Device for creating a three-dimensional object

Abstract

Device (10, 200) for producing a three-dimensional object, wherein the device (10, 200) comprises: a housing (12, 202) with a surface (104) defining a build container (16, 212) for receiving build modules (214) of different sizes or for receiving multiple build modules (214), wherein the build modules (214) each comprise a build chamber (228) for receiving a layer of build material from a build material distributor (242); and a central distributor (18, 268) for selectively releasing a coalescing agent onto parts of the layer of building material to be received by the building material distributor (242), so that when energy is applied to the layer, the parts of the layer coalesce and solidify to form a layer of a three-dimensional object; wherein the device (10, 200) allows the removal of a building module (214) from the building container (16, 212), while the device (10, 200) continues with the creation of another three-dimensional object in a building module (214), wherein the construction module (214) comprises a housing (216) wherein wheels (218) are attached to an underside of the housing (216) so that the construction module (214) can be rolled as a transport cart.

Description

BACKGROUND

[0001] Additive manufacturing systems that create three-dimensional objects layer by layer have previously been offered as a potentially practical way to produce three-dimensional objects in small quantities.

[0002] The quality of objects produced with such systems can vary greatly depending on the type of additive manufacturing technology used. In general, objects of lower quality and stability can be produced with low-cost systems, while objects of high quality and stability can be produced with more expensive systems.

[0003] DE 10 2009 056 696 A1 describes a system for the layer-by-layer construction of a molded body, wherein the system is equipped with a build box. US 2006 / 0290032 A1 describes a manufacturing process for a three-dimensional model. EP 1 704 989 A2 describes a laser sintering system with a removable build box. DE 10 2009 036 153 A1 describes a laser sintering and laser melting device with a build chamber into which an interchangeable container can be inserted. US 2002 / 0079601 A1 describes a 3D printer with print heads for printing binder and ink onto a build material bed in a build chamber. EP 1 563 928 A2 describes a device for the layer-by-layer construction of models. DE 10 2012 009 071 A1 describes a device for producing three-dimensional objects with an adjustment device. SHORT DESCRIPTION

[0004] Some examples are described with reference to the following figures: Fig. 1a is a simplified schematic drawing of an apparatus for generating a three-dimensional object according to some examples. Fig. Figure 1b is a simplified schematic drawing of an apparatus for generating a three-dimensional object according to some examples. Fig. 2a is a simplified perspective view of an additive manufacturing system according to some examples; Fig. 2b is a simplified perspective view of a removable build module for an additive manufacturing system according to some examples; Fig. 2c is a simplified perspective view of a removable build module for an additive manufacturing system according to some examples; Fig. 2d is a simplified perspective view of a construction structure of a building module according to some examples; Fig. 2e is a simplified side view of a construction structure of a building module according to some examples; Fig. 2f is a simplified perspective view of an additive manufacturing system incorporating removable build modules according to some examples; Fig. 2g is a simplified perspective view of an additive manufacturing system incorporating a removable build module according to some examples; Fig. 2h is a simplified perspective view of a removable build module for an additive manufacturing system according to some examples; Fig. 3 is a simplified side view of a construction structure of a building module according to some examples; Fig. 4 is a flowchart illustrating a method for a three-dimensional object according to some examples; and Fig. 5a-d show a series of cross-sectional side views of layers of building material corresponding to some examples. - DETAILED DESCRIPTION

[0005] The following terms, when used in the specification or claims, shall have the meanings set forth below. The singular forms "a," "an," and "the" mean "one or more." The terms "including" and "comprising" are intended to have the same inclusive meaning as the term "comprising."

[0006] Using an additive manufacturing system, a three-dimensional object can be created by solidifying portions of one or more successive layers of build material. The build material can be in powder form, and the properties of created objects depend on the type of build material and the type of solidification mechanism used. In some examples, solidification can be achieved using a liquid binder to chemically solidify the build material. In other examples, solidification can be achieved by temporarily applying energy to the build material. This can include, for example, the use of a coalescing agent, which is a material that, upon application of an appropriate amount of energy to a combination of build material and coalescing agent, can cause the build material to coalesce and solidify. In other examples, other solidification methods can be used.

[0007] However, some additive manufacturing systems may be designed in such a way that they do not offer sufficient flexibility and speed. For example, it may be difficult to maintain print continuity when the build material needs to be refilled or the system needs to be cleaned. Furthermore, there may be time delays between print jobs. Furthermore, in some examples, these systems may be designed to require a high degree of user interaction, such as handling build material and cleaning.

[0008] Accordingly, the present disclosure provides an additive manufacturing system that can accommodate build modules in a removable manner. The modular design can, for example, provide versatility by enabling the insertion of different types of build modules, such as modules of different sizes and / or a plurality of build modules simultaneously. The modular design can also provide high productivity by enabling faster use and fewer interruptions in the ongoing use of the system, for example, by enabling the execution of consecutive print jobs with few or no time delays between them. The build modules can be provided with housings that may contain a build chamber, build material chamber, and / or a motor for moving the chambers. This design can enable faster cleaning of a build module when it is removed.The building modules can also be easily inserted into and removed from the additive manufacturing system.

