actuators or a planar XY linear motor. The build station 260 may communicate with the XY motion system so that the build station 260 can be moved to any point within the range of the XY positioning device 230. The XY motion system may be scalable so that the build station 260 can be moved and accurately positioned to receive a printed layer transferred from any of the multiple transfer devices 216 associated with the printer system. The XY positioning device 230 may be further scalable so that the build station 260 can be moved to an unloading position away from all printer modules associated with the printer. The clearance from the associated modules may be set in the XY plane or by spacing orthogonal to the XY plane. The build station 260 may also be provided with a rotational motion system to provide rotational alignment of the build plate 214 with the transfer device 216.

[0083] In another embodiment, precise positioning of build plate 214 can be provided by a hexagonal mount that can provide translation along the X, Y, and Z axes, as well as rotation about at least one axis.

[0084] In some embodiments, once all printed layers have been transferred to the assembly apparatus, the 3D printer may apply heat, radiation, pressure, or other suitable methods to adhere the stacked layers to each other to form the printed part. For example, heat may be applied in the final stage (or before the final stage) to sinter adjacent layers to each other. In other embodiments, the stacked layers may be attached to each other to form the finished part without such post-processing, or the part may be sintered into its finished form after being removed from the assembly apparatus.

[0085] Multi-method 3D printing system

[0086] Figure 13 One embodiment of a multi-method 3D printer system 1300 is shown. Figure 13 Four printer modules 1302, 1304, 1306 and four transfer devices are shown in association with an assembly device. As used herein, a "printer module" includes a patterning and deposition system capable of creating a printed object on a receiver device. Each of the four printer modules can implement different patterning and deposition technologies. The ejection material printer module 1302, such as an inkjet printer module, may include the above-mentioned Figure 2. Printer module 1304 is shown as an electrophotographic 3D printer, while printer module 1306 is shown as a material jetting printer. Multi-method printer system 1300 may include printer modules based on 3D printing technologies other than the one shown, such as laminated object manufacturing or selective laser melting, fused deposition modeling, or other suitable 3D printing methods.

[0087] Figure 13 A printer system is shown having four printer modules / transfer devices, wherein the four printer modules / transfer devices are aligned at right angles to adjacent modules, with their proximal ends facing the center of the XY positioner device 230. It will be appreciated that this configuration is not limited to four printer modules A, and may also include two printer modules, three printer modules, or more than four printer modules. It will also be appreciated that the printed component removal area can be provided by horizontally spacing any open area of ​​the XY positioner 230, or by vertically spacing the assembly station 260 from the printer modules A and transfer modules B. It will also be appreciated that the alignment of adjacent modules can be parallel rather than orthogonal. Other configurations will be apparent to those skilled in the art.

[0088] like Figure 13 As shown, the multi-material multi-method 3D printer 1300 includes a plurality of printer modules and associated transfer devices integrated by an assembly device. Each printer module can adjust the following operating parameters, such as printing thickness, binder concentration, binder type, and material type. Although adjusting the operating parameters may significantly affect the properties of the final printed object, each printer module generally creates a printed object based on a specific method. A non-exhaustive list of potential methods includes jet binder printing, electrophotographic printing, offset printing, and jet material printing. The method for creating a given printed object can be selected based on the capabilities of the various methods, such as the practical thickness range, minimum feature size, accuracy, and printing rate. Although most printing methods may be compatible with one or more materials, the base material may require special preparation for use with a specific method.

[0089] In practice, a multi-material, multi-method 3D printer can be configured with a printer module for each combination of printer methods and materials required for the final manufactured part. In one embodiment, at least one of the multiple printer modules comprising the multi-method 3D printer system can be quickly and portably replaced with another module based on the requirements of a specific final part. In another embodiment, the multi-method 3D printer can be integrated into a modular unit capable of using different methods to print different layers of any given part.

