Printing bed assembly for additive manufacturing system

Abstract

A print bed assembly for an additive manufacturing system, the print bed assembly comprising: a gantry (202); a carrier plate (204) comprising an upper surface (206) extending in an X direction and a Y direction; a support structure (220) disposed on the gantry and including a straight edge extending in the X-direction; a construction plate; and at least one abutment portion for aligning the building plate in the Y direction with respect to the carrier plate. In a first state S1, when the build plate is placed on the support structure at an angle (A1) relative to the upper surface of the carrier plate, the build plate contacts the straight edge of the support structure and the at least one abutment. In a second state S2, when the build plates are placed downward onto the upper surface of the carrier plate, the build plates remain aligned because the build plates still contact the at least one abutment.

Description

Technical Field

[0001] The present invention relates to a printing bed assembly for an additive manufacturing system and also relates to an additive manufacturing system comprising the printing bed assembly. Background Art

[0002] Fused filament fabrication (FFF) is an additive manufacturing process that typically uses a continuous filament of a thermoplastic material. The filament can be fed from a filament supply unit to a moving, heated print head and can be deposited onto the upper surface of a build plate through a print nozzle. Further, the print head can be moved relative to the build plate under control to produce a work product, which can include multiple deposited layers. In some cases, it may also be necessary to move the work product vertically by a small amount to start a new layer. In this way, a three-dimensional object can be produced from a thermoplastic material.

[0003] Further, the build plate is part of the print bed assembly. The print bed assembly may also include a mounting base (e.g., a gantry) and a carrier plate. The print bed assembly may be vertically movable to allow the work product to move relative to the print head. The build plate may be removably arranged on the carrier plate. In order to ensure reliable printing on the build plate, the build plate may have to be aligned and fixed with desired accuracy in all directions (e.g., X, Y, and Z directions). The build plate may be removably coupled to the carrier plate using a clamp, a vacuum-based coupling, or a magnet-based coupling.

[0004] Conventionally, when a build plate is to be arranged on a carrier plate, the build plate must be disposed at a shallow insertion (i.e., positioning) angle relative to the carrier plate. Such a shallow insertion angle may allow for insertion of the build plate when the build plate is coupled to the carrier plate at a rear end using a clamp or other such fixing element.

[0005] However, when the build plate is magnetically coupled to the carrier plate, such a shallow insertion angle may be cumbersome and may hinder the convenient insertion of the build plate. More particularly, for a magnetically held flexible build plate, if the build plate is held at a shallow insertion angle, the magnetic forces acting on the build plate may pull the build plate onto the carrier plate without proper alignment, causing friction that may be difficult for the user to overcome. Accordingly, such a shallow insertion angle may extend the insertion time of the magnetically held build plate because the user may have to devote extra effort and attention to correctly place the build plate. In some cases, such a shallow insertion angle may result in incorrect placement of the build plate on the carrier plate. Overall, this phenomenon may have an undesirable impact on the usability, efficiency, and reliability of the additive manufacturing system. Summary of the invention

[0006] An object of the present invention is to provide a new and improved print bed assembly for an additive manufacturing system. The print bed assembly may include a plurality of components that may support a work product being formed by the additive manufacturing system.

[0007] According to a first aspect of the present invention, a print bed assembly for an additive manufacturing system is provided. The print bed assembly includes a stage. The print bed assembly also includes a carrier plate arranged on the stage. The carrier plate includes an upper surface extending in the X direction and in the Y direction perpendicular to the X direction. The print bed assembly further includes a support structure, which is arranged on the stage and includes a straight edge extending in the X direction. The print bed assembly includes a build plate to be placed on the carrier plate. The print bed assembly also includes at least one abutment, which is arranged on the stage and spaced apart from the straight edge of the support structure. The at least one abutment is arranged to limit the movement of the build plate relative to the carrier plate in the Y direction when the build plate (by a user or a robot) is placed on the straight edge of the support structure at an angle relative to the upper surface of the carrier plate.

[0008] The abutment may serve as a guide member during movement of the build plate from the first state to the second state. The support structure and the at least one abutment may allow for easier insertion and coupling of the build plate with the carrier plate. Further, when inserting the build plate, the build plate may be set at a larger angle, which may allow for easier manipulation of the build plate during insertion, thereby improving the user experience. The increased angle between the build plate and the carrier plate is particularly advantageous for magnetically held build plates. More particularly, due to the increased angle, the user may not have to make additional efforts to overcome friction between the carrier plate and the build plate that may be generated due to the magnetic pull between the build plate and the carrier plate. Further, the at least one abutment may provide instant alignment of the build plate in the Y direction. Furthermore, the design of the abutment may allow for easy disengagement and engagement of the build plate with the abutment.

[0009] The print bed assembly described herein can be user-friendly and reliable in operation. Further, the print bed assembly described herein can also improve the usability and efficiency of the additive manufacturing system. It should be noted that the present invention is also advantageous in additive manufacturing systems having a build plate that is not magnetically held to a carrier, such as a glass plate or a metal plate placed on a carrier plate without magnets therein.

[0010] In an embodiment, the print bed assembly further comprises at least one X-alignment structure arranged to align the build plate relative to the carrier plate in the X-direction. The at least one X-alignment structure may allow for easier insertion of the build plate by providing instant alignment in the X-direction. Further, when the build plate is in the second state, the at least one X-alignment structure may also secure the build plate in the X-direction to prevent any movement of the build plate in the X-direction.

[0011] In an embodiment, the at least one X-alignment structure includes one or more pins extending upward from the stage to a level higher than the level of the upper surface of the carrier plate. In such an embodiment, the at least one X-alignment structure can prevent any movement of the build plate in the X direction when the build plate is in the second state. Further, the pins can have a simple design, can be easily incorporated, and can be cost-effectively manufactured.

[0012] In an embodiment, the at least one X-alignment structure comprises one or more profiles extending upward from the stage to a level higher than the level of the upper surface of the carrier plate. In such an embodiment, the at least one X-alignment structure can prevent any movement of the build plate in the X direction when the build plate is in the second state. Further, the one or more profiles can have a simple design, can be easily incorporated, and can be cost-effectively manufactured.

[0013] In an embodiment, the at least one abutment comprises one or more profiles extending upward from the stage to a level higher than the level of the upper surface of the carrier plate. In such an embodiment, when the build plate is in the second state, the at least one Y-alignment structure can prevent any movement of the build plate in the Y direction. Further, the one or more profiles can have a simple design, can be easily incorporated, and can be cost-effectively manufactured.

[0014] In an embodiment, the at least one abutment comprises one or more pins extending upward from the stage to a level higher than the level of the upper surface of the carrier plate. In such an embodiment, when the build plate is in the second state, the at least one Y-alignment structure can prevent any movement of the build plate in the Y direction. Further, the pins have a simple design, can be easily incorporated, and can be cost-effectively manufactured.

[0015] In an embodiment, the build plate includes one or more cutouts at its rear side to receive one or more pins. In the first state of the build plate, the one or more cutouts may allow for receiving the pin and engaging the pin with the build plate for alignment in the Y direction. Further, in the second state of the build plate, the one or more cutouts may still receive the pin to prevent any movement of the build plate in the Y direction. Furthermore, based on the position of the one or more cutouts and the position of the pin, the one or more cutouts may engage with the pin to further align the build plate in the X direction when the build plate is in the first state, and prevent any movement of the build plate in the X direction when the build plate is in the second state.

[0016] In an embodiment, at least one of the one or more cutouts has a V-shape, and at least another cutout has a U-shape. When the build plate is in a first state, the V-shaped cutout together with the corresponding pin can align the build plate in the Y direction and the X direction. When the build plate is in a second state, the V-shaped cutout together with the corresponding pin can prevent any movement of the build plate in the Y direction and the X direction. Further, when the build plate is in the second state, the U-shaped cutout together with the corresponding pin can prevent the build plate from rotating along a horizontal plane.

[0017] In an embodiment, each of the one or more pins includes a body portion and a head portion. The head portion of the pin is configured to lock with the build plate when the build plate is arranged on the carrier plate. When the build plate is in the second state, the head portion can fix the build plate in the Z direction, thereby providing an additional locking feature.

[0018] In an embodiment, the support structure is separate from the carrier plate. For example, the support structure may be a separate component spaced apart from the carrier plate.

[0019] In an embodiment, the support structure is an integral part of the carrying plate.For example, the straight edge of the support structure may be similar to the top edge at the rear side of the carrying plate.