[0009] Fig. 1a is a simplified schematic diagram of an apparatus 10 for creating a three-dimensional object according to some examples. The apparatus 10 may include a housing 12 having a surface 14 defining a build receptacle 16 for receiving build modules of different sizes or for receiving a plurality of build modules. By "different sizes" it is meant that the build receptacle 16 is capable of receiving at least one build module at a time, whether that build module has a first size or a second size. By "receiving a plurality of build modules" it is meant that the build receptacle 16 is capable of receiving two or more build modules at the same time. Accordingly, the build receptacle 16 is not limited to receiving a build module of a fixed size. The build modules may each include a build chamber for receiving a layer of build material from a build material dispenser.The apparatus 10 may include an agent dispenser 18 for selectively dispensing a coalescing agent onto portions of the layer of build material to be received by the build material dispenser, such that when energy is applied to the layer, the portions of the layer coalesce and solidify to form a sheet of a three-dimensional object.

[0010] Fig. 1b is a simplified schematic diagram of an apparatus 100 for creating a three-dimensional object according to some examples. The apparatus 100 may include a housing 102 having a surface 104 defining a build volume 106 for receiving a build module of a variety of sizes or for receiving a plurality of build modules. The build modules may each include a build chamber for receiving a layer of build material from a build material distributor. The apparatus 100 may include a center distributor receptacle 108 removably including a center distributor for selectively dispensing a coalescing agent onto portions of the layer of build material to be received by the build material distributor, such that when energy is applied to the layer, the portions of the layer coalesce and solidify to form a sheet of a three-dimensional object.

[0011] Fig. Figure 2a is a simplified perspective view of an additive manufacturing system 200 according to some examples. The additive manufacturing system 200 may include a housing 202. The housing 202 may include various components, such as a center manifold and other components, as explained in more detail below.

[0012] The housing 202 may include side housing portions 204, a central housing portion 206, and a rear housing portion 208. The surfaces of these housing elements may define the build containment container 212, which includes a containment volume. Fig. 2a shows the receiving volume 212 in cuboid shape, however, in other examples, the receiving volume 212 may have other shapes depending on the configuration and shape of the side housing parts 204, a middle housing part 206 and a rear housing part 208. As in Fig. As shown in Figure 2a, the central housing portion 206 and the receiving volume 212 may extend a sufficient length along the y-axis direction so that the system 200 may be considered a wide-format system. In other examples, the central housing portion 206 and the receiving volume 212 may have shorter or longer lengths along the y-axis direction.

[0013] The additive manufacturing system 200 may include a system controller 256, which may include a processor 258 for executing instructions, for example, as described in the methods of this document. The processor 258 may be, for example, a microprocessor, a microcontroller, a programmable gate array, an application-specific integrated circuit (ASIC), a computer processor, or the like. The processor 258 may, for example, include multiple cores on one chip, multiple cores on multiple chips, multiple cores on multiple devices, or combinations thereof. In some examples, the processor 258 may include at least one integrated circuit (IC), other control logic, other electronic circuitry, or combinations thereof.

[0014] Controller 256 may support direct user interaction. For example, system 200 may include user input devices coupled to processor 258, such as one or more of a keyboard, touchpad, buttons, keypad, dials, mouse, trackball, card reader, or other input devices. Furthermore, system 200 may include output devices coupled to processor 212, such as one or more of a liquid crystal display (LCD), printer, video monitor, touchscreen display, light-emitting diode (LED), or other output devices. The output devices may respond to commands to display textual information or graphical data.

[0015] The processor 258 may be connected to a computer-readable storage medium 260 via a communications bus. The computer-readable storage medium 260 may comprise a single medium or multiple media. For example, the computer-readable storage medium 260 may comprise either memory of the ASIC, separate memory in the controller 256, or both. The computer-readable storage medium 260 may be any electronic, magnetic, optical, or other physical storage device. For example, the computer-readable storage medium 260 may be, for example, random access memory (RAM), static memory, read-only memory, electrically erasable programmable read-only memory (EEPROM), a hard disk, an optical drive, a storage drive, a CD, a DVD, and the like. The computer-readable storage medium 260 may be non-volatile.The computer-readable storage medium 260 may store, encode, or execute computer-executable instructions 262 that, when executed by the processor 258, may cause the processor 258 to perform one or more of the methods or operations disclosed herein according to various examples.

[0016] Fig. 2b-c are simplified perspective views of a removable build module 214 for an additive manufacturing system 200 according to some examples. The build module 214 may include a housing 216. Wheels 218 may be attached to a bottom of the housing 216 so that the build module 214 can be rolled as a dolly. Alternatively, fixed legs may be provided instead of wheels. However, in some examples, no wheels 218 or legs may be attached. A cover 222 may be removably connected to the housing 216 and thus be part of the top of the build module 214. When the cover 222 is removed, as in Fig. 2b, a structural structure 224, which may be contained in the housing 216, may be exposed. In Fig. Figure 2c shows the cover installed. Housing 216 and cover 222 can prevent build material from escaping from the build module 214.