[0090] As described above, implementations of the present invention are directed to a 3D printer system comprising a plurality of printer modules, each of which may be associated with one of a plurality of transfer devices, all of which may be coupled to an assembly device. A central computer system may coordinate the operation of all components of the 3D printer system, as follows: Figure 14 As shown. The plurality of printer modules may include printer modules that employ at least two different deposition and patterning technologies, and each of the plurality of printer modules may be configured to create printed objects of one material or of multiple materials. Each printer module may create printed objects of different materials, some printer modules may use the same material, or all printer modules of the 3D multi-method printer system may use the same material. The printer module with the associated transfer device may be configured to be easily combined with or removed from the assembly device, thereby making it easy to custom configure the printer to match the build requirements.

[0091] When using Figure 13 In the case of a multi-process 3D printer as shown, the jetting material 3D printing module 1302 can have a build plate 214 on which subsequent inkjet printed layers can be stacked as described above, or a central build plate can be used to stack layers from multiple printing modules. The jetting material module 1302 can cooperate with other printer modules 1304, 1306 to assemble a printed part that includes parts made from stacked inkjet printed layers and other parts made from other processes, such as a jetted binder part produced by the printer module 1306.

[0092] In one embodiment, the inkjet 3D printing module 1302 may include a receiver device including a substrate, an inkjet print head configured to deposit an ink comprising a suspension of a particulate material in a liquid carrier on the substrate to form a printed layer, a removal system configured to remove a portion of the liquid carrier from the printed layer using a pressure differential to form a dried layer, and a transfer system configured to transfer the dried layer to a build station.

[0093] Material Type

[0094] The types of materials used for printing can be broadly divided into two basic categories: robust materials and volatile materials.

[0095] Robust materials are those that can undergo post-printing processing steps to become incompressible voxels of the final printed part. Robust materials can withstand post-processing steps with the same composition and structure as the printed material.

[0096] Examples of such materials include ceramics, such as alumina, which start as Al2O3 powder and exist as a high-density block of Al2O3 after a post-printing sintering process, or metals, such as stainless steel alloy powder, which exist as a solid block with the same alloy content as at the start after a post-printing sintering process.

[0097] Robust materials can also begin as precursors to the final material. Post-printing processes can cause the robust material's precursor to react to form new compounds or change phases or crystal types. Examples of such materials are aluminum powder, which transforms into aluminum oxide in a controlled oxidizing atmosphere during post-printing heat treatment, or powdered glass used in ceramic processes, where the glass transforms into crystals during sintering.

[0098] A volatile material is a material that can occupy a voxel within a printed part, designed to be immediately occupied by a gas or vacuum after a post-processing step. During the printing process and during assembly of printed layers into a printed part, the volatile material can comprise a solid or semi-solid material. During the post-processing step, the volatile material can be converted to a form that can easily escape from the printed part, such as a gas or liquid. Including a continuous voxel of volatile material within a volume of robust material results in the formation of a cavity with a predetermined structure after the post-processing step. This cavity can communicate with the exterior of the printed part through pre-designed channels or be completely sealed. Sealed cavities can then be occupied by a predetermined gas or vacuum. Examples of volatile materials include organic materials such as polyethylene or polyethylene oxide, which decompose into CO2 and water at temperatures below 450°C, or carbon powder, which can be oxidized to CO2 at higher temperatures through a controlled heat treatment atmosphere. As the volatile material converts to a gas, the gas can escape from the structure before the robust material is sintered into a dense block.

[0099] Patterning

[0100] As described above, the inkjet 3D printing module 1302 is configured to create a structure of one or more materials in a complex three-dimensional pattern, wherein the structure is constructed in layers, each layer including one or more materials. The pattern of each material in each layer can be formed in a manner similar to the pattern formation of each layer of a traditional 3D printer. Specifically, the pattern of each layer can be derived from a slice of the entire structure using CAD software such as SolidWorks. Unlike traditional 3D printers, the computer system 1400 can separate the pattern of each layer included in the design file 1406 into more than one material and input it into the computer system 1400 via the input device 1404.