[0020] In an embodiment, the build plate comprises a flexible metal plate and the carrier plate comprises one or more magnets. In such an embodiment, it may be particularly advantageous to arrange the build plate at a large angle relative to the carrier plate so as to minimize the effect of magnetic pull between the build plate and the carrier plate.

[0021] In an embodiment, the build plate comprises two extensions at the rear side of the build plate, and wherein the carrier plate comprises two ramps for guiding the extensions during placement of the build plate onto the carrier plate. The ramps help the user to position the build plate and thus provide a more ergonomic handling of the build plate. It should be noted that the build plate may comprise extensions while the carrier plate has no ramps. It should also be noted that the build plate may comprise a different number of extensions at the rear side, such as one, three, four or even more extensions.

[0022] According to a second aspect, an additive manufacturing system is provided that includes a print bed assembly as described above. Due to the specially designed print bed assembly, the additive manufacturing system can exhibit improved usability, reliability and efficiency. The additive manufacturing system can be a fused filament fabrication (FFF) system. However, the present invention is not limited to FFF systems. For example, the additive manufacturing system can be a pellet extruder printing system, a 3D inkjet printing system, a selective laser sintering (SLS) system, etc. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.

[0024] Figure 1 Schematically illustrates a front view of an additive manufacturing system according to an embodiment of the present invention;

[0025] Figure 2 Schematically shows the Figure 1 a perspective view of a print bed assembly associated with an additive manufacturing system, wherein a build plate of the print bed assembly remains away from a carrier plate;

[0026] Figure 3A Schematically shows Figure 2 a side cross-sectional view of a portion of a print bed assembly of , wherein the build plate is placed in a first state;

[0027] Figure 3B yes Figure 3A A detailed view of a portion of

[0028] Figure 4 Schematically showing a perspective view of a Y-alignment structure according to an embodiment of the present invention;

[0029] Figure 5 Schematically shows Figure 2 a perspective view of a print bed assembly with a build plate resting on a carrier plate;

[0030] Figure 6 Schematically showing a perspective view of a Y-alignment structure according to an embodiment of the present invention;

[0031] Figure 7 schematically illustrates a top view of a building plate according to an embodiment of the present invention;

[0032] Fig. 8A schematically shows a perspective view of a print bed assembly according to another embodiment of the present invention;

[0033] Figure 8B Schematically shows Fig. 8A a side cross-sectional view of a portion of a print bed assembly;

[0034] Fig. 9 Schematically showing a perspective view of a print bed assembly having two X-alignment structures and two Y-alignment structures according to yet another embodiment of the present invention;

[0035] Fig.10 Schematically showing a perspective view of a print bed assembly having two X-alignment structures and two Y-alignment structures according to an embodiment of the present invention;

[0036] Fig.11Schematically showing a perspective view of a print bed assembly having two X-alignment structures and one Y-alignment structure according to another embodiment of the present invention;

[0037] Fig. 12A schematically shows a perspective view of a print bed assembly having two X-alignment structures, one Y-alignment structure, and a separate support structure according to yet another embodiment of the present invention;

[0038] Fig. 12B Shows Fig. 12A A side cross-sectional view of a portion of an embodiment of;

[0039] Fig.13 schematically illustrates a perspective view of a print bed assembly having a Y-alignment structure and a separate support structure according to an embodiment of the present invention;

[0040] Fig.14A schematically illustrates a perspective view of a print bed assembly having a Y-alignment structure, a separate support structure, and a locking member according to another embodiment of the present invention;

[0041] Fig. 14B Shows Fig.14A A side cross-sectional view of a portion of an embodiment of;

[0042] Fig.15A Schematically shows a side view of a portion of an embodiment, wherein the building plate is in a first state S1, and

[0043] Fig. 15B Schematically shows Fig.15A 0046] Side view of a portion of an embodiment of wherein the build plate is in a second state S2.

[0044] It should be noted that items with the same reference numerals in different drawings have the same structural features and the same functions, or are the same signals. If the function and / or structure of such items has been explained, it is not necessary to repeat the explanation thereof in the detailed description. DETAILED DESCRIPTION

[0045] Figure 1A front view of an additive manufacturing system 100 according to an embodiment of the present invention is schematically shown. The additive manufacturing system 100 may be a fused filament fabrication (FFF) system. However, the present invention is not limited to an FFF system. For example, the additive manufacturing system 100 may be a pellet extruder printing system, a 3D inkjet printing system, a selective laser sintering (SLS) system, etc. The additive manufacturing system 100 includes a housing 102 and a print head 104 arranged in the housing 102. The housing 102 may be generally box-shaped and define a hollow space 108 (also interchangeably referred to as a build chamber 108). A user interface 110 is arranged at the front side of the housing 102. The user interface 110 may include a display for displaying information about a print job and one or more input devices for receiving user instructions. The additive manufacturing system 100 is arranged to build each part / component in a layer-by-layer manner using information from a software model (e.g., a computer-aided design (CAD) model). The print head 104 may include at least one extruder (not shown) that can receive consumable materials (e.g., filament 106). The filament 106 may include a thermoplastic material. The consumable material may be melted by the at least one extruder, and the melted consumable material may be utilized to produce the parts / components. The print head 104 may be movable along the X direction and / or the Y direction.

[0046] The additive manufacturing system 100 also includes a print bed assembly 200. The additive manufacturing system 100 can deposit consumable materials from the print head 104 onto the print bed assembly 200 in a layer-by-layer manner to form a three-dimensional (3D) printed object. The print bed assembly 200 is received in the hollow space 108 of the housing 102. Further, the print bed assembly 200 can be spaced apart from the print head 104 in the vertical direction. The print bed assembly 200 can be movable along the Z direction. The X direction, the Y direction, and the Z direction are perpendicular to each other. In other examples, the print bed assembly 200 can be stationary, and the print head 104 can be movable in the Z direction in addition to being movable in the X direction and / or the Y direction. In another embodiment, the print head 104 is movable in the Z direction, and the print bed assembly 200 is movable in the X direction and the Y direction. It should be noted that the additive manufacturing system 100 can include any arrangement of components that can be synchronously operated to manufacture a 3D printed object without any limitation.

[0047] Figure 2 A perspective view schematically shows a print bed assembly 200 for an additive manufacturing system 100 according to an embodiment (see Figure 1). The print bed assembly 200 includes a gantry 202. The gantry 202 can be embodied as a base for the print bed assembly 200. It should be noted that the gantry 202 can include any arrangement of elements that can allow for mounting one or more components of the print bed assembly 200. The gantry 202 can be movable to enable movement of the print bed assembly 200. Specifically, the gantry 202 can be coupled to one or more drive devices to vertically move the gantry 202. The gantry 202 can also be guided by one or more rods (not shown) extending through holes (not shown) at the rear side of the gantry 202. Figure 2 In the embodiment of the present invention, the shape of the stand 202 is generally rectangular. Alternatively, the stand 202 may be implemented in any other shape (e.g., a square shape) without any limitation. Further, the stand 202 may be made of any suitable material (e.g., metal). In an example, the stand 202 may include a housing 102 (see FIG. 1 ). Figure 1 ) is movably coupled to one or more fastening elements (not shown). The stage 202 defines opposite ends 264, 266 spaced apart from each other along the X-direction. The print bed assembly 200 further includes a carrier plate 204 disposed on the stage 202. The carrier plate 204 may be spaced apart from the stage 202 in the Z-direction. The carrier plate 204 may be coupled to the stage 202 via a number of mechanical fasteners (not shown). The mechanical fasteners may include screws, bolts, pins, etc. The height of the mechanical fasteners may be adjustable so as to properly level the carrier plate 204 when placed on the carrier plate, and thereby properly level the build plate 224. The carrier plate 204 includes an upper surface 206 extending in the X-direction and in the Y-direction perpendicular to the X-direction. Further, the carrier plate 204 defines a front side 210 and a rear side 212, each of which extends in the X-direction. In Figure 2 In the embodiment of the present invention, the shape of the carrier plate 204 is generally rectangular. Alternatively, the carrier plate 204 can have any other shape, such as a square shape. The carrier plate 204 can be made of any suitable material, including but not limited to metal, ceramic, and polymer. Figure 2 In the example of FIG. 2 , build plate detection sensor 205 is disposed in a cavity at rear edge 212 of carrier plate 204 .