[0017] As in Fig. As shown in Figure 2c, the structural assembly 224 may be removable from the housing 216 as a drawer by a user using a handle 220 attached to a side surface of the structural assembly 224. Additional handles may be provided on the surface of the structural assembly 224. In other examples, an automatic and / or electronic mechanism may be used to automatically open the drawer, for example, when the user provides input such as pressing a button on the housing 216 or the structural assembly 224.

[0018] Fig. 2d-e depict a simplified perspective view and a simplified side view of a build structure 224 of a build module 214 according to some examples. As depicted, the build structure 224 has been completely removed from the housing 216. The build structure 224 may include a build material chamber 226 and a build chamber 228.

[0019] A support member 230 may be provided in the build material chamber 224. A piston 232 may be attached to a bottom of the support member 230. A motor 234 may drive the piston 232 to effect mobility of the support member 230 along the z-axis. Similarly, a support member 236 may be provided in the build chamber 228. A piston 238 may be attached to a bottom of the support member 236. A motor 240 may drive the piston 238 to effect mobility of the support member 236 along the z-axis. In one example, the support members 230 and 236 may have dimensions ranging from approximately 10 cm x 10 cm to 100 cm x 100 cm. In other examples, the support members 230 and 236 may have larger or smaller dimensions.

[0020] Fig. 2e shows building material 246 stored on top of the support member 230 in the building material chamber 226. Fig. 2e also shows a previously applied layer 248 of build material on top of the support member 238 in the build material chamber 228. The previously applied build material 248 includes a portion 250 that has been processed and solidified into a part of a three-dimensional object by the additive manufacturing system 200.

[0021] In some examples, the build material may be a powder material. The term powder material, as used in this document, is intended to include dry and wet powder materials, solids, and granules. In some examples, the build material may comprise a mixture of air and solid polymer particles, for example, in a ratio of approximately 40% air and approximately 60% solid polymer particles. One suitable material may be Nylon 12, which may be purchased, for example, from Sigma-Aldrich Co. LLC. Another suitable Nylon 12 material may be PA 2200, which may be purchased from Electro Optical Systems EOS GmbH. Further examples of suitable build materials may include, for example, powdered materials made of metals, composites, ceramics, glass, resins, polymers, and the like.However, it should be understood that the examples described in this document are not limited to powder materials or to any of the aforementioned materials. In other examples, the construction material may be a paste or gel. According to one example, a suitable construction material may be a powdered semi-crystalline thermoplastic material.

[0022] The build structure 224 may include a build material distributor 242, such as a wiper blade or roller. The build material distributor 242 may be driven by a motor 244 to deliver, e.g., dispense and / or apply, successive layers of build material from the support member 230 in the build material chamber 226 to the support member 236 in the build material chamber 228. However, in other examples, the build material distributor 242 may instead be a component of the system 200 and mounted on or within the housing 202.

[0023] With further reference to Fig. 2a, a fastening element 252 may be mounted on the housing 22 at the bottom of the central housing part 206. Alternatively or additionally, fastening elements may be mounted on the side housing parts 204 and / or the rear housing 208. In Fig. In Figure 2a, the fastening element 252 is shown extending longitudinally along the length of the central housing portion 206; however, in other examples, the fastening elements 252 may have other configurations. In some examples, multiple separate fastening elements 252 may be provided at various points along the length of the bottom surface of the central housing portion 206.

[0024] With further reference to Fig. 2b, a fastener 254 may be mounted on the top of the housing 216. Alternatively or additionally, fasteners may be mounted on any other surface of the housing 216, including each of the four side surfaces. In Fig. In Figure 2b, the fastener 254 is shown extending longitudinally along the length of the housing 216; however, in other examples, the fasteners 254 may have other configurations. In some examples, multiple separate fasteners 254 may be provided at various points along the length of the top surface of the housing 216.

[0025] Together, the fasteners 252 and 254 may be coupled such that the additive manufacturing system 200 may be detachably coupled to and removably receive the build module 214 within the receiving volume 212. As illustrated, the build module 214 may be received laterally or generally laterally, e.g., horizontally or generally horizontally, within the receiving volume 212. The fasteners 252 and 254 may be magnetic fasteners, mechanical fasteners, and / or other types of fasteners.

[0026] If the fasteners 252 and 254 are magnetic fasteners, each of them may be magnetic, meaning that each of them may be made of a suitable material such that, in the presence of a magnetic field, it is subjected to a force and / or generates a magnetic field itself. Thus, if the fasteners 252 and 254 are in sufficient proximity to each other, they may be attracted to each other to lock the build module 214 in the additive manufacturing system 200. For example, the fasteners 252 and 254 may be permanent magnets such as ferromagnets or anti-anti-ferromagnets, ferrimagnets, paramagnets, diamagnets, or electromagnets.

