System and method for modifying data representing three-dimensional objects

Abstract

System (200) for creating a three-dimensional object, wherein the system (200) comprises the following: a processor (212) for: Receiving nozzle data relating to a nozzle (205) of a center distributor (202) used for center delivery, wherein the center distributor (202) extends in a side-width configuration with its length over the entire width of a support element (204); Modifying data (600a, 700a) representing a three-dimensional first object (602a, 702) and a three-dimensional second object (602b, 702) to ensure that the nozzle (205) associated with a forbidden area (606) is not used to create the two three-dimensional objects (602a, 602b); wherein the three-dimensional first object (602a, 702) is not located in the prohibited area (606) and the three-dimensional second object (602b, 702) is located in the prohibited area (606), wherein the processor (212) is configured to modify the data (600a) in order to revoke or displace the three-dimensional second object (602b, 702) which is located in the forbidden area (606), and not to displace the three-dimensional first object (602a, 702) which is not located in the forbidden area (606), so that the nozzle (205) is not used to create the three-dimensional second object (602b, 702); and Cause, in the case of displacement, the creation of the three-dimensional first object (602a, 702) and the three-dimensional second object (602b, 702) in accordance with the modified data (600b, 600c) representing the two three-dimensional objects (602a, 602b, 702), or, in the case of revocation, only the three-dimensional first object (602a, 702) in accordance with the modified data (600b) representing the three-dimensional first object (602a, 702).

Description

BACKGROUND

[0001] Additive manufacturing systems that create three-dimensional objects on a layer-by-layer basis have been proposed as a potentially convenient way to produce three-dimensional objects. The quality of objects produced with such systems can vary greatly depending on the type of additive manufacturing technology used.

[0002] The document EP 2 199 068 A2 deals with the printing of three-dimensional objects. SHORT DESCRIPTION

[0003] Some examples are described with reference to the following figures: Fig. 1a illustrates a system for creating a three-dimensional object according to some examples; Fig. 1b is a flowchart illustrating a method according to some examples; Fig. 1c is a block diagram illustrating a non-transitory computer-readable storage medium according to some examples; Fig. 2a is a simplified isometric illustration of an additive manufacturing system according to some examples; the Fig. 2b-c are simplified schematic views of center manifolds and support members mounted on movable supports according to some examples; Fig. 3 is a flowchart illustrating a method for creating a three-dimensional object according to some examples; the Fig. 4-7 respectively illustrate center manifolds and data representing a three-dimensional object modified based on data relating to nozzles; the Fig. 8a-d show a series of cross-sectional side views of layers of building material according to some examples; Fig. 9 is a flowchart illustrating a method for creating a three-dimensional object according to some examples; and the Fig. 10a-b respectively depict center manifolds and data representing a three-dimensional object modified based on data relating to nozzles. DETAILED DESCRIPTION

[0004] The following terminology is intended to mean the following when recited in the specification or claims. The singular forms "a," "an," and "the" mean "one or more." For example, the term "nozzle" in the claims and description means "one or more nozzles." The terms "including" and "having" are intended to have the same inclusive meaning as the term "comprising."

[0005] Some additive manufacturing systems create three-dimensional objects by solidifying portions of successive layers of build material, such as powdered or solid build material. The properties of created objects can depend on the type of build material and solidification mechanism used. In some examples, solidification can be achieved by using a liquid binder to chemically solidify build material. In other examples, solidification can be achieved by temporarily applying energy to the build material. This can involve, for example, the use of a coalescing agent, a material that, when an appropriate amount of energy is applied to a combination of build material and coalescing agent, can cause the build material to coalesce and solidify.In some examples, a multi-agent additive manufacturing system may be used, such as that described in PCT Application No. PCT / EP2014 / 050841. For example, in addition to selectively delivering coalescing agent to layers of build material, coalescing modifier agent may also be selectively delivered to layers of build material. A coalescing modifier agent may serve to modify the degree of coalescence of a portion of build material to which the coalescing modifier agent has been delivered or penetrated. In still other examples, other methods of consolidation may be used, for example, selective laser sintering (SLS), light polymerization, among others. The examples described herein may be used with any of the above additive manufacturing systems and suitable adaptations thereof.