[0101] Figure 14 The control Figure 2A computer system 1400 for a 3D inkjet printer is shown. A central processing unit (CPU) 1402 communicates with an input device 1404, which may be provided with a design file 1406. In some embodiments, a user may create the design file 1406 using CAD software or the like on the computer system 1400 or another computer. In other embodiments, the user may receive the design file from a file repository such as Thingiverse, Pinshape, or other file sharing sites, or from a commercial provider of 3D designs. The CPU 1402 may store the design file 1406 or intermediate calculations used to control the print station control unit 1408 in a memory 1410 and may communicate with the user via an output device 1412.

[0102] The CPU 1402 may communicate with the plurality of print station control units 1408 via the interface bus 1414 to control the dispensing of ink from the inkjet printheads 202 as described above, as well as other functions of the print station control units 1408. Figure 15 As shown, the print station control unit 1408 can communicate with the receiver device 204, inkjet print head 202, pressure device 602, adjustment device 208, curing device 210, solvent extraction device 212, alignment sensor 906, transfer device 216, and assembly device 262 (which may include XY positioner 230 and build station 260) through the device controller 1502 to control each of these devices to deposit ink as instructed by the design file 1406 interpreted by the CPU 1402. The CPU 1402 can receive status information and sensor information and can use control signaling systems known in the art to send control signals to any of these devices to facilitate printing as described herein.

[0103] Figure 16 Block diagram 1600 illustrates an exemplary software architecture 1602, portions of which may be used in conjunction with the various hardware architectures described herein that can implement any of the features described above. Figure 161602 is a non-limiting example of a software architecture, and it should be understood that many other architectures can be implemented to facilitate the functionality described herein. The software architecture 1602 can be executed on hardware such as a central processing unit 1402, which can include file storage, a processor, memory, and input / output (I / O) components, among others. A representative hardware layer 1604 is shown, which can represent, for example, the devices described herein. The representative hardware layer 1604 includes a processing unit 1606 and associated executable instructions 1608. The executable instructions 1608 represent the executable instructions of the software architecture 1602, including implementations of the methods, modules, etc. described herein. The hardware layer 1604 also includes a memory / storage device 610, which also includes executable instructions 1608 and accompanying data. The hardware layer 1604 can also include other hardware modules 1612. The instructions 1608 stored by the processing unit 1608 can be part of the instructions 1608 stored by the memory / storage device 1610.

[0104] Exemplary software architecture 1602 can be conceptualized as layers, each providing various functionalities. For example, software architecture 1602 may include layers and components such as an operating system (OS) 1614, libraries 1616, frameworks 1618, applications 1620, and a presentation layer 1644. In operation, applications 1620 and / or other components within a layer may invoke API calls 1624 to other layers and receive corresponding results 1626. The layers shown are representative in nature, and other software architectures may include additional or different layers. For example, some mobile or proprietary operating systems may not provide framework / middleware 1618.

[0105] OS 1614 can manage hardware resources and provide public services. OS 1614 may include, for example, a kernel 1628, servers 1630, and drivers 1632. Kernel 1628 may serve as an abstraction layer between hardware layer 1604 and other software layers. For example, kernel 1628 may be responsible for memory management, processor management (e.g., scheduling), component management, networking, security settings, etc. Server 1630 may provide other public services for other software layers. Driver 1632 may be responsible for controlling the underlying hardware or interfacing with the underlying hardware layer 1604. For example, driver 1632 may include a display driver, a camera driver, a memory / storage device driver, a peripheral device driver (e.g., via a universal serial bus (USB)), a network and / or wireless communication driver, an audio driver, etc., depending on the hardware and / or software configuration.

[0106] Libraries 1616 may provide common infrastructure that can be used by applications 1620 and / or other components and / or layers. Libraries 1616 generally provide functionality used by other software modules to perform tasks, rather than interacting directly with OS 1614. Libraries 1616 may include system libraries 1634 (e.g., the C standard library), which may provide functionality such as memory allocation, string manipulation, and file operations. Additionally, libraries 1616 may include API libraries 1636, such as media libraries (e.g., supporting the rendering and manipulation of image, sound, and / or video data formats), graphics libraries (e.g., OpenGL libraries for rendering 2D and 3D graphics on a display), database libraries (e.g., SQLite or other relational database functions), and web libraries (e.g., WebKit, which may provide web browsing functionality). Libraries 1616 may also include a variety of other libraries 1638 to provide a variety of functionality for applications 1620 and other software modules.