[0027] If the fasteners 252 and 254 are mechanical fasteners, one of the fasteners 252 and 254 may be a locking member and the other a receiving member. For example, the locking member may be inserted into or connected to the receiving member to lock the build module 214 in the additive manufacturing system 200.

[0028] When the build module 214 is inserted into the receiving volume 212 of the system 200, the cover 222 is intended to be removed so that the components in the system, such as the center manifolds, power sources, heaters, and sensors, can interact with the build chamber 228 and any build material therein, as explained below.

[0029] Fig. 2f-g are simplified perspective views of an additive manufacturing system that has incorporated removable build modules according to some examples. In general, build modules may have any length along the x-axis direction or the y-axis direction. For example, as shown, build modules 214a-d of different sizes may have any length along the x-axis direction. For example, in Fig. 2g, a single module 214d has a length along the y-axis direction that allows it to fill the entire receiving volume 212 when inserted into the system 200. In Fig. 2f, several building modules 214a-c with smaller lengths can be arranged in a row along the y-axis direction in order to fill the entire receiving volume 212. Thus, in Fig. 2f, the build chambers and support elements of the 214-ac build modules are arranged in a row. In addition, Fig. 2f shows construction modules of different lengths, for example, the construction modules 214a-c can have different lengths from each other.

[0030] Fig. Figure 2h is a simplified perspective view of the removable build module 214c for an additive manufacturing system according to some examples. The build module 214c is shown removed from the system 200 in Fig. 2f. As shown, because it is longer than the building module 214 from Fig. 2b-2e, the build module 214c may have a build material chamber 226c that is longer along the y-axis direction than the build material chamber 226 of the build module 214, and may have a build chamber 228c that is longer along the y-axis direction than the build material chamber 228. Although not shown, the build module 214d may have chambers that extend in the y-axis direction over the entire length of the build module 214d.

[0031] In addition, although not shown, the building modules and chambers may also differ in their width along the x-axis direction.

[0032] In some examples, other configurations of building modules and / or building structures may be used. Fig. Figure 3 is a simplified side view of a construction structure 324 of a construction module according to some examples. In addition to receiving the construction structure 224 in a removable manner, the housing 216 of the Fig. 2b-c also removably accommodate the build structure 324. When the build structure 324 is located in the housing 216, the cover 222 can be removed from the housing 216 to expose the build structure 324 and its build chamber 328.

[0033] The structural assembly 324 may be removable from the housing 216 as a drawer by a user using a handle attached to a side of the structural assembly 324. Additional handles may be provided on the surface of the structural assembly 324. In other examples, an automatic and / or electronic mechanism may be used to automatically open the drawer, for example, when the user provides input such as pressing a button on the housing 216 or the structural assembly 324.

[0034] In Fig. 3, the build structure 324 has been completely removed from the housing 216. The build structure 324 may include a build material chamber 326 and a build chamber 328. The build material chamber 326 may be located below the build material chamber 328. This may, for example, allow for a wide build material chamber 328 so that wide layers of build material can be dispensed into it.

[0035] A support member 330 may be provided in the build material chamber 326. Build material 246 is shown supported on top of the support member 330 in the build material chamber 326. The support member 330 may be angled so that build material 246 can slide downward under gravity. A support member 336 may be provided in the build chamber 328. A pre-applied layer 248 of build material is shown on top of the support member 338 in the build chamber 328. The pre-applied build material 248 includes the portion 250 that was processed and solidified into a part of a three-dimensional object by the additive manufacturing system 200. A piston 338 may be attached to a bottom surface of the support member 336. A motor 340 may drive the piston 338 to effect mobility of the support member 336 along the z-axis. In one example, the support elements 330 and 336 may have dimensions in the range of approximately 10 cm x 10 cm to 100 cm x 100 cm.In other examples, the support members 330 and 336 may have larger or smaller dimensions.

[0036] One or more build material distributors 332, 284, and 342 may be used to deliver, e.g., dispense and / or apply, successive layers of build material from the support member 330 in the build material chamber 326 to the support member 336 in the build material chamber 328. For example, the build material distributor 332, e.g., a rotatable ball, wheel, or roller, may be mounted in the build material chamber 326. A motor 234 may drive the build material distributor 332 to rotate to move the build material 246, as shown by the curved arrow. A build material distributor 384 mounted on the structure 324, e.g., a conveyor, may be driven by a motor 344 to subsequently move the build material 246 upward in the z-axis direction, as shown by the arrow.A build material distributor 342, such as a wiper blade or roller, attached to the build structure 324 may be driven by a motor 344 to move longitudinally in the y-axis direction to roll build material 242 into the support member 336 in the build material chamber 328. In some examples, the build material distributor 342 may instead be a component of the system 200 and mounted on or within the housing 202.