[0006] In some examples, certain nozzles in agent distributors such as print heads may be defective, e.g., partially or completely clogged. Therefore, some agent may not be delivered to parts of the build material as intended, and those parts of the build material may not solidify as intended. Thus, created objects may not be faithful replicas of the three-dimensional object model used to create the object. In some examples, nozzles may become clogged due to problems during the printing process.

[0007] In some examples, a single nozzle may be used to print at each addressable location, while in other examples, there may be nozzle redundancy in the sense that multiple nozzles may be used to print at each addressable location. In both cases, for example, some nozzles of a center manifold may be overused relative to other nozzles of the center manifold. In some examples, overuse of a nozzle may cause the nozzle to fire drops of an undesirably larger size.

[0008] Accordingly, in some examples, the present disclosure provides for shifting the coordinates of an object in response to data related to the nozzles, such as data related to whether the nozzles are defective or data related to nozzle usage. Thus, for example, unclogged and / or less used nozzles may be used to create the object.

[0009] Fig. 1a is a block diagram illustrating a system 100 for creating a three-dimensional object according to some examples. The system 100 may include a processor 102 for receiving nozzle data relating to a nozzle of an agent dispenser to be used for agent dispensing. The processor 102 may be operable to modify data representing a three-dimensional object to cause the three-dimensional object to be translated so that the nozzle is not used to create the three-dimensional object. The processor 102 may cause the three-dimensional object to be created in accordance with the modified data representing the three-dimensional object.

[0010] Fig. 1b is a flowchart illustrating a method 110 according to some examples. At 112, nozzle data may be obtained from a processor. The nozzle data may relate to a nozzle of a compound manifold to be used for compound dispensing. At 114, data representing a three-dimensional object may be transformed by the processor to cause the three-dimensional object to be translated so that the nozzle is avoided during creation of the three-dimensional object. At 116, the three-dimensional object may be created in accordance with the modified data.

[0011] Fig. 1c is a block diagram illustrating a non-transitory computer-readable storage medium 120 according to some examples. The non-transitory computer-readable medium 120 may include executable instructions that, when executed by a processor, can cause the processor to receive nozzle data related to a nozzle of a center manifold. The nozzle data may represent malfunction or excessive usage related to other nozzles of the center manifold. The non-transitory computer-readable medium 120 may include executable instructions that, when executed by the processor, can cause the processor to modify, based on the nozzle data, data representing a three-dimensional object to be created to change a location of the three-dimensional object such that the nozzle is not used when the three-dimensional object is created.

[0012] Fig. 2a is a simplified isometric illustration of an additive manufacturing system 200 according to some examples. The system 200 may, as described below with respect to the flowchart of Fig. 3 described, to create a three-dimensional object.

[0013] In some examples, the build material may be a powder-based build material. The term powder-based materials as used herein is intended to include both dry and wet powder-based materials, particulate materials, and granular materials. In some examples, the build material may include a mixture of air and solid polymer particles, for example, at a ratio of approximately 40% air and approximately 60% solid polymer particles. One suitable material may be Nylon 12, available, for example, from Sigma-Aldrich Co. LLC. Another suitable Nylon 12 material may be PA 2200, available from Electro Optical Systems EOS GmbH.Other examples of suitable construction materials may include, for example, powdered metal materials, powdered composite materials, powdered ceramic materials, powdered glass materials, powdered resin materials, powdered polymer materials, and the like, and combinations thereof. However, it should be noted that the examples described herein are not limited to powder-based materials or to the materials listed above. In other examples, the construction material may be in the form of a paste, a liquid, or a gel. According to one example, a suitable construction material may be a powdered semi-crystalline thermoplastic material.

[0014] The additive manufacturing system 200 may include a system controller 210. All of the operations and methods disclosed herein may be implemented and controlled in the additive manufacturing system 200 and / or the controller 210.