[0048] The print bed assembly 200 further includes a build plate 224 to be placed on the carrier plate 204. During printing, consumable materials can be deposited on the build plate 224 to form a 3D printed object. Figure 2 , build plate 224 has not yet been placed on carrier plate 204. Figure 2In the embodiment of the present invention, the building plate 224 includes a flexible metal plate. However, the building plate 224 can be made of any other suitable material. For example, any type of transparent or non-transparent glass or metal can be used to manufacture the building plate 224.

[0049] exist Figure 2 In the embodiment of the present invention, build plate 224 comprises a substantially rectangular plate with rounded corners. Alternatively, build plate 224 may comprise any other shape suitable for building an object thereon. Preferably, the dimensions of build plate 224 are similar to the dimensions of carrier plate 204, so that when build plate 224 is placed on carrier plate 204, at least front edge 226 and rear edge 228 of build plate 224 are aligned with respective front side 210 and rear side 212 of carrier plate 204. In this way, build plate 224 is fully supported. When build plate 224 is placed on carrier plate 204 (see, e.g., Figure 5 ), build plate 224 contacts upper surface 206 of carrier plate 204. In an example, a separate adhesive sheet (not shown) may be placed on build plate 224, on which a 3D printed object may be formed.

[0050] The print bed assembly 200 also includes at least one abutment 230, 232 disposed on the stage 202. Figure 2 In the embodiment of the present invention, the print bed assembly 200 includes two abutments 230, 232 (also referred to as Y-alignment structures). Alternatively, the print bed assembly 200 may include a single abutment or more than two abutments, such as four abutments. Further, each abutment 230, 232 is coupled to the stage 202 herein. When viewed in the Y direction, each abutment 230, 232 is located behind the rear side of the carrier plate 204. It should be noted that in this embodiment, the abutment does not contact the carrier plate 204.

[0051] Abutment 230 is substantially similar in design to abutment 232. Abutments 230, 232 are arranged to align build plate 224 relative to carrier plate 204 in the Y direction. Figure 2 In the embodiment of FIG. 2 , abutments 230 , 232 also align build plate 224 in the X direction relative to carrier plate 204. Thus, in this case, abutments 230 , 232 may be referred to as “XY alignment structures” because they align build plate 224 in each of the X and Y directions. Abutments 230 , 232 may allow for easier installation of build plate 224 by providing instant alignment of build plate 224 in the Y direction as well as the X direction.

[0052] like Figure 2As shown, in this embodiment, the carrier plate 204 includes one or more magnets 214. Specifically, the carrier plate 204 includes a plurality of magnets 214 spaced apart from each other in the X direction and the Y direction. The magnets 214 in the carrier plate 204 can allow the build plate 224 to be coupled to the carrier plate 204. The magnets 214 are received in the carrier plate 204. Specifically, the carrier plate 204 defines a plurality of holes (not shown). Each hole is configured to receive at least a portion of the corresponding magnet 214 therein. It should be noted that the build plate 224 can be coupled to the carrier plate 204 using other fastening means (such as a clamp, a mechanical fastener, a vacuum coupling, etc.), without any limitation. In an example, in addition to magnetic coupling, the print bed assembly 200 may include one or more fasteners (not shown) that can couple the build plate 224 to the carrier plate 204. It should be noted that Y-alignment structures 230, 232, together with support structure 220, may allow for easier insertion of build plate 224, especially when build plate 224 is metal and carrier plate 204 includes magnets 214. Furthermore, the design of Y-alignment structures 230, 232 may allow for easy disengagement and engagement of build plate 224 with build plate 224.

[0053] Further, the print bed assembly 200 includes a print bed cover 216. The print bed cover 216 is coupled to the stage at the rear side of the stage 202. The print bed cover 216 defines a pair of slots 218 spaced apart from each other along the X direction. The pair of slots 218 are defined at opposite ends 264, 266 of the stage 202. The shape of the slots 218 is substantially rectangular. In an example, the print bed cover 216 can be made of a polymer.

[0054] Print bed assembly 200 may further include a heating element (not shown) disposed below or in carrier plate 204. The heating element may maintain the temperature of one or more components of print bed assembly 200, such as carrier plate 204 or build plate 224, at a desired temperature level. The heating element may be disposed between carrier plate 204 and stage 202.

[0055] In this embodiment, build plate 224 includes a pair of rear tabs 242. Rear tabs 242 extend from rear edge 228 of build plate 224 along the Y direction. Tabs 242 are also referred to as build plate extensions 224. When build plate 224 is placed on carrier plate 204, rear tabs 242 are received in slots 218 defined by print bed cover 216. Rear tabs 242 are substantially rectangular in shape.

[0056] Build plate 224 further includes a pair of handles 244 extending from front edge 226 of build plate 224 along the Y direction. Handles 244 are substantially rectangular in shape. It should be noted that handles 244 may include any other shape or design. For example, each handle 244 may define an opening to help hold build plate 224.

[0057] Further, the building plate 224 includes one or more cutouts 246, 248 to receive one or more pins 230, 232. Specifically, the building plate 224 includes two cutouts 246, 248. Each cutout 246, 248 at least partially receives the first state S1 (e.g., Figure 3A shown) and a second state S2 (as shown Figure 5 Thus, cutouts 246, 248 allow pins 230, 232 to engage with build plate 224 in each of first state S1 (also referred to as tilted state S1) and second state S2 (also referred to as final state S2) of build plate 224. One or more cutouts 246, 248 may have various shapes, such as a V-shape or a U-shape. Figure 2 In the embodiment, the first cutout (eg, cutout 246) has a V-shape and the second cutout (eg, cutout 248) has a U-shape.

[0058] Figure 3A Shows Figure 2 FIG. 2 is a cross-sectional side view of the print bed assembly 200 through one of the Y alignment structures 230. Figure 3A , build plate 224 is disposed in a first state S1 in which build plate 224 is placed against alignment structures 230, 232 and forms an angle A1 relative to upper surface 206 of carrier plate 204. If build plate 224 is positioned (i.e., by a user) in first state S1, build plate 224 should contact all Y alignment structures 230, 232. Next, build plate 224 may be moved to a second state S2 (e.g., Figure 5 204). When build plate 224 is placed flat on carrier plate 204, build plate 224 is in second state S2. Build plate 224 may be lowered (i.e., rotated, see R1) while remaining at the rear side of carrier plate 204 with a straight edge (see Figure 3B222) to move build plate 224 from first state S1 to second state S2, in which case the back side acts as a support structure. If build plate 224 is correctly lowered onto upper surface 206 of carrier plate 204, build plate 224 still contacts at least one Y-alignment structure 230, 232. This allows build plate 224 to be optimally aligned relative to carrier plate 204, at least in the Y direction. Once build plate 224 is placed on carrier plate 204, no further adjustments to build plate 224 are required.

[0059] Figure 3B yes Figure 3A A detailed view of a portion of a Figure 3B As shown, the print bed assembly 200 further includes a support structure 220, which is arranged on the stage 202 and includes a straight edge 222 extending in the X direction. At least one Y alignment structure 230, 232 is arranged on the stage 202, beside the support structure 220. Specifically, at least one Y alignment structure 230, 232 is arranged adjacent to the support structure 220 along the Y direction. Figure 2 In the embodiment of FIG. 2 , support structure 220 is an integral part of carrier plate 204. Specifically, in this case, rear edge 212 of carrier plate 204 is used to support the building plate in the first state S1.

[0060] Further, in Figure 3A and Figure 3B 204. In the first state S1, when the build plate 224 is placed on the support structure 220 at an angle A1 relative to the upper surface 206 of the carrier plate 204, the build plate 224 contacts the straight edge 222 of the support structure 220 and at least one Y-alignment structure 230, 232 (see Figure 2 ). It should be noted that Figure 3A and Figure 3B 20 , only Y-alignment structure 230 is visible, however, build plate 224 also contacts Y-alignment structure 232 in its first state S1. Further, support structure 220 provides a rotation hinge point about which build plate 224 can be moved in direction R1 to place build plate 224 on carrier plate 204. In addition, straight edge 222 of support structure 220 can define an axis about which build plate 224 can be rotated in direction R1. It should be noted that preferably, each Y-alignment structure 230, 232 maintains constant contact with build plate 224 during rotation of build plate 224 along direction R1. Therefore, Y-alignment structures 230, 232 can serve as guide members during rotation of build plate 224.