[0037] In some examples, the build module 214 may include a controller and a computer-readable medium with similar features as the controller 256 and the computer-readable medium 260 described above. In such examples, the computer-readable medium may store data and / or instructions specifying features of the build module 214, such as its size, the size of each of its chambers, the type of stored build material provided in its build material chamber, and the like. This data and / or instructions may be stored in such a way that the controller 256 can access them when the build module 214 is inserted into the system 200 to create a three-dimensional object. In some examples, e.g.Regarding the type of build material in the build module 214, an input device with similar features to the input device of the controller 256 discussed above on the build module may receive input from a user regarding the type of build material stored in the build module 214. In some examples, a sensor on the build module 214 may automatically detect the type of build material.

[0038] The additive manufacturing system 200 may include a coalescing agent dispenser 268 for selectively dispensing coalescing agent to successive layers of build material provided on one or more support members 236 in one or more build chambers 228. A coalescing agent is a material that, upon application of a suitable amount of energy to a combination of build material and coalescing agent, can cause the build material to coalesce and solidify. As a non-limiting example, a suitable coalescing agent may be an ink-like formulation comprising carbon black, for example, the ink formulation known commercially as CM997A, available from Hewlett-Packard Company. In one example, such an ink may additionally comprise an infrared light absorber. In one example, such an ink may additionally comprise a near-infrared light absorber.In one example, such an ink may additionally comprise a visible light absorber. Examples of inks comprising visible light enhancers are dye-based colored inks and pigment-based colored inks, for example, the inks commercially known under the names CE039A and CE042A, which can be purchased from Hewlett-Packard Company.

[0039] The controller 256 may control the selective delivery of coalescing agent to a layer of provided build material according to instructions including agent delivery control data 266 stored in the computer-readable medium 260.

[0040] The agent distributor 268 may be a printhead, such as a thermal printhead or a piezo inkjet printhead. The printhead may include arrays of nozzles. In one example, a printhead such as those commonly used in commercially available inkjet printers may be used. In other examples, the agents may be dispensed through spray nozzles instead of printheads. Other dispensing mechanisms may also be used.

[0041] The agent manifold 268 can be used to selectively dispense, e.g., apply, coalescing agents when in the form of suitable fluids, such as liquids. In some examples, the agent manifold 268 can be selected to dispense drops of an agent at a resolution between 300 and 1200 dots per inch (DPI), for example, 600 DPI. In other examples, the agent manifold 268 can be selected to be capable of dispensing drops of an agent at a higher or lower resolution. In some examples, the agent manifold 268 can include an array of nozzles through which the agent manifold 268 can selectively eject drops of a fluid. In some examples, each droplet may be on the order of approximately 10 picoliters (pi) per droplet, although in other examples, a center distributor 268 capable of delivering a larger or smaller droplet size may be used.In some examples, a center distributor 268 capable of dispensing variable droplet sizes may be used.

[0042] In some examples, the center manifold 268 may be a fixed part of the system 200. In some examples, the center manifold 268 may not be fixed but may be user-replaceable; in this case, it may be removably accommodated, e.g., insertable into a suitable center manifold receptacle, e.g., the interface module of the system 200.

[0043] In the example after Fig. 2a, the center manifold 268 has a length in the x-axis direction that allows it to extend across the entire width in the x-axis direction of the support member 236 or 336 of the build module 214 in a so-called "page-wide array" configuration. In one example, this may be achieved by appropriately arranging multiple printheads. In other examples, a single printhead may be used that has an array of nozzles with a length that allows them to extend across the width of the support member 236 or 336. In other examples, the center manifold 268 may have a shorter length that does not allow them to extend across the entire width of the support member 236 or 336.

[0044] The center distributor 268 may be mounted on a movable carriage so that it is movable in both directions across the entire length of the row of one or more support elements 236 or 336 along the illustrated y-axis, as indicated by arrows 270. This allows for the selective dispensing of coalescing agent across the entire width and length of the support elements 236 or 336 in a single pass.

[0045] It should be noted that the term “width” used here is used to mean, in general, the shortest dimension in the plane parallel to the x and y axes, which in Fig. 2a-e, while the term "length" as used herein is used to generally refer to the longest dimension in that plane. However, it should be understood that in other examples, the term "width" may be interchangeable with the term "length." For example, in other examples, the center manifold 268 may have a length that allows it to extend the entire length of the support members 236 or 336, while the movable carriage can move in either direction across the width of the support members 236 or 336.

[0046] In another example, the center manifold 268 does not have a length that allows it to extend the entire length of the support members 236 or 336, but is additionally movable in both directions across the width of the support members 236 or 336 in the illustrated x-axis. This configuration allows for the selective dispensing of coalescing agent across the entire width and length of the support 204 in multiple passes. However, other configurations, such as a "page-wide array" configuration, may enable the faster creation of three-dimensional objects.

[0047] The coalescing agent distributor 268 may include a supply of coalescing agent or may be connected to a separate supply of coalescing agent.