[0107] Framework 1618 (sometimes also referred to as middleware) provides a higher-level common infrastructure that can be used by applications 1620 and / or other software modules. For example, framework 1618 can provide various graphical user interface (GUI) functions, advanced resource management, or advanced location services. Framework 1618 can also provide a wide range of other APIs for applications 1620 and / or other software modules.

[0108] Applications 1620 include built-in applications 1640 and / or third-party applications 1642. Examples of built-in applications 1640 may include, but are not limited to, a contacts application, a browser application, a location application, a media application, a messaging application, and / or a gaming application. Third-party applications 1642 may include any application developed by an entity other than the vendor of a particular platform. Applications 1620 may use functionality available via OS 1614, libraries 1616, frameworks 1618, and presentation layer 1644 to create a user interface for interacting with the user.

[0109] Some software architectures use virtual machines, such as virtual machine 1648. Virtual machine 1648 provides an execution environment where applications / modules can execute as if they were executed on a hardware machine. Virtual machine 1648 can be hosted by a host OS (e.g., OS 1614) or a hypervisor and can have a virtual machine monitor 1646 that manages the operation of virtual machine 1648 and interoperates with the host operating system. Software architectures that may be different from software architecture 1602 outside the virtual machine are executed within virtual machine 1648, such as OS 1650, libraries 1652, frameworks 1654, applications 1656, and / or presentation layer 1658.

[0110] Figure 17A block diagram of components of an exemplary machine 1700 is shown, which is configured to read instructions from a machine-readable medium (e.g., a machine-readable storage medium) and perform any of the functions described herein. The exemplary machine 1700 is in the form of a computer system having instructions 1716 (e.g., in the form of software components) that can be executed to cause the machine 1700 to perform any of the functions described herein. Thus, the instructions 1716 can be used to implement the modules or components described herein. The instructions 1716 cause the unprogrammed and / or unconfigured machine 1700 to operate as a specific machine configured to perform the functions described. The machine 1700 can be configured to operate as a standalone device or can be coupled (e.g., networked) to other machines. In a networked deployment, the machine 1700 can operate in the capacity of a server machine or a client machine in a server-client network environment, or as a node in a peer-to-peer or distributed network environment. The machine 1700 may be embodied as, for example, a server computer, a client computer, a personal computer (PC), a tablet computer, a laptop computer, a netbook computer, a set-top box (STB), a gaming and / or entertainment system, a smartphone, a mobile device, a wearable device (e.g., a smartwatch), and an Internet of Things (IoT) device. Furthermore, while only a single machine 1700 is shown, the term "machine" includes any collection of machines that individually or jointly execute instructions 1716.

[0111] The machine 1700 may include a processor 1710, a memory 1730, and I / O components 1750, which may be communicatively coupled via, for example, a bus 1702. The bus 1702 may include multiple buses that couple various elements of the machine 1700 via various bus technologies and protocols. In an example, the processor 1710 (including, for example, a central processing unit (CPU), a graphics processing unit (GPU), a digital signal processor (DSP), an ASIC, or a suitable combination thereof) includes one or more processors 1712a through 1712n that execute instructions 1716 and process data. In some examples, one or more processors 1710 may execute instructions provided or recognized by one or more other processors 1710. The term "processor" includes multi-core processors, which include cores that can execute instructions simultaneously. Although Figure 17 Multiple processors are shown, but machine 1700 may include a single processor with a single core, a single processor with multiple cores (e.g., a multi-core processor), multiple processors each with a single core, multiple processors each with multiple cores, or any combination thereof. In some examples, machine 1700 may include multiple processors distributed across multiple machines.