[0015] The controller 210 may include a processor 212 for executing instructions that can implement the methods described herein. The processor 212 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 212 may include, for example, multiple cores on a single chip, multiple cores across multiple chips, multiple cores across multiple devices, or combinations thereof. In some examples, the processor 212 may include at least one integrated circuit (IC), other control logic, other electronic circuitry, or combinations thereof.

[0016] The controller 210 may support direct user interaction. For example, the additive manufacturing system 200 may include user input devices 220 coupled to the processor 212, such as a keyboard, a touchpad, buttons, a keypad, knobs, a mouse, a trackball, a card reader, or other input devices. The additive manufacturing system 200 may also include output devices 222 coupled to the processor 212, such as a liquid crystal display (LCD), a printer, a video monitor, a touchscreen display, a light-emitting diode (LED), or other output devices. The output devices 222 may respond to instructions to display textual information or graphical data.

[0017] The processor 212 may be in communication with a computer-readable storage medium 216 via a communication bus 214. The computer-readable storage medium 216 may include a single medium or multiple media. For example, the computer-readable storage medium 216 may include one or both of a memory of the ASIC and separate memory in the controller 210. The computer-readable storage medium 216 may be an electronic, magnetic, optical, or other physical storage device. For example, the computer-readable storage medium 216 may be 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 216 may be non-volatile.The computer-readable storage medium 216 may store, encode, or carry computer-executable instructions 218 that, when executed by the processor 212, may cause the processor 212 to perform one of the methods or acts disclosed herein according to various examples.

[0018] The system 200 may include a coalescing agent dispenser 202 for selectively delivering coalescing agent to successive layers of build material provided on a support member 204. By way of non-limiting example, a suitable coalescing agent may be an ink-like formulation comprising carbon black, such as the ink formulation commercially known as CM997A available from the 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. In one example, such an ink may additionally comprise a UV light absorber.Examples of inks that include visible light absorbers are dye-based colored inks and pigment-based colored inks, such as inks commercially known as CM993A and CE042A, available from Hewlett-Packard Company. In some examples, the agent distributor 202 can be used to selectively dispense, e.g., deposit, coalescing agents when in the form of suitable fluids such as a liquid. The controller 210 controls the selective dispensing of coalescing agents to a layer of provided build material in accordance with agent dispensing control data of the instructions 218. The coalescing agent distributor 202 can include a supply of coalescing agents or can be connectable to a separate supply of coalescing agents.

[0019] Fig. 2b is a simplified schematic view of a center manifold with multiple print heads 202a-b mounted on a movable support 203a and the support member 204 according to some examples, and Fig. Figure 2c is a simplified schematic view of a plurality of center manifolds 202c-d mounted on a movable support 203b and the support member 204 according to some examples. Any of these configurations may be used in the system 200. The center manifolds 202a-d may each have similar features to the previously described center manifold 202.

[0020] In Fig. 2b, each of the center manifolds 202a-b has a length that allows it to span the entire width of the support member 204 in a so-called page-wide array configuration. In some examples, each center manifold 202a-b may be a single printhead with an array of nozzles having a length that allows it to span the width of the support member 204 along the illustrated x-axis, as in Fig. 2b. In other examples, a suitable arrangement of multiple printheads may be placed linearly to achieve a page-wide array configuration. Thus, using the carrier 203a, the agent manifolds 202a-b may be bidirectionally movable across the length of the support member 204 along the illustrated y-axis. This enables the selective dispensing of coalescing agent across the entire width and length of the support member 204 in a single pass.

[0021] In Fig. 2c, each of the center manifolds 202c-d may have a shorter length that does not allow it to encompass the entire width of the support member 204. In this example, each of the center manifolds 202c-d may be movable laterally across the entire width of the support member 204 along the illustrated x-axis. Thus, using the carrier 203b, the center manifolds 202c-d may be movable bidirectionally across the length of the support member 204 along the illustrated y-axis. This enables the selective dispensing of coalescing agent across the entire width and length of the support member 204 in multiple passes.