[0048] In some examples, additional coalescing agent distributors may be present, such as the agent distributor 274. In some examples, the distributors of system 200 may be located on the same carriage, either adjacent to one another or separated by a short distance. In other examples, two or more carriages may each contain one or more distributors. For example, each distributor may be located in its own separate carriage. Any additional distributors may have similar features as discussed above with respect to the coalescing agent distributor 268. However, in some examples, different agent distributors may dispense different coalescing agents, for example.

[0049] The system 200 may additionally include an energy source 272 attached to the housing 202. The energy source 272 may be operable to apply energy to the build material to cause portions of the build material to solidify, depending on where coalescing agent has been dispensed or penetrated. In some examples, the energy source 272 is an infrared (IR) radiation source, near-infrared radiation source, or halogen radiation source. In some examples, the energy source 272 may be a single energy source capable of uniformly applying energy to the build material applied to the support member 236 or 336. In some examples, the energy source 272 may comprise a grouping of energy sources.

[0050] In some examples, energy source 272 is configured to apply energy substantially uniformly to the entire surface of a layer of build material. In these examples, energy source 272 may be said to be a non-focused energy source. In these examples, energy may be applied to an entire layer simultaneously, which may increase the speed at which a three-dimensional object is created.

[0051] In other examples, the energy source 272 is configured to apply energy substantially evenly to a portion of the total surface of a layer of build material. For example, the energy source 272 may be configured to apply energy substantially to a strip of the total surface of a layer of build material. In these examples, the energy source may be moved or scanned across the layer of build material so that a substantially equal amount of energy is ultimately applied across the entire surface of a layer of build material.

[0052] In some examples, the energy source 272 may be mounted on a movable carriage.

[0053] In other examples, the energy source 272 may apply a variable amount of energy as it is moved across the layer of build material, for example, according to the agent delivery control data 208. For example, the controller 210 may control the energy source to apply energy only to portions of the build material to which coalescing agent has been applied.

[0054] In other examples, energy source 272 may be a focused energy source, such as a laser beam. In this example, the laser beam may be controlled to scan across all or part of a layer of build material. In these examples, the laser beam may be controlled to scan across a layer of build material according to agent delivery control data. For example, the laser beam may be controlled to apply energy to the portions of a layer to which coalescing agent is delivered.

[0055] In some examples, the system 200 may additionally include a heater or preheater for heat dissipation to maintain the build material applied to the support elements 236 within a predetermined temperature range. The heater may comprise a grouping of heating elements. The heating elements may each be any heating element, for example, a heat lamp such as an infrared lamp. The configuration may be optimized to ensure homogeneous heat distribution over the area over which the build material extends. Each heating element or group of heating elements may have an adjustable current or voltage supply to variably control the local energy density applied to the build material surface.

[0056] Fig. 4 is a flowchart illustrating a method 400 for creating a three-dimensional object according to some examples. The method may be computer-aided. In some examples, the illustrated sequences may be varied so that some steps occur concurrently, some steps may be added, and some steps may be omitted. In the description of Fig. 3 reference is made to Fig. 2a, Fig. 2nd, Fig. 3 and Fig. 5a-d. Fig. 5a-d show a series of cross-sectional side views of layers of building material corresponding to some examples.

[0057] At 402, the controller 210 may receive agent dispensing control data 208. The agent dispensing control data 208 may define, for each layer of the three-dimensional object to be created, the parts or locations on the build material to which coalescing agent, if any, is to be dispensed. The agent dispensing control data 208 may be derived by a suitable three-dimensional object processing system internal or external to the system 200. In some examples, the agent dispensing control data 208 may be generated based on object design data representing a three-dimensional model of an object to be created and / or from object design data representing properties of the object. The model may define the solid parts of the object and may be processed by the three-dimensional object processing system to generate layers of parallel planes of the model.Each layer can define a portion of a corresponding layer of build material to be solidified by the additive manufacturing system. The object property data can include properties of the object, such as density, surface roughness, strength, and the like.

[0058] At 404, a computer-readable medium on the build module 214 may determine and / or store build module data representing build module characteristics, such as the type of build material used, based, for example, on user input or detection by a sensor. Other features of the build module, such as the physical dimensions of the build module, may be stored in advance on the computer-readable medium, as explained above.

[0059] At 406, one or more build modules 214 may be picked up by the system 200. The controller 256 of the system 200 may access the computer-readable data of build modules 214 to determine the build module data.

[0060] At 408, a layer 276 of building material may be provided as in Fig. 5a. For example, the controller 210 may control the build distributor 242 to build the layer 276 on a previously completed layer 248, shown in Fig. 2e and Fig. 4a. The finished layer 248 may include a solidified portion 250. Even if a finished layer 248 in Fig. 5a-d for illustrative purposes, it should be understood that steps 408 to 412 may be applied from the beginning to generate the first layer 248.

[0061] In some examples, for example, when using the building structure 224, the layer 276 may be delivered as follows. With respect to Fig. 2e and Fig. 4a, the support element 230 can be positioned in the build material chamber 226 by the piston 232 in the z-axis direction in such a way that a portion of the stored build material 246 extends beyond the upper edge of the build structure 224.