[0112] The memory / storage 1730 may include a main memory 1732, a static memory 1734 or other memory, and a storage unit 1736, all of which may be accessed by the processor 1710 via, for example, the bus 1702. The storage unit 1736 and the memories 1732, 1734 store instructions 1716 that embody any one or more of the functions described herein. The memory / storage 1730 also stores temporary, intermediate, and / or long-term data for the processor 1710. The instructions 1716 may also reside, completely or partially, within the memories 1732, 1734, within the storage unit 1736, within at least one of the processors 1710 (e.g., within a command buffer or cache), within at least one memory in the I / O component 1750, or any suitable combination thereof during execution thereof. Thus, the memories 1732, 1734, the storage unit 1736, the memory in the processor 1710, and the memory in the I / O component 1750 are examples of machine-readable media.

[0113] As used herein, a "machine-readable medium" refers to a device that is capable of temporarily or permanently storing instructions and data that cause the machine 1700 to operate in a specific manner. As used herein, the term "machine-readable medium" does not include transient electrical or electromagnetic signals themselves (e.g., on a carrier wave propagating through the medium); therefore, the term "machine-readable medium" may be considered to be tangible and non-transitory. Non-limiting examples of non-transitory, tangible machine-readable media include, but are not limited to, non-volatile memory (e.g., flash memory or read-only memory (ROM)), volatile memory (e.g., static random access memory (RAM) or dynamic RAM), buffer memory, cache memory, optical storage media, magnetic storage media and devices, network-accessible or cloud storage, other types of storage, and / or any suitable combination thereof. The term "machine-readable medium" applies to a single medium or a combination of multiple media that stores instructions (e.g., instructions 1716) for execution by the machine 1700, such that when executed by one or more processors 1710 of the machine 1700, the instructions cause the machine 1700 to perform one or more of the functions described herein. Thus, a "machine-readable medium" may refer to a single storage device, as well as a "cloud-based" storage system or storage network that includes multiple storage devices or devices.

[0114] I / O components 1750 may include various hardware components suitable for receiving input, providing output, generating output, transmitting information, exchanging information, capturing measurements, etc. The specific I / O components 1750 included in a particular machine will depend on the type and / or function of the machine. For example, a mobile device such as a mobile phone may include a touch input device, while a headless server or IoT device may not include such a touch input device. Figure 17The specific examples of I / O components shown in the figure are in no way limiting, and the machine 1700 may include other types of components. The grouping of I / O components 1750 is merely to simplify the discussion and is in no way limiting. In various examples, the I / O components 1750 may include a user output component 1752 and a user input component 1754. The user output component 1752 may include, for example, a display component (e.g., a liquid crystal display (LCD) or a projector) for displaying information, an acoustic component (e.g., a speaker), a tactile component (e.g., a vibration motor or a force feedback device), and / or other signal generators. The user input component 1754 may include, for example, an alphanumeric input component (e.g., a keyboard or a touch screen), a pointing component (e.g., a mouse device, a touchpad, or other pointing tool), and / or a tactile input component (e.g., a physical button or touch screen that provides position and / or touch force or touch gestures), which are configured to receive various user inputs, such as user commands and / or selections.

[0115] In some examples, I / O components 1750 may include a biometric component 1756, a motion component 1758, an environmental component 1760, and / or a position component 1762, as well as a number of other possible sensor components. Biometric component 1756 may include, for example, components for detecting body expressions (e.g., facial expressions, vocal expressions, hand or body gestures, or eye tracking), measuring biosignals (e.g., heart rate or brain waves), and identifying people (e.g., through voice-based, retinal, and / or facial recognition). Motion components may include, for example, acceleration and / or rotation sensors for various components of the 3D printer. Environmental components may include, for example, light sensors (e.g., photodiodes, photoresistors, or phototransistors), acoustic sensors (e.g., piezoelectric sensors or acoustic wave sensors), or temperature sensors (e.g., thermocouples or thermistors) that can sense environmental conditions at various locations within the 3D printer. Position component 1762 may include, for example, a position sensor (e.g., a Global Positioning System (GPS) receiver), an altitude sensor (e.g., a barometric pressure sensor from which altitude can be derived), and / or an orientation sensor (e.g., a magnetometer).