[0061] It should be noted that in this embodiment, two ramps 234, 235 are arranged in carrier plate 204 for guiding tab 242 during installation of build plate 224. Since the length of tab 242 is limited in this example, once build plate 224 contacts abutment 230 in the inclined state S1, the tab will separate from ramps 234, 235, see also Figure 3B This is because in state S1, the middle section at the back side of build plate 224 (i.e., the area between flaps 242) will be in contact with top edge 222 at back side 212 of carrier plate 204, which causes the flaps to be lifted relative to the slope of the carrier plate. Figure 3B In the illustrated situation S1 , tabs 242 abut against abutments 230 , 232 , while build plate 224 rests on top edge 222 of carrier plate 206 at the rear side.

[0062] Since the Y-alignment is arranged beside the carrier plate 204, the space behind the carrier plate 204 is used to insert / place the build plate at a certain angle. Depending on the distance between the Y-alignment and the carrier plate 204 and the thickness of the build plate 224, the build plate 224 can be inserted at a certain angle range A1. In practice, the angle A1 of the build plate 224 relative to the upper surface 206 of the carrier plate 204 is in the range of 5 degrees to 80 degrees. In the example, the angle A1 of the build plate 224 relative to the upper surface 206 can be in the range of 10 degrees to 45 degrees. It should be noted that the larger angle A1 when inserting the build plate 224 can allow easier manipulation of the build plate 224 when the build plate 224 is rotated in the direction R1. The increased angle A1 between the build plate 224 and the carrier plate 204 is particularly advantageous for the magnetically held build plate. More specifically, due to the increased angle A1, the user may not have to make additional efforts to overcome the friction between the carrier plate 204 and the build plate 224 that may be generated due to the magnetic pull between the build plate 224 and the carrier plate 204.

[0063] As from Figure 3B As can be seen, at least one Y-alignment structure 230, 232 includes one or more pins extending upward from stage 202 to a level LV1 that is higher than a level LV2 of upper surface 206 of carrier plate 204. In other words, at least one Y-alignment structure 230, 232 extends higher than upper surface 206 of carrier plate 204 relative to the Z direction. Level LV1 and level LV2 are defined along the Z direction relative to stage 202. Since level LV1 is higher than level LV2, build plate 224 can be in constant contact with at least one Y-alignment structure 230, 232 even when build plate 224 is in second state S2.

[0064] Y-alignment structures 230, 232 may be interchangeably referred to as pins 230, 232. Pins 230, 232 include a first segment 236 and a second segment 238 fixedly coupled to first segment 236. Second segment 238 is removably coupled to stage 202 via fastener 240. In another example, second segment 238 may be integral with stage 202. Further, in each of the first state S1 and the second state S2 of build plate 224, first segment 236 is engaged with build plate 224.

[0065] It should be noted that, because the Y-alignment structure is disposed beside (i.e., behind) carrier plate 204 (rather than on top of the carrier plate as in known devices), the edge of carrier plate 204 can be used to articulate / rotate build plate 204 from state S1 to state S2. During this rotational movement, when a user or robot applies sufficient minimal force, build plate 224 remains in contact with the Y-alignment structure; thus, also in state S2, the build plate is fully aligned, at least in the Y direction.

[0066] Figure 4 Schematically shows a three-dimensional view of the Y alignment structure 230, 232 according to an embodiment of the present invention. Figure 4 As shown, the shape of the first section 236 of the structure 230, 232 is cylindrical. Further, the shape of the second section 238 is hexagonal. The height of the pins 230, 232 is such that the top of the pin is above the top surface 206 of the carrier plate 204. This prevents the build plate 224 from moving over the pins 230, 232 in the state S2 due to excessive force by the user.

[0067] Figure 5 A perspective view of assembly 200 is shown in a second state S2, wherein build plate 224 is placed onto carrier plate 204. In this embodiment, build plate 224 completely covers carrier plate 204. Preferably, the dimension of build plate 224 in the X direction is equal to or substantially equal to the dimension of carrier plate 204, as will be appreciated by the skilled person.

[0068] exist Figure 5 In the embodiment of the present invention, the cutout 246 has a V-shape and the cutout 248 has a U-shape. Figure 3A ), notch 246 and pin 230 together align build plate 224 in the X direction and the Y direction. In the second state S2, notch 246 and pin 230 can prevent any movement of build plate 224 in the X direction and the Y direction. Further, in the first state S1, notch 248 and pin 232 together align build plate 224 in the X direction and the Y direction. In addition, in the second state S2, notch 248 and pin 232 together limit the rotation of build plate 224 in the horizontal plane (i.e., the XY plane) along direction R2.

[0069] Figure 6 Another design of at least one Y alignment structure 630, 632 that can be used with the print bed assembly 200 is shown (see Figure 2 3). Each Y alignment structure 630, 632 is embodied herein as a pin. The Y alignment structures 630, 632 are interchangeably referred to as pins 630, 632. The Y alignment structures 630, 632 are substantially similar in function to Figure 4 and Figure 5 However, each of the one or more pins 630, 632 includes a body portion 634 and a head portion 640. The body portion 634 includes a first section 636 and a second section 638 fixedly coupled to the first section 636. The second section 638 is configured to couple with the gantry 202 (see Figure 2 and Figure 3A ). Further, in the first state S1 of the building plate 224 (see Figure 3A ) and the second state S2 (see Figure 5 ), first section 636 is engaged with build plate 224 (see Figure 2 and Figure 3A ).like Figure 6 As shown, the shape of the first section 636 is cylindrical. Further, the shape of the second section 638 is hexagonal.

[0070] Further, head portion 640 is fixedly coupled to second section 638. The shape of head portion 640 is circular. The head portion 640 of corresponding pins 630, 632 is configured to lock with building plate 224 when building plate 224 is arranged on carrier plate 204 (see Figure 3A and Figure 5 When build plate 224 is in the second state, head portion 640 may prevent any movement of build plate 224 along the Z direction (see Figure 3A and Figure 5 ). Thus, head portion 640 provides an additional locking feature for build plate 224. It should be noted that, as with respect to Figure 4 and Figure 6 As explained, the design of the Y-alignment structure 230, 232, 630, 632 is exemplary in nature, and the Y-alignment structure 230, 232, 630, 632 may include any other design. The Y-alignment structure 230, 232, 630, 632 may be made of any material including, but not limited to, metal or ceramic. In an example, the Y-alignment structure 230, 232, 630, 632 may be made of sheet metal. The Y-alignment structure 230, 232, 630, 632 has a simple design, is easy to incorporate, and can be manufactured cost-effectively.

[0071] Figure 7 24. A top view of build plate 224 is shown. Build plate 224 includes a pair of cutouts 246, 248, wherein cutout 246 has a V-shape and cutout 248 has a U-shape. U-shaped cutout 248 preferably has a U-shape, wherein the U-shape has a flat bottom line or at least a partially flat bottom line. When build plate 224 is properly placed (i.e., aligned) on carrier plate 204, the flat portion extends in the X direction. In such an embodiment, each cutout 246, 248 and corresponding Y alignment structure 230, 232 (see Figure 2 , Figure 3 and Figure 5 ) will help align the build plate 224 in the Y direction. Further, the cutout 246 and its corresponding Y alignment structure 230 will also limit any movement of the build plate 224 in the X direction.

[0072] Fig. 8A and Figure 8B Another embodiment of the present invention is shown. Fig. 8A A print bed assembly substantially similar to print bed assembly 200 (see Figure 2 , Figure 3 and Figure 5 ) of a print bed assembly 800. The print bed assembly 800 includes: a stage 202; a carrier plate 204; a build plate 224 having a rear wing 242; and a support structure 220 including a straight edge 222 similar to that described above. Fig. 8A In the embodiment of the present invention, the print bed assembly 800 includes a print bed cover 816. The print bed cover 816 includes a pair of cover members 850. Each cover member 850 is configured to cover the corresponding rear wing 242 when the build plate 224 is arranged on the carrier plate 204. Further, each cover member 850 defines an opening 852. Each opening 852 is configured to at least partially receive the corresponding Y-alignment structure 830, 832 therein. The Y-alignment structures 830, 832 are embodied as pins in this article. The Y-alignment structures 830, 832 are substantially similar to the Y-alignment structures 230, 232 in shape and function. However, in this embodiment, the height of each Y-alignment structure 830, 832 (see Figure 8B ) are greater than the height of the Y-aligned structures 230 and 232 (see Figure 4 ).

[0073] Figure 8B A cross-sectional view of a portion of the print bed assembly 800 is shown. Figure 8B As shown, the rear wing 242 is covered by the print bed cover 816. Further, in this embodiment, the Y alignment structures 830, 832 (see Fig. 8A) together with the cover member 850 completely encloses the rear flap 242, thereby preventing the build plate 224 from sliding off due to improper manipulation by the user. This can improve the reliability of the print bed assembly 800. In an example, the print bed cover 816 can be made of a polymer. Accordingly, the print bed cover 816 can be appropriately spaced apart from any component of the print bed assembly 800 (such as the build plate 224 that becomes hot during operation).