[0062] The support element 236 in the build chamber 228 can be positioned by the piston 236 in the z-axis direction such that a predetermined gap is created above the previously applied layer 248 of build material. The build material dispenser 242 can then move longitudinally in the y-axis direction to roll the excess portion of the stored build material 246 into the predetermined gap to create a new layer 276 in the build chamber 228. The dispensing can be based on the data and / or instructions related to features of the build module stored in the computer-readable medium of the build module.

[0063] In some examples, for example, when using the building structure 324, the layer 276 may be delivered as follows. With respect to Fig. 3 and Fig. 4a, the support element 330 in the build material chamber 326 can be positioned by the piston 332 in the z-axis direction in such a way that a portion of the stored build material 246 extends beyond the upper edge of the build structure 324. The support element 336 in the build chamber 328 can be positioned by the piston 336 in the z-axis direction in such a way that a predetermined gap is created above the previously applied layer 248 of build material. Subsequently, the build material distributors 332, 284, and 342 can be used to dispense the layer 276. The stored build material 246 can be moved along the arrows in Fig. 3 and rolled into the predetermined gap to create the new layer 276 in the build chamber 228. The dispensing may be based on the data and / or commands stored in the computer-readable medium of the build module relating to features of the build module.

[0064] At 410, a coalescing agent 278 may be selectively delivered to one or more portions of the surface of the layer 276 of build material, as in Fig. 5b. The selective delivery of the coalescing agent 278 may occur in patterns onto portions of the layer 276, which the agent delivery control data 208 may define, to solidify and become part of the three-dimensional object to be created. "Selective delivery" means that coalescing agent may be delivered to selected portions of the surface layer of the build material in various patterns. The patterns may be defined by the agent delivery control data 208 and may be based on the data and / or instructions stored in the computer-readable medium of the build module related to features of the build module.

[0065] Fig. 5c shows coalescing agent 278 having substantially completely penetrated into layer 276 of build material, but in other examples, the degree of penetration may be less than 100%.

[0066] At 412, a predetermined amount of energy may be temporarily applied to the layer 276 of build material. In various examples, the applied energy may be infrared or near-infrared energy, microwave energy, ultraviolet (UV) light energy, halogen light, ultrasound, or the like. The temporary application of energy may cause portions of the build material onto which coalescing agent 278 has been delivered or penetrated to be heated above the melting point of the build material and to coalesce. Upon cooling, the coalesced portions solidify and form part of the three-dimensional object to be created. As explained above, such a portion 250 may have been created in a prior step. The heat absorbed during the application of energy may propagate to the previously solidified portion 250 and cause the portion 250 to be partially heated above its melting point.This effect contributes to the production of a part 280 having stronger interlayer bonding between adjacent layers of consolidated build material, as shown in . Fig. 5d.

[0067] After a layer of build material has been processed as described above, new layers of build material can be provided on top of the previously processed layers of build material. In this way, the previously processed layer of build material serves as a support for a subsequent layer of build material. The process of blocks 408 through 412 can then be repeated to create a three-dimensional object layer by layer.

[0068] Furthermore, at any time during blocks 408 through 412, additional build modules 214 may be included by the system 200, such as block 406. Thus, while the method 400 repeats blocks 408 through 412, a parallel instance of the method 400 may be executed such that the system 200 can execute multiple print jobs simultaneously with different three-dimensional objects on different build modules 214. In other examples, immediately after the first instance of the method 400 is completed and a three-dimensional object is created, the second instance of the method 400 may continue with blocks 408 through 412 such that the second three-dimensional object is created immediately after the first is completed, with little or no time delay in between.

[0069] Furthermore, in some examples, there may be little or no time delay even if build modules 214 need to be cleaned or refilled during the creation of three-dimensional objects. For example, if a build module 214 needs to be cleaned or refilled, the build module 214 may be removed from the system 200 while the system 200 continues creating other three-dimensional objects in other build modules 214. Furthermore, the construction of the build module 214, for example, its fully functional build system including the motors 234 and 240 in Fig. 2d-e or the engines 334, 340, 344 and 344 in Fig.3 enable quick and easy cleaning of the build module 214. For example, the housing 216 can help prevent build material from escaping to undesired locations within the build module 214. Furthermore, the build module 214 can be inserted into a cleaning device that automatically cleans the parts of the build module 214, for example, while the motors are running, allowing build material to be shaken out of the components of the build module 214. In some examples, manual cleaning steps can also be performed, for example, while the motors are running.

[0070] All features disclosed in this specification (including the appended claims, abstract, and drawings) and / or all steps of any method or process disclosed herein may be combined in any combination, except for combinations in which at least some of these features and / or steps are mutually exclusive.

[0071] In the foregoing description, numerous details are set forth to facilitate an understanding of the subject matter disclosed herein. However, examples may be practiced without some or all of these details. Other examples may include modifications and variations of the details set forth above. The appended claims are intended to cover such modifications and variations.