[0116] The I / O components 1750 may include a communication component 1764 that may implement various operational techniques for coupling the machine 1304 to the network 1770 and / or the device 1780 via respective communication couplings 1772 and 1782. The communication component 1764 may include one or more network interface components or other suitable devices for interfacing with the network 1770. The communication component 1764 may include, for example, components suitable for providing wired communication, wireless communication, cellular communication, near field communication (NFC), Bluetooth communication, Wi-Fi, and / or communication via other forms. The device 1780 may include other machines or various peripheral devices (e.g., coupled via USB).

[0117] In some examples, communication component 1764 can detect an identifier or include components suitable for detecting an identifier. For example, communication component 1764 can include a radio frequency identification (RFID) tag reader, an NFC detector, an optical sensor (e.g., a one-dimensional or multi-dimensional barcode, or other optical code), and / or an acoustic detector (e.g., a microphone for identifying tagged audio signals). In some examples, location information can be determined based on information from communication component 1762, such as, but not limited to, geographic location via an Internet Protocol (IP) address, location via Wi-Fi, cellular, NFC, Bluetooth, or other wireless station identification and / or signal triangulation.

[0118] Below, other features, characteristics and advantages of this application will be described one by one:

[0119] Article 1: A three-dimensional (3D) printer comprising a receiver device comprising a substrate, an inkjet print head configured to deposit ink comprising a suspension of a particulate material in a liquid carrier onto the substrate to form a printed layer; a removal system configured to remove a portion of the liquid carrier from the printed layer using a pressure differential to form a dried layer; and a transfer system configured to transfer the dried layer to a build station.

[0120] Item 2: The 3D printer of Item 1, wherein the substrate is permeable and the removal system is configured to evacuate space on a side of the substrate opposite the printed layer.

[0121] Item 3: The 3D printer of Item 1 or 2, wherein the substrate comprises perforated metal.

[0122] Item 4: The 3D printer of any one of Items 1-3, wherein the substrate comprises a fiber material.

[0123] Item 5: The 3D printer of any one of Items 1-4, wherein the removal system is configured to apply pressure to a surface of the printed layer opposite the substrate.

[0124] Article 6: The 3D printer of any one of Articles 1-5, wherein the removal system comprises a pressure chamber.

[0125] Article 7: The 3D printer of any one of Articles 1-6, wherein the removal system comprises a pressure belt.

[0126] Clause 8: The 3D printer of any one of Clauses 1-7, wherein the removal system comprises a pressure plate.

[0127] Item 9: The 3D printer of any one of Items 1-8, wherein the receiver device is configured to transfer the printed layer away from the inkjet printing print head prior to removing the liquid carrier from the printed layer.

[0128] Item 10: The 3D printer of any of Items 1-9, wherein the removal system is configured to remove the liquid carrier during transfer of the printed layer to the build station.

[0129] Clause 11: The 3D printer of any of Clauses 1-10, wherein the transfer system is configured to transfer the dried layer to a stack of printed layers in the build station.

[0130] Item 12: The 3D printer of any one of Items 1-11, wherein the ink comprises a binder liquid, and wherein the printer further comprises a curing system configured to cure the binder liquid to solidify it.

[0131] Article 13: The 3D printer described in any one of Articles 1-12 also includes an adjustment device configured to adjust the printed layer to increase the density of the particulate material in the printed layer.

[0132] Article 14: A 3D printer as described in any of Articles 1-13, wherein the conditioning system is configured to mechanically compact the particulate material in the printed layer.

[0133] Clause 15: The 3D printer of any of Clauses 1-14, wherein the conditioning system is further configured to apply a surface conditioning material to the dried printed layer.

[0134] Clause 16: The 3D printer of any of Clauses 1-15, wherein the build station comprises an XY controller.

[0135] Clause 17: The 3D printer of any one of Clauses 1-16, wherein the build station includes a Z-axis controller.

[0136] Item 18: The 3D printer of any one of Items 1-17, further comprising another printing module configured to form a printed layer on a substrate using a method other than inkjet printing.