[0022] As in the Fig. As shown in Figures 2b-c, each of the agent manifolds 202 and 202a-d may be printheads, such as a thermal inkjet printhead or a piezo inkjet printhead. Each printhead may have rows of nozzles 205. In one example, printheads 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 employed.

[0023] A respective nozzle sensor 207 may be coupled to each nozzle 205. The nozzle sensor 207 may, for example, be a drop detector. Each sensor 207 may detect whether its respective nozzle 205 is malfunctioning, e.g., partially or completely clogged. In some examples, the drop detector may include a light-emitting diode (LED) and a photoreceptor, such as a photodiode or a charge-coupled device (CCD), on separate sides of the fluid path in the nozzle. The LED may generate light, and the photoreceptor may detect the light from the LED, creating a light path that is substantially perpendicular to the fluid path. An interruption in the light path may occur when a drop of fluid passes through the light path. Thus, it can be concluded that if reduced interruptions in the light path are detected, then the nozzle 205 is partially clogged, and if no interruptions in the light path are detected, then the nozzle 205 is completely clogged.In other examples, the drop detector may include an electrostatic sensing mechanism in which a passing drop of fluid can cause an electrostatic differential on a plate. In other examples, an agent manifold with the nozzles 205 may perform indexing movements along the x-axis to allow each nozzle to attempt to dispense agent onto build material at different locations along the x-axis. An optical sensor may then be moved along the carrier to detect, for each nozzle 205, whether drops of agent have not been successfully dispensed, indicating that the respective nozzle 205 is clogged. In other examples, other types of sensors 207 may be used. In some examples, each nozzle sensor 207 may detect how many drops have been ejected from its respective nozzle 205. In some examples, other types of sensors may be used.Data representing any of the above measurements may be provided to controller 210.

[0024] In some examples, the controller 210 may determine the usage of the nozzles 205 based on the measurements, for example, the total amount of drops dispensed by the nozzle 205 in its lifetime, the frequency of use of the nozzle 205, and / or whether the nozzle 205 has not been used for more than a predetermined amount of time, etc. In other examples, the controller 210 may instead generate the data based on instructions 218, such as the agent dispense control data that may define drops of agent to be dispensed from each nozzle 205.

[0025] In some examples, the center manifolds may be fixed rather than movable, and the support member 204 may move relative to the center manifolds.

[0026] It should be noted that the term “width” as used herein is used to mean generally the shortest dimension in the plane parallel to the Fig. 2a-c, while the term "length" as used herein is used to generally refer to the longest dimension in that plane. It should be noted, however, that the term "width" may be interchangeable with the term "length" in other examples.

[0027] The system 200 may further include a build material dispenser 224 for providing, e.g., dispensing or forming, successive layers of build material onto the support member 204. Suitable build material dispensers 224 may include, for example, a wiper blade and a roller. Build material may be supplied to the build material dispenser 224 from a hopper or build material storage. In the example shown, the build material dispenser 224 moves along the length (y-axis) of the support member 204 to deposit a layer of build material. As described above, a layer of build material is deposited onto the support member 204, whereas subsequent layers of build material are deposited onto a previously deposited layer of build material. The build material dispenser 224 may be a fixed part of the system 200 or may not be a fixed part of the system 200, but instead, for example, may be part of a removable module.In some examples, the build material distributor 224 may be attached to the support 203a or 203b.

[0028] In some examples, build material dispenser 224 may provide a layer of build material with a thickness ranging from about 50 to about 300 micrometers, or about 90 to about 110 micrometers, or about 250 micrometers, although in other examples, thinner or thicker layers of build material may be provided. The thickness may be controlled by controller 210, for example, based on instructions 218.