Claims

[1] Device (10, 200) for generating a three-dimensional object, the device (10, 200) comprising: a housing (12, 202) having a surface (104) defining a build receiving container (16, 212) for receiving build modules (214) of different sizes or for receiving multiple build modules (214), the build modules (214) each comprising a build chamber (228) for receiving a layer of build material from a build material distributor (242); and an agent distributor (18, 268) for selectively dispensing a coalescing agent onto portions of the layer of build material to be received by the build material distributor (242) such that, when energy is applied to the layer, the portions of the layer coalesce and solidify to form a sheet of a three-dimensional object; wherein the device (10, 200) allows the removal of a construction module (214) from the construction receiving container (16, 212) while the device (10, 200) continues to create another three-dimensional object in a construction module (214), wherein the construction module (214) comprises a housing (216), wherein wheels (218) are mounted on an underside of the housing (216) so that the construction module (214) can be rolled as a transport trolley. [2] The apparatus (10, 200) of claim 1, further comprising an energy source (272) for applying energy to the layer of build material to be received by the build material distributor (242) to cause coalescence and subsequent solidification of a portion of the layer of build material. [3] The apparatus (10, 200) of claim 1, further comprising the build material distributor (242) coupled to the housing (12, 202) to provide the layer of build material in the build chamber (228) and to provide successive layers of build material on a previously provided layer of build material. [4] The apparatus (10, 200) of claim 1, wherein the build module (214) includes the build material distributor (242) for providing the layer of build material in the build chamber (228) and providing successive layers of build material on a previously provided layer of build material. [5] The device (10, 200) of claim 1, wherein the housing (12, 202) comprises a first fastening element coupled to a second receiving element of the building module (214) to lock the building module (214) in the housing (12, 202). [6] The apparatus (10, 200) of claim 1, further comprising a controller (256) mounted on the housing (12, 202) for controlling the agent distributor (18, 268) to selectively deliver the coalescing agent to the build material based on build module data representing characteristics of the build module (214). [7] Device (10, 200) according to claim 1, wherein the construction receiving container (16, 212) is intended to receive construction modules (214) of different sizes. [8] Apparatus (10, 200) according to claim 1, wherein the construction receiving container (16, 212) is intended to receive a plurality of construction modules (214). [9] The device (10, 200) of claim 8, wherein each of the plurality of building modules (214) has a different size. [10] The apparatus (10, 200) of claim 1, wherein the construction receiving container (16, 212) is designed to receive the construction modules (214) of different sizes or the plurality of construction modules (214) generally laterally. [11] Device (10, 200) for generating a three-dimensional object, the device (10, 200) comprising: a housing (12, 202) having a surface (104) defining a build volume (106) for receiving various sizes of one or more build modules (214), the build modules (214) each comprising a build chamber (228) for receiving a layer of build material from a build material distributor (242); and a center distributor receptacle (108) removably receiving a center distributor (18, 268) for selectively dispensing a coalescing agent onto portions of the layer of build material to be received by the build material distributor (242) such that, when energy is applied to the layer, the portions of the layer coalesce and solidify to form a sheet of a three-dimensional object; wherein the device (10, 200) allows the removal of a construction module (214) from the construction receiving container (16, 212) while the device (10, 200) continues to create another three-dimensional object in a construction module (214), wherein the construction module (214) comprises a housing (216), wherein wheels (218) are mounted on an underside of the housing (216) so that the construction module (214) can be rolled as a transport trolley. [12] The apparatus (10, 200) of claim 11, further comprising the build material distributor (242) attached to the housing (12, 202) to provide the layer of build material in the build chamber (228) and to provide subsequent layers of build material on a previously provided layer of build material. [13] Device (10, 200) according to claim 11, wherein the construction receiving container (16, 212) is intended to receive construction modules (214) of different sizes. [14] Apparatus (10, 200) according to claim 11, wherein the construction receiving container (16, 212) is intended to receive a plurality of construction modules (214). [15] Device (10, 200) for generating a three-dimensional object, the device (10, 200) comprising: a housing (12, 202) having a construction receiving container (16, 212) for receiving construction modules (214) of different sizes or for receiving a plurality of construction modules (214), wherein the construction modules (214) each comprise a construction chamber (228) for receiving a layer of construction material from a construction material distributor (242); a medium distributor (18, 268) mounted on the housing (12, 202) for selectively delivering a coalescing agent to portions of the layer of building material to be received by the building material distributor (242); and an energy source (272) mounted on the housing (12, 202) for applying energy to the layer of building material to be received by the building material distributor (242) to cause the coalescing and subsequent solidification of the portions of the layer of building material onto which the coalescing agent has been delivered; wherein the device (10, 200) allows the removal of a construction module (214) from the construction receiving container (16, 212) while the device (10, 200) continues to create another three-dimensional object in a construction module (214), wherein the construction module (214) comprises a housing (216), wherein wheels (218) are mounted on an underside of the housing (216) so that the construction module (214) can be rolled as a transport trolley.

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