[0074] Fig. 9 A print bed assembly 900 is shown in accordance with an embodiment of the present invention. Fig. 9 The print bed assembly 900 is substantially similar in function to Figure 2 , Figure 3 and Figure 5 Print bed assembly 900 includes: a stage 202; a carrier plate 204 having an upper surface 206; and a support structure 220 including a straight edge 222 similar to that described above. Print bed assembly 900 also includes a build plate 924 to be placed on the carrier plate 204. Build plate 924 is different from build plate 224 (see Figure 2 , Figure 3 and Figure 5 ). Specifically, build plate 924 includes a pair of cutouts 946, 948 disposed at opposite ends 954, 956 of build plate 924. Cutouts 946, 948 are substantially rectangular in shape. Build plate 224 also defines a rear edge 928 that extends between the pair of cutouts 946, 948 in the X-direction. It should be noted that details related to the positioning of build plate 224 of print bed assembly 200 in first state S1 and second state S2 (as described with respect to FIGS. 3 and 4, respectively) are not disclosed. Figure 2 ) also applies to the positioning of the build plate 924 of the print bed assembly 900.

[0075] Further, the print bed assembly 900 includes two Y alignment structures 930, 932. Fig. 9 In the embodiment of the present invention, Y-alignment structures 930, 932 align build plate 924 in the Y direction relative to carrier plate 204. Specifically, in a first state of build plate 924 (i.e., during insertion of build plate 924), Y-alignment structures 930, 932 align build plate 924 in the Y direction. Y-alignment structures 930, 932 engage with rear edge 928 of build plate 924 to align build plate 924 in the Y direction. Furthermore, in a second state of build plate 924 (i.e., when build plate 924 is placed on carrier plate 204), Y-alignment structures 930, 932 prevent any movement of build plate 924 along the Y direction. Y-alignment structures 930, 932 are embodied as pins 930, 932 and are interchangeably referred to as pins. Y-alignment structures 930, 932 are substantially similar in design and function to those of FIGS. 3 and 4. Figure 4Alternatively, the Y alignment structures 930, 932 may be substantially similar in design to those described with respect to Figure 6 Y-aligned structures 630, 632 explained.

[0076] Further, the print bed assembly 900 includes at least one X-alignment structure 958, 960 arranged to align the build plate 924 relative to the carrier plate 204 in the X direction. Specifically, the print bed assembly 900 includes two X-alignment structures 958, 960 that align the build plate 924 in the X direction. The X-alignment structures 958, 960 are spaced apart from each other in the X direction and are disposed at respective opposite ends 264, 266 of the stage 202. In the first state of the build plate 924, the X-alignment structures 958, 960 engage with corresponding cutouts 946, 948 in the build plate 924 to align the build plate 924 in the X direction. In addition, in the second state of the build plate 924, the X-alignment structures 958, 960 can prevent any movement of the build plate 924 along the X direction.

[0077] exist Fig. 9 In the embodiment of the present invention, at least one X-alignment structure 958, 960 includes one or more pins that extend upward from stage 202 to a level higher than the level of upper surface 206 of carrier plate 204. In other words, at least one X-alignment structure 958, 960 extends higher than upper surface 206 of carrier plate 204 relative to the Z direction. Since the level of at least one X-alignment structure 958, 960 is higher than the level of upper surface 206, build plate 924 can contact at least one X-alignment structure 958, 960 even when build plate 924 is in the second state. X-alignment structures 958, 960 may be interchangeably referred to as pins 958, 960. It should be noted that X-alignment structures 958, 960 may be substantially similar in design to those described with respect to FIGS. 3 and 4. Figure 4 Alternatively, the X-alignment structures 958, 960 may be substantially similar in design to those described with respect to Figure 6 Y-aligned structures 630, 632 explained.

[0078] Further, when build plate 924 is in the first state (i.e., tilted state S1), build plate 924 contacts each of the following: straight edge 222 of support structure 220, at least one Y-alignment structure 930, 932, and at least one X-alignment structure 958, 960. Furthermore, when build plate 924 is in the second state (i.e., flat end state S2), build plate 924 still contacts at least one Y-alignment structure 930, 932 and at least one X-alignment structure 958, 960.

[0079] The print bed assembly 900 also includes a print bed cover 916. The print bed cover 916 defines a pair of through holes 962 spaced apart from each other in the X direction. Each through hole 962 is configured to receive at least a portion of a corresponding Y alignment structure 930, 932 to allow the corresponding Y alignment structure 930, 932 to be attached to the stage 202.

[0080] Fig.10 A print bed assembly 1000 is shown according to another embodiment of the present invention. Fig.10 The print bed assembly 1000 is substantially similar in function to Figure 2 , Figure 3 and Figure 5 Print bed assembly 1000 includes: a stage 202; a carrier plate 204 having an upper surface 206; a print bed cover 216; and a support structure 220 including a straight edge 222 similar to that described above. Print bed assembly 1000 also includes a build plate 1024 to be placed on carrier plate 204. Build plate 1024 is different from build plate 224 (see Figure 2 , Figure 3 and Figure 5 ). Specifically, build plate 1024 does not include any cutouts (e.g., cutouts 246, 248 in build plate 224). It should be noted that details related to the positioning of build plate 224 of print bed assembly 200 in first state S1 and second state S2 (as described with respect to FIGS. 3 and 4, respectively) are not disclosed. Figure 5 ) also applies to the positioning of the build plate 1024 of the print bed assembly 1000.

[0081] Further, print bed assembly 1000 includes at least one Y alignment structure 1030, 1032. At least one Y alignment structure 1030, 1032 includes one or more contours that extend upward from stage 202 to a level higher than the level of upper surface 206 of carrier plate 204. In other words, at least one Y alignment structure 1030, 1032 extends higher than upper surface 206 of carrier plate 204 relative to the Z direction. Since the level of at least one Y alignment structure 1030, 1032 is higher than the level of upper surface 206, build plate 1024 can contact at least one Y alignment structure 1030, 1032 even when build plate 1024 is in second state S2. Print bed assembly 1000 herein includes two Y alignment structures 1030, 1032. In Fig.10In the embodiment of FIG. 1 , each Y-alignment structure 1030 , 1032 is embodied as a substantially vertical member extending from stage 202 in the Z direction. Y-alignment structures 1030 , 1032 also extend along the X direction and are disposed at respective opposite ends 264 , 266 of stage 202 . Each Y-alignment structure 1030 , 1032 defines a first length L1 along the X direction. Y-alignment structures 1030 , 1032 are arranged to align build plate 1024 in the Y direction relative to carrier plate 204 . Specifically, in a first state of build plate 1024 (i.e., during insertion of build plate 1024 ), Y-alignment structures 1030 , 1032 align build plate 1024 in the Y direction. Furthermore, in a second state of build plate 1024 (i.e., when build plate 1024 is placed on carrier plate 204 ), Y-alignment structures 1030 , 1032 may prevent any movement of build plate 1024 along the Y direction.

[0082] Further, print bed assembly 1000 includes at least one X-alignment structure 1058, 1060 arranged to align build plate 1024 relative to carrier plate 204 in the X direction. At least one X-alignment structure 1058, 1060 includes one or more contours that extend upward from stage 202 to a level higher than the level of upper surface 206 of carrier plate 204. In other words, at least one X-alignment structure 1058, 1060 extends higher than upper surface 206 of carrier plate 204 relative to the Z direction. Since the level of at least one X-alignment structure 1058, 1060 is higher than the level of upper surface 206, build plate 1024 can contact at least one X-alignment structure 1058, 1060 even when build plate 1024 is in the second state. Print bed assembly 1000 herein includes two X-alignment structures 1058, 1060. In Fig.10 In the embodiment of the present invention, each X-alignment structure 1058, 1060 is embodied as a substantially vertical member extending from the stage 202 in the Z direction. The X-alignment structures 1058, 1060 extend along the Y direction and are disposed at respective opposite ends 264, 266 of the stage 202. Further, the X-alignment structures 1058, 1060 are substantially parallel to each other. In addition, the Y-alignment structures 1030, 1032 are substantially perpendicular to each X-alignment structure 1058, 1060. Each X-alignment structure 1058, 1060 defines a second length L2 along the Y direction. Fig.10 In the embodiment of the present invention, the first length L1 of each Y-alignment structure 1030 , 1032 is greater than the second length L2 of each X-alignment structure 1058 , 1060 .