[0029] In some examples, there may be a number of additional resource distributors and building material distributors relative to those shown in the Fig. 2a-c. In some examples, the distributors of the system 200 may be located as shown in the Fig. 2b-c, are located on the same carrier, either adjacent to each other or separated by a short distance. In other examples, two or more carriers may each contain distributors. For example, each distributor may be located in its own separate carrier. Additional distributors may have similar features to those discussed earlier with respect to the coalescing agent distributor 202. However, in some examples, different agent distributors may dispense, for example, different coalescing agents and / or coalescing modifier agents.

[0030] In the example shown, the support member 204 is movable in the z-axis so that, as new layers of build material are unloaded, a predetermined gap is maintained between the surface of the most recently unloaded layer of build material and the bottom surface of the center distributor 202. In other examples, however, it is possible for the support member 204 not to be movable in the z-axis and for the center distributor 202 to be movable in the z-axis.

[0031] The system 200 may also include an energy source 226 for applying energy to the build material to cause solidification of portions of the build material according to the location where coalescing agent has been delivered or penetrated. In some examples, the energy source 226 is an infrared (IR) radiation source, a near-infrared radiation source, a halogen radiation source, or a light-emitting diode. In some examples, the energy source 226 may be a single energy source capable of uniformly applying energy to the build material deposited on the support 204. In some examples, the energy source 226 may include a plurality of energy sources.

[0032] In some examples, energy source 226 is configured to apply energy in a substantially uniform manner to the entire area of ​​a layer of build material. In these examples, an entire layer may have energy applied to it simultaneously, which may help increase the speed at which a three-dimensional object can be created.

[0033] In other examples, energy source 226 is configured to apply energy in a substantially uniform manner to a portion of the entire surface area of ​​a layer of build material. For example, energy source 226 may be configured to apply energy to a strip of the entire surface area 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 area of ​​a layer of build material.

[0034] In some examples, the energy source 226 may be mounted on the movable support 203a or 203b.

[0035] In other examples, the energy source 226 may apply a variable amount of energy while moving across the layer of build material, for example, in accordance with instructions 208. For example, the controller 210 may control the energy source to apply energy to portions of build material where coalescing agent has been applied, but not to portions where no coalescing agent has been applied.

[0036] In further examples, energy source 226 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 a portion of the build material layer. In these examples, the laser beam may be controlled to scan across a layer of build material in accordance with agent delivery control data. For example, the laser beam may be controlled to apply energy to those portions of a layer to which coalescing agent is delivered.

[0037] The combination of the delivered energy, the building material and the coalescing agent can be selected so that (i) parts of the building material to which no coalescing agent has been delivered do not coalesce when energy is temporarily applied thereto; (ii) parts of the building material to which coalescing agent has been delivered or penetrated by it coalesce when energy is temporarily applied thereto.

[0038] In some examples, system 200 may additionally include a preheater to maintain build material deposited on support 204 within a predetermined temperature range. The use of a preheater may help reduce the amount of energy required by energy source 226 to cause coalescence and subsequent solidification of the build material to which coalescing agent has been delivered or penetrated.

[0039] The controller 210 may receive or create agent delivery control data 208 that defines, for each slice of the three-dimensional object to be built, the parts or locations on the build material, if any, to which the agent is to be delivered.

[0040] In some cases, the resource dispensing control data 208 may be created based on article design data representing a three-dimensional model of an article to be created and / or on article design data representing properties of the article. The model may define the solid parts of the article and may be processed by the three-dimensional article processing system to create slices of parallel planes of the model. Each slice may define a portion of a respective layer of build material to be solidified by the additive manufacturing system. The article property data may define properties of the article such as density, surface roughness, strength, and the like.

[0041] The article design data and article property data may, for example, be received from a user via an input device 220, as input from a user, from a software driver, from a software application such as a computer-aided design (CAD) application, or may be obtained from a memory that stores standard or user-defined article design data and article property data.

[0042] In some examples, the article processing system may receive data related to properties of the additive manufacturing system 200. Such properties may include, for example, build material layer thickness, coalescing agent properties, build material properties, and energy source 226 properties, heater 230 properties, and temperature sensor 228 properties.