[0137] Article 19: A three-dimensional (3D) printing method comprising: depositing an ink comprising a particulate material and a liquid carrier onto a substrate using an inkjet print head to form a printed layer; transferring the printed layer from the inkjet print head, removing a portion of the liquid carrier from the printed layer using a pressure difference to form a dried printed layer; and transferring the dried printed layer to a build station to form a stack of printed layers.

[0138] Item 20: The method of Item 19, wherein removing a portion of the liquid carrier from the printed layer using a pressure differential comprises evacuating a space adjacent to the substrate opposite to a side of the substrate on which the printed layer is deposited.

[0139] Item 21: The method of Item 19 or 20, wherein removing a portion of the liquid carrier from the printed layer using a pressure differential comprises applying pressure to a surface of the layer opposite to a surface deposited on the substrate.

[0140] Item 22: The method of any one of Items 19-21, wherein the step of transferring the printed layer from the inkjet print head occurs before the step of forming the dried printed layer using a pressure differential.

[0141] Item 23: The method of any one of Items 19-22, further comprising adjusting the printed layer to increase the density of the particulate material in the printed layer.

[0142] Clause 24: The method of any of Clauses 19-23, wherein the ink comprises a liquid binder, the method further comprising curing the binder to convert it into a solid.

[0143] Item 25: An inkjet printer comprising: a receiver device comprising a substrate; an inkjet print head configured to deposit ink comprising a suspension of particulate material in a liquid carrier onto the substrate to form a printed layer; and a removal system configured to remove a portion of the liquid carrier from the printed layer using a pressure differential.

[0144] Although various embodiments have been described, this description is intended to be illustrative and not restrictive, and it should be understood that more embodiments and examples within the scope of the embodiments are possible. Although many possible feature combinations are shown in the drawings and discussed in this specification, many other combinations of the disclosed features are also possible. Unless otherwise specifically limited, any feature of any embodiment can be used in combination with or replace any other feature or element in any other embodiment. Therefore, it should be understood that any feature shown and / or discussed in the present invention can be implemented together in any suitable combination. Therefore, the embodiments are not limited except in accordance with the appended claims and their equivalents. In addition, various modifications and changes can be made within the scope of the appended claims.

[0145] Although the above describes what is considered to be the best mode and / or other examples, it should be understood that various changes can be made thereto, and the subject matter disclosed herein can be implemented in various forms and examples, and that the present teachings can be applied to many applications, only some of which are described herein. The appended claims are intended to protect any and all applications, modifications, and variations that fall within the actual scope of the present teachings.

[0146] Unless otherwise indicated, all measurements, values, ratings, positions, quantities, dimensions and other specifications set forth in this specification, including the appended claims, are approximate and not exact. They are intended to have a reasonable range consistent with the functions to which they relate and with customary practice in the art to which they pertain.

[0147] The scope of protection of the present invention is limited solely by the appended claims. When interpreted in light of this specification and the subsequent prosecution, the scope is intended and should be interpreted to be as broad as consistent with the ordinary meaning of the language used in the claims and to include all structural and functional equivalents. Notwithstanding the foregoing, no claim is intended to encompass subject matter that does not comply with the requirements of sections 101, 102, or 103 of the Patent Act, nor should they be construed in such a manner. Any unintentional generalization of such subject matter is hereby disclaimed.

[0148] Except as stated above, nothing stated or described, whether or not mentioned in the claims, is intended or should be construed as conferring any element, step, feature, object, benefit, advantage, or equivalent to the public.

[0149] It should be understood that the terms and expressions used herein have the ordinary meanings that these terms and expressions have with respect to their corresponding respective fields of investigation and research, unless the specific meanings of these terms and expressions are otherwise set forth herein. Relational terms such as first and second may be used only to distinguish one entity or action from another, without requiring or implying any actual such relationship or order between such entities or actions. The terms "comprise," "comprising," or any other variant thereof are intended to encompass non-exclusive inclusion, such that the process, method, article, or device comprising a series of elements not only includes those elements, but may also include other elements not explicitly listed or other elements inherent to such processes, methods, articles, or devices. Without further limitation, an element beginning with "one" or "an" does not exclude the presence of other identical elements in the process, method, article, or device comprising the element.