[0083] In the first state, each X-alignment structure 1058, 1060 aligns build plate 1024 in the X direction. Additionally, in the second state of build plate 1024, each X-alignment structure 1058, 1060 prevents any movement of build plate 1024 along the X direction. Fig.10 In the embodiment of the present invention, the X-alignment structure 1058 and the Y-alignment structure 1030 are manufactured as separate components. Alternatively, the X-alignment structure 1058 and the Y-alignment structure 1030 can be integral and manufactured as a single component. For example, the X-alignment structure 1058 and the Y-alignment structure 1030 can together form an L-shaped XY alignment structure. Similarly, in Fig.10 In an embodiment, the X-alignment structure 1060 and the Y-alignment structure 1032 are manufactured as separate components. Alternatively, the X-alignment structure 1060 and the Y-alignment structure 1032 may be integral and manufactured as a single component. For example, the X-alignment structure 1060 and the Y-alignment structure 1032 may together form an L-shaped XY alignment structure.

[0084] The Y-alignment structures 1030, 1032 and the X-alignment structures 1058, 1060 may be made of any material including, but not limited to, metal or ceramic. In an example, the Y-alignment structures 1030, 1032 and the X-alignment structures 1058, 1060 may be made of sheet metal. The Y-alignment structures 1030, 1032 and the X-alignment structures 1058, 1060 may have a simple design, may be easily incorporated, and may be cost-effectively manufactured.

[0085] Further, when build plate 1024 is in first state S1, build plate 1024 contacts each of: straight edge 222 of support structure 220, at least one Y-alignment structure 1030, 1032, and at least one X-alignment structure 1058, 1060. Furthermore, when build plate 1024 is in second state S2, build plate 1024 still contacts at least one Y-alignment structure 1030, 1032 and at least one X-alignment structure 1058, 1060.

[0086] Fig.11 A print bed assembly 1100 is shown according to another embodiment of the present invention. Fig.11 The print bed assembly 1100 is substantially similar in function to Figure 2 , Figure 3 and Figure 5 Print bed assembly 1100 includes a gantry 202, a carrier plate 204, a print bed cover 216, and a support structure 220, which includes a straight edge 222 as described above. Print bed assembly 1100 also includes a build plate 1124 to be placed on the carrier plate 204. Build plate 1124 is different from build plate 224 (see Figure 2 , Figure 3 and Figure 5 ). Build plate 1124 defines a rear edge 1128. Rear edge 1128 extends along the X direction between opposite ends 1154, 1156 of build plate 1124. It should be noted that details related to the positioning of build plate 224 of print bed assembly 200 in first state S1 and second state S2 (as described with respect to FIGS. 3 and 4, respectively) are not disclosed. Figure 2 ) also applies to the positioning of the build plate 1124 of the print bed assembly 1100.

[0087] Further, the print bed assembly 1100 includes at least one Y alignment structure 1130. The at least one Y alignment structure 1130 herein includes one or more profiles. The print bed assembly 1100 herein includes a single Y alignment structure 1130 extending along the X direction between the opposite ends 264, 266 of the stage 202. Fig.11 104, Y-alignment structure 1130 is embodied as a substantially vertical member extending from stage 202 in the Z direction. Y-alignment structure 1130 is arranged to align build plate 1124 in the Y direction relative to carrier plate 204. Specifically, in a first state of build plate 1124 (i.e., during insertion of build plate 1124), Y-alignment structure 1130 aligns build plate 1124 in the Y direction. Furthermore, in a second state of build plate 1124 (i.e., when build plate 1124 is placed on carrier plate 204), Y-alignment structure 1130 prevents any movement of build plate 1124 along the Y direction.

[0088] Further, print bed assembly 1100 includes at least one X-alignment structure 1158, 1160 arranged to align build plate 1124 in the X direction relative to carrier plate 204. At least one X-alignment structure 1158, 1160 herein includes one or more profiles. Fig.11 In the embodiment of the present invention, the print bed assembly 1100 includes two X-alignment structures 1158, 1160. The X-alignment structures 1158, 1160 extend along the Y direction and are disposed at the respective opposite ends 264, 266 of the stage 202. Further, the X-alignment structures 1158, 1160 are substantially parallel to each other. In addition, the Y-alignment structure 1130 is substantially perpendicular to each of the X-alignment structures 1158, 1160. Fig.11 In the embodiment of the present invention, each X-alignment structure 1158, 1160 is embodied as a substantially vertical member extending from stage 202 in the Z direction. In the first state of build plate 1124, each X-alignment structure 1158, 1160 aligns build plate 1124 in the X direction. In addition, in the second state of build plate 1124, each X-alignment structure 1158, 1160 prevents any movement of build plate 1124 along the X direction.

[0089] exist Fig.11 In an embodiment, the X-alignment structures 1158, 1160 and the Y-alignment structure 1130 are manufactured as separate components. Alternatively, the X-alignment structures 1158, 1160 and the Y-alignment structure 1130 may be integral and manufactured as a single component. For example, the X-alignment structures 1158, 1160 and the Y-alignment structure 1130 may together form a U-shaped XY alignment structure. The Y-alignment structure 1130 and the X-alignment structures 1158, 1160 may be made of any material including, but not limited to, metal or ceramic. In an example, the Y-alignment structure 1130 and the X-alignment structures 1158, 1160 may be made of sheet metal. The Y-alignment structure 1130 and the X-alignment structures 1158, 1160 may have a simple design, may be easily incorporated, and may be cost-effectively manufactured.

[0090] Further, when build plate 1124 is in the first state, build plate 1124 contacts each of: straight edge 222 of support structure 220, at least one Y-alignment structure 1130, and at least one X-alignment structure 1158, 1160. Additionally, when build plate 1124 is rotated downward to the second state, build plate 1124 still contacts at least one Y-alignment structure 1130 and at least one X-alignment structure 1158, 1160.

[0091] Fig. 12A A print bed assembly 1200 is shown according to yet another embodiment of the present invention. Fig. 12A The print bed assembly 1200 is substantially similar in function to Figure 2 , Figure 3 and Figure 5 Print bed assembly 1200 includes a gantry 202 and a carrier plate 204 similar to those described above. Print bed assembly 1200 also includes a build plate 1224 to be placed on carrier plate 204. Build plate 1224 is different from build plate 224 (see Figure 2 , Figure 3 and Figure 5 ). Build plate 1224 includes a pair of cutouts 1246, 1248 disposed at opposite ends 1254, 1256 of build plate 1224. Cutouts 1246, 1248 are substantially rectangular in shape. Build plate 1224 defines a rear edge 1228 extending along the X direction and disposed between cutouts 1246, 1248. It should be noted that details related to the positioning of build plate 224 of print bed assembly 200 in first state S1 and second state S2 (as described with respect to FIGS. 3 and 4, respectively) are not disclosed. Figure 2 ) also applies to the positioning of the build plate 1224 of the print bed assembly 1200.

[0092] Further, the print bed assembly 1200 includes at least one X-alignment structure 1258, 1260 arranged to align the build plate 1224 relative to the carrier plate 204 in the X direction. Specifically, the print bed assembly 1200 includes two X-alignment structures 1258, 1260. The X-alignment structures 1258, 1260 are spaced apart from each other in the X direction and are disposed at respective opposite ends 264, 266 of the stage 202. Fig. 12A In the embodiment of the present invention, X-alignment structures 1258, 1260 align build plate 1224 in the X-direction relative to carrier plate 204. Specifically, in a first state of build plate 1224 (i.e., during insertion of build plate 1224), X-alignment structures 1258, 1260 align build plate 1224 in the X-direction. X-alignment structures 1258, 1260 engage with corresponding cutouts 1246, 1248 in build plate 1224 to align build plate 1224 in the X-direction. Additionally, in a second state of build plate 1224 (i.e., when build plate 1224 is placed on carrier plate 204), X-alignment structures 1258, 1260 prevent any movement of build plate 1224 along the X-direction.

[0093] Each X-alignment structure 1258, 1260 comprises a pin herein. The X-alignment structures 1258, 1260 may be interchangeably referred to as pins 1258, 1260. It should be noted that each X-alignment structure 1258, 1260 is substantially similar in design to the pins 1258, 1260 described with respect to FIGS. Figure 4 Alternatively, the X-alignment structures 1258, 1260 may be substantially similar in design to those described with respect to Figure 6 Y-aligned structures 630, 632 explained.