[0043] The agent delivery control data 208 can describe, for each layer of build material to be processed, locations or portions of the build material to which coalescing agent is to be delivered. In one example, the locations or portions of the build material to which coalescing agent is to be delivered are defined by respective patterns.

[0044] Fig. 3 is a flowchart illustrating a method 300 for creating a three-dimensional object according to some examples. Aspects of the method may be computer-implemented. In some examples, the illustrated orders may be varied so that some elements may occur simultaneously, some elements may be added, and some elements may be omitted.

[0045] When describing the Fig. 3 is on the Fig. 2, 4-7 and 8a-c. The Fig. 4-7 respectively represent center manifolds and data representing a three-dimensional object modified based on data relating to nozzles. As shown, each of the Fig. 4-7 the carrier 203a from Fig. 2b with center distributors 202a-b. However, in other examples, the methods described herein may comprise the carrier 203b from Fig. 2c or other supports and center dividers. In addition, the Fig. 4-7 each contain original data 400a, 500a, 600a, and 700a, which represent the three-dimensional object to be created, and each contain data 400b, 500b, 600b-c, and 700b, which are each created based on modifications of the respective original data 400a, 500a, 600a, and 700a. Fig. 4-7 show a schematic view of the center distributors 202a-b and xy cross sections of the data 400a-b, 500a-b, 600a-c and 700a-b. Fig. 8a-c show a series of cross-sectional side views of layers of building material according to some examples.

[0046] At 302, data representing the three-dimensional object may be created or obtained by the controller 210. "Data representing the three-dimensional object" is defined herein to include data defining the object from its initial creation as a three-dimensional object model to its conversion into slice data and to its conversion into a shape suitable for controlling a center manifold. Such data is also defined to include data used by a center manifold to define which nozzles of a center manifold are to be used. Thus, it should be noted that "data representing the three-dimensional object" includes, for example, both (1) data corresponding to locations on a support element so that the object can be moved to be created at a different location on the platform, e.g.if the support element is fixed, or (2) data corresponding to nozzles of a means to be used, even if the location of the object to be created on the platform is not moved but the support element is moved, e.g., if the support element is movable, so that "moving" the object herein may correspond to the use of different nozzles.

[0047] At 304, data relating to the nozzles 205 of the center manifolds may be obtained and / or created by the controller 210.

[0048] In some examples, the data may represent dimensions by the nozzle sensors 207 of the nozzles 205. For example, each nozzle sensor 207 may measure whether its respective nozzle 205 is malfunctioning, e.g., partially or completely clogged, as discussed above. In the examples of Fig. 4-6, nozzles 404, 504, and 604 may be detected as non-functional. Thus, controller 210 may identify respective regions 406, 506, and 606 in data 400a, 500a, and 600a corresponding to non-functional nozzles 404, 504, and 604. If regions 406, 506, or 606 contain items, e.g., all or part of an item, then such items may be moved to different regions in the data corresponding to functional nozzles, as described.

[0049] In other examples, the data may represent the usage of each nozzle 205, for example, the total amount of drops ejected by the nozzle 205 during its lifetime, the frequency of use of the nozzle 205, and / or whether the nozzle 205 has not been used for more than a predetermined amount of time, etc. In some examples, the data representing the usage of each nozzle 205 may be based on the measurements by the nozzle sensors 207 of how many drops were ejected from each nozzle 205. In other examples, the controller 210 may instead create the data based on instructions 218, such as data representing the previous usage of the nozzle 205 in creating three-dimensional objects. In the example of Fig. 7, according to one of the above methods, it may be determined that the utilization of the center nozzles 706 should be higher than the utilization of the edge nozzles 704. Thus, the controller 210 may identify edge regions 706 corresponding to the edge nozzles 704 and a center region 707 corresponding to the center nozzles 705. The underutilization of the edge nozzles 704 relative to the center nozzles 705 may occur over time, for example, because data representing three-dimensional objects typically defines objects to be printed in the center of the build material area.

[0050] At 306, the data representing the three-dimensional object may be modified based on the data related to the nozzles to