[0150] The Abstract of the present invention is provided to enable the reader to quickly ascertain the nature of the technical disclosure. It should be understood that it should not be used to interpret or limit the scope or meaning of the claims. Furthermore, in the foregoing detailed description, it can be seen that various features are grouped together in various examples in order to simplify the disclosure. This manner of disclosure should not be interpreted as reflecting an intention to request protection for more features than are expressly recited in each claim. On the contrary, as reflected in the appended claims, the present subject matter lies in fewer features than all the features of a single disclosed example. Accordingly, the appended claims are hereby incorporated into the detailed description, with each claim standing on its own as a separately claimed subject matter.

Claims

1. A three-dimensional (3D) printer comprising: a receiver device comprising a substrate; an inkjet printhead configured to deposit an ink comprising a suspension of particulate material in a liquid carrier onto the substrate to form a printed layer; a removal system configured to remove a portion of the liquid carrier from the printed layer using a pressure differential to form a dry layer; as well as a transfer system configured to transfer the dry layer to a building station; wherein the removal system comprises a vacuum chamber and a liquid permeable support, wherein the vacuum chamber and the liquid permeable support are both located on a side of the substrate opposite to the inkjet print head; and The removal system includes a pressure plate configured to apply pressure to a surface of the printed layer opposite the substrate.

2. The three-dimensional (3D) printer according to claim 1, characterized in that: The substrate is permeable, and the removal system is configured to evacuate the space on a side of the substrate opposite the printed layer.

3. The three-dimensional (3D) printer according to claim 2, characterized in that: The substrate comprises perforated metal.

4. The three-dimensional (3D) printer according to claim 2, characterized in that: The substrate comprises a fibrous material.

5. The three-dimensional (3D) printer according to claim 1, characterized in that: The receiver device is configured to transfer the printed layer away from the inkjet printhead prior to removing the liquid carrier from the printed layer.

6. The three-dimensional (3D) printer according to claim 1, characterized in that: The removal system is configured to remove the liquid carrier during transfer of the printed layer to the build station.

7. The three-dimensional (3D) printer according to claim 1, characterized in that: The transfer system is configured to transfer the dry layer onto a stack of printed layers in the build station.

8. The three-dimensional (3D) printer according to claim 1, characterized in that: The ink includes a binder liquid; and, The printer also includes a curing system configured to cure the adhesive liquid to solidify it.

9. The three-dimensional (3D) printer according to claim 1, characterized in that: Also included is an adjustment device configured to adjust the printed layer to increase the density of the particulate material in the printed layer.

10. The three-dimensional (3D) printer according to claim 9, characterized in that: The conditioning device is configured to mechanically compact the particulate material in the printed layer.

11. The three-dimensional (3D) printer according to claim 9, characterized in that: The conditioning device is further configured to apply a surface conditioning material to the dried printed layer.

12. The three-dimensional (3D) printer according to claim 1, characterized in that: The build station includes an XY controller.

13. The three-dimensional (3D) printer according to claim 12, characterized in that: The build station includes a Z-axis controller.

14. The three-dimensional (3D) printer according to claim 1, characterized in that: Also included are other printing modules configured to form a printed layer on a substrate using methods other than inkjet printing.

15. An inkjet printer comprising: a receiver device comprising a substrate; an inkjet printhead configured to deposit an ink comprising a suspension of particulate material in a liquid carrier onto the substrate to form a printed layer; as well as a removal system configured to remove a portion of the liquid carrier from the printed layer using a pressure differential; wherein the removal system comprises a vacuum chamber and a liquid permeable support, wherein the vacuum chamber and the liquid permeable support are both located on a side of the substrate opposite to the inkjet print head; and The removal system includes a pressure plate configured to apply pressure to a surface of the printed layer opposite the substrate.

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