[0094] Further, the print bed assembly 1200 includes at least one Y alignment structure 1230. Fig. 12A 1224 , Y-alignment structure 1230 is embodied as a substantially vertical member extending from stage 202 along the Z direction. Y-alignment structure 1230 is centrally located between opposite ends 264, 266 of stage 202. Y-alignment structure 1230 is arranged to align build plate 1224 relative to carrier plate 204 in the Y direction. Specifically, in a first state of build plate 1224 (i.e., with the build plate inserted at an angle), Y-alignment structure 1230 aligns build plate 1224 in the Y direction. Y-alignment structure 1230 engages with rear edge 1228 of build plate 1224 to align build plate 1224 in the Y direction. Additionally, in a second state of build plate 1224, Y-alignment structure 1230 prevents any movement of build plate 1224 along the Y direction.

[0095] Fig. 12B Shows Fig. 12A A side cross-sectional view of a portion of an embodiment of Fig. 12B As shown, the print bed assembly 1200 includes a support structure 1220 that is disposed on the stage 202 and includes a straight edge 1222 extending in the X direction. Fig. 12A In an embodiment, the support structure 1220 is separate from the carrier plate 204. The support structure 1220 is disposed between the carrier plate 204 and the Y-alignment structure 1230. The support structure 1220 and the Y-alignment structure 1230 are substantially parallel to each other. In addition, the support structure 1220 and the Y-alignment structure 1230 are integral with each other. The support structure 1220 and the Y-alignment structure 1230 can be made of any material including, but not limited to, metal or ceramic. In an example, the support structure 1220 and the Y-alignment structure 1230 can be made of sheet metal. The support structure 1220 and the Y-alignment structure 1230 can have a simple design, can be easily incorporated, and can be cost-effectively manufactured.

[0096] When build plate 1224 is properly placed in the first (i.e., tilted) state, build plate 1224 contacts each of: straight edge 1222 of support structure 1220, at least one Y-alignment structure 1230, and at least one X-alignment structure 1258, 1260. Additionally, when build plate 1224 is in the second (i.e., flat) state, build plate 1224 still contacts at least one Y-alignment structure 1230 and at least one X-alignment structure 1258, 1260.

[0097] Fig.13 A print bed assembly 1300 is shown in accordance with an embodiment of the present invention. Fig.13 The print bed assembly 1300 is substantially similar in function to Figure 2 , Figure 3 and Figure 5 The print bed assembly 1300 includes a gantry 202 and a carrier plate 204 similar to those described above. The print bed assembly 1300 also includes a build plate 1324 to be placed on the carrier plate 204. The build plate 1324 is different from the build plate 224 (see FIG. 3, Figure 4 and Figure 5 ). Build plate 1324 defines a rear edge 1328. Rear edge 1328 extends along the X-direction between opposite ends 1354, 1356 of build plate 1324. It should be noted that details related to the positioning of build plate 224 of print bed assembly 200 in first state S1 and second state S2 (as described with respect to FIGS. 3 and 4, respectively) are not disclosed. Figure 2 ) also applies to the positioning of the build plate 1324 of the print bed assembly 1300.

[0098] Further, the print bed assembly 1300 includes at least one Y alignment structure 1330. Specifically, the print bed assembly 1300 includes a single Y alignment structure 1330. The Y alignment structure 1330 extends between the opposite ends 264, 266 of the stage 202. Fig.13 In the embodiment of the present invention, the Y-alignment structure 1330 is substantially U-shaped. Specifically, the Y-alignment structure 1330 includes a pair of first portions 1368, and a second portion 1370 connected to the pair of first portions 1368 and extending between the pair of first portions. The first portion 1368 extends along the Y direction, and the second portion 1370 extends along the X direction. The first portions 1368 are disposed at the respective opposite ends 264, 266 of the stage 202, and the first portions 1368 are parallel to each other. Further, the second portion 1370 is substantially perpendicular to each first portion 1368.

[0099] exist Fig.13 In the embodiment of , the pair of first portions 1368 and the second portion 1370 are integral with each other. Y-alignment structure 1330 is arranged to align build plate 1324 in the Y direction relative to carrier plate 204. Specifically, in the first state of build plate 1324 (i.e., during insertion of build plate 1324), second portion 1370 of Y-alignment structure 1330 aligns build plate 1324 in the Y direction. Furthermore, in the second state of build plate 1324 (i.e., when build plate 1324 is placed on carrier plate 204), second portion 1370 prevents any movement of build plate 1324 along the Y direction. Fig.13 In the embodiment of the present invention, Y-alignment structure 1330 also aligns build plate 1324 in the X direction. Specifically, in the first state of build plate 1324, first portion 1368 of Y-alignment structure 1330 aligns build plate 1324 in the X direction. Furthermore, in the second state of build plate 1324, first portion 1368 may prevent any movement of build plate 1324 along the X direction. It should be noted that Y-alignment structure 1330 may be referred to as an “XY alignment structure” because it aligns build plate 1324 in each of the X direction and the Y direction.

[0100] Further, the print bed assembly 1300 includes a support structure 1320 disposed on the stage 202 and including a straight edge 1322 extending in the X direction. Fig.13In an embodiment of the present invention, the support structure 1320 is separated from the carrier plate 204. The support structure 1320 is disposed between the carrier plate 204 and the Y-alignment structure 1330. The support structure 1320 and the second portion 1370 of the Y-alignment structure 1330 are substantially parallel to each other. In addition, the support structure 1320 and the Y-alignment structure 1330 are integral with each other. The support structure 1320 and the Y-alignment structure 1330 can be made of any material including, but not limited to, metal or ceramic. In an example, the support structure 1320 and the Y-alignment structure 1330 can be made of sheet metal. The support structure 1320 and the Y-alignment structure 1330 can have a simple design, can be easily incorporated, and can be cost-effectively manufactured.

[0101] It should be noted that when build plate 1324 is in first state S1, build plate 1324 contacts straight edge 1322 of support structure 1320 and at least one Y-alignment structure 1330. Furthermore, when build plate 1324 is in the second state, build plate 1324 still contacts at least one Y-alignment structure 1330.

[0102] Fig.14A A print bed assembly 1400 is shown in accordance with an embodiment of the present invention. Fig.14A The print bed assembly 1400 is substantially similar in function to Figure 2 , Figure 3A and Figure 5 The print bed assembly 1400 includes a gantry 202 and a carrier plate 204 similar to those described above. The print bed assembly 1400 also includes a build plate 1424 to be placed on the carrier plate 204. The build plate 1424 is different from the build plate 224 (see Figure 2 , Figure 3A and Figure 5 ). Build plate 1424 defines a rear edge 1428. Rear edge 1428 extends along the X-direction between opposite ends 1454, 1456 of build plate 1424. It should be noted that details related to the positioning of build plate 224 of print bed assembly 200 in first state S1 and second state S2 (such as respectively Figure 3A and Figure 5 ) also applies to the positioning of the build plate 1424 of the print bed assembly 1400.

[0103] Fig. 14B Shows Fig.14A A side cross-sectional view of a portion of an embodiment of Fig. 14BAs shown, the print bed assembly 1400 includes at least one Y alignment structure 1430. Specifically, the print bed assembly 1400 includes a single Y alignment structure 1430 herein. The Y alignment structure 1430 extends between the opposite ends 264, 266 of the stage 202. In this embodiment, the Y alignment structure 1430 is substantially U-shaped. Specifically, the Y alignment structure 1430 includes a pair of first portions 1468, and a second portion 1470 connected to the pair of first portions 1468 and extending between the pair of first portions, see also Fig.14A The first portion 1468 is disposed at the respective opposite ends 264, 266 of the stage 202 and extends along the Y direction. Further, the second portion 1470 extends between the opposite ends 264, 266 of the stage 202 along the X direction. The first portions 1468 are substantially parallel to each other. In addition, the second portion 1470 is substantially perpendicular to each first portion 1468. Fig.14A and Fig. 14B In the embodiment, the first portion 1468 and the second portion 1470 are integral with each other.

[0104] Y-alignment structure 1430 is arranged to align build plate 1424 in the Y direction relative to carrier plate 204. Specifically, in the first state of build plate 1424 (i.e., during insertion of build plate 1424), second portion 1470 of Y-alignment structure 1430 aligns build plate 1424 in the Y direction. Furthermore, in the second state of build plate 1424 (i.e., when build plate 1424 is placed on carrier plate 204), second portion 1470 prevents any movement of build plate 1424 along the Y direction. Fig.14A In the embodiment of the present invention, Y-alignment structure 1430 also aligns build plate 1424 in the X direction. Specifically, in the first state of build plate 1424, first portion 1468 of Y-alignment structure 1430 aligns build plate 1424 in the X direction. Furthermore, in the second state of build plate 1424, first portion 1468 can prevent any movement of build plate 1424 along the X direction. Y-alignment structure 1430 can be referred to as an “XY alignment structure” because it aligns build plate 1424 in each of the X direction and the Y direction.

[0105] Further, the print bed assembly 1400 includes a support structure 1420 disposed on the stage 202 and including a straight edge 1422 extending in the X direction. Fig.14A and Fig. 14B In the embodiment of the present invention, the support structure 1420 is separated from the carrier plate 204. The support structure 1420 is disposed between the carrier plate 204 and the Y-alignment structure 1430. The second portion 1470 of the support structure 1420 and the Y-alignment structure 1430 are substantially parallel to each other.

[0106] exist Fig.14A and Fig. 14B In an embodiment of the present invention, the print bed assembly 1400 further includes a locking member 1472. The locking member 1472 extends along the X direction. The locking member 1472 extends between the first portion 1468 of the Y alignment structure 1430 and is connected to the first portion. In addition, the locking member 1472 is connected to the second portion 1470 and extends orthogonally from the second portion 1470. When the build plate 1424 is in the second state, the locking member 1472 prevents any movement of the build plate 1424 along the Z direction. Therefore, the locking member 1472 provides an additional locking feature for the build plate 1424. Further, the support structure 1420, the Y alignment structure 1430 and the locking member 1472 are integral with each other. The support structure 1420, the Y alignment structure 1430 and the locking member 1472 can be made of any material including, but not limited to, metal or ceramic. In an example, the support structure 1420, the Y alignment structure 1430 and the locking member 1472 can be made of sheet metal. The support structure 1420, Y-alignment structure 1430, and locking member 1472 can have a simple design, can be easily incorporated, and can be cost-effectively manufactured.

[0107] Further, when build plate 1424 is in the first state, build plate 1424 contacts straight edge 1422 of support structure 1420 and at least one Y-alignment structure 1430. In an example, build plate 1424 may also contact locking member 1472, for example, to align build plate 1424 in the Z direction. Furthermore, when build plate 1424 is in the second state, build plate 1424 still contacts at least one Y-alignment structure 1430 and also contacts locking member 1472.

[0108] It should be noted that in the above embodiments, during rotation of build plate 224, 924, 1024, 1124, 1224 from tilted state S1 to mounted state S2, the build plate rotates about the straight edge of carrier plate 204 or separate support structure 1222, but because abutment(s) (e.g., pins 230, 232) extend in the Z direction and the build plate continuously contacts the abutment (due to, for example, a slight force applied by a user), the build plate will also move slightly forward, i.e., in the reverse Y direction. This mechanism will be referred to as Fig.15A and Fig. 15B Let's explain in further detail.

[0109] Fig.15AA side view of a portion of one embodiment is schematically shown, wherein the build plate is in a first state S1. The build plate can be positioned by a user in this state, where the user places the build plate on a straight edge of a support structure (in this case, top edge 1522 of the back side of carrier plate 1504). In state S1, the build plate forms an angle α with the top surface of carrier plate 1504.

[0110] exist Fig.15A , the distance d1 between the abutment 1530 and the rear top edge 1522 of the carrier plate 1504 is indicated. In state S1, the length of the build plate 1524 extending beyond the rear side of the carrier plate is equal to L1 = d1 / sin(α). In the final state S2, see Fig. 15B , the length L2 of build plate 1524 beyond the rear side of the carrier plate is equal to d1. By rotating the build plate from S1 to S2, the build plate will also move in the direction opposite to the Y direction in addition to the rotation because L2 is less than L1. This slight lateral movement does not affect the alignment because the rear end of build plate 1504 will always remain aligned with the Y alignment structure (i.e., abutment 1530) due to the construction.

[0111] Thus, once the build plate has been placed in the mounted state S2, no final correction of its position is required. This is particularly advantageous in systems where the build plate comprises metal and is attracted to the carrier plate by means of magnets, and also in embodiments where there is high friction between the build plate and the carrier plate.

[0112] The present invention has been described above with reference to several exemplary embodiments as shown in the accompanying drawings. Modifications and alternative implementations of some parts or elements are possible and are included in the scope of protection as defined in the appended claims. It should be noted that the embodiments mentioned above illustrate rather than limit the present invention, and that a person skilled in the art will be able to design many alternative embodiments. It should also be noted that the present invention can be implemented in other additive manufacturing devices, such as a selective laser sintering system or any other additive manufacturing system using a build plate that needs to be aligned on a carrier. In the claims, any reference numerals placed between brackets should not be interpreted as limiting the claims. The use of the verb include and its conjugations does not exclude the presence of elements or steps other than those stated in the claim. The article 'a' or 'an' in front of an element does not exclude the presence of a plurality of such elements. The mere fact that specific measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used advantageously.

Claims

1. A printing bed assembly (200) for an additive manufacturing system (100), the printing bed assembly (200) include: Stand (202); A carrier plate (204) arranged on the stage (202), the carrier plate (204) comprising an upper surface (206) extending in an X direction and in a Y direction perpendicular to the X direction; a support structure (220, 1220, 1320, 1420) disposed on the stage (202) and comprising a straight edge (222, 1222) extending in the X direction; a build plate (224, 724) to be placed on the carrier plate (204); and At least one abutment (230, 232) is arranged on the stage (202) and spaced apart from the straight edge of the support structure (220, 1220, 1320, 1420), and the at least one abutment (230, 232) is arranged to limit the movement of the build plate (224, 724) relative to the carrier plate (204) in the Y direction when the build plate is placed on the straight edge of the support structure (220, 1220, 1320, 1420) at an angle (A1) relative to the upper surface (206) of the carrier plate (204).

2. The print bed assembly of claim 1 , further comprising at least one X-alignment structure arranged to align the build plate relative to the carrier plate (204) in the X-direction.

3. The print bed assembly (200) according to claim 2, in, The at least one X-alignment structure (958, 960, 1258, 1260) includes one or more pins (958, 960, 1258, 1260) extending upward from the gantry (202) to a level higher than the level of the upper surface (206) of the carrier plate (204).

4. The print bed assembly (200) according to claim 2, in, The at least one X-alignment structure (1060, 1160) includes one or more contours that extend upward from the stage (202) to a level higher than the level of the upper surface (206) of the carrier plate (204).

5. The print bed assembly (200) according to claims 1 to 4, in, The at least one abutment (1030, 1032) includes one or more contours that extend upwardly from the stand (202) to a level higher than the level of the upper surface (206) of the carrier plate (204).

6. The print bed assembly (200) according to claims 1 to 4, in, The at least one abutment (230, 232) includes one or more pins (230, 232) extending upward from the stand (202) to a level (LV1) higher than a level (LV2) of an upper surface (206) of the carrier plate (204).

7. The print bed assembly (200) according to claim 6, in, The build plate (224, 724) includes one or more cutouts (246, 248) at a rear side thereof to receive the one or more pins (230, 232, 630, 632, 830, 832).

8. The print bed assembly (200) according to claim 7, in, At least one of the one or more cutouts (246) has a V-shape and at least another cutout (248) has a U-shape.

9. A print bed assembly (200) according to any one of claims 6 to 8, in, Each of the one or more pins (630, 632) includes a body portion (534) and a head portion (540), and wherein the head portion (540) of the pin (630, 632) is configured to lock with the build plate (224) when the build plate (224) is disposed on the carrier plate (204).

10. A print bed assembly (200) according to any one of the preceding claims, in, The support structure (1220, 1320, 1420) is separate from the carrier plate (204).

11. The print bed assembly (200) according to any one of claims 1 to 9, in, The support structure (220) is an integral part of the carrier plate (204).

12. A print bed assembly (200) according to any one of the preceding claims, in, The build plate (224, 724, 924, 1024, 1124, 1224, 1324, 1424) includes a flexible metal plate, and the carrier plate (204) includes one or more magnets (214).

13. A print bed assembly (200) according to any one of the preceding claims, in, The build plate comprises two extensions at a rear side of the build plate, and wherein the carrier plate (204) comprises two ramps for guiding the extensions during placement of the build plate onto the carrier plate.

14. An additive manufacturing system (100) comprising a print bed assembly (200) according to any one of the preceding claims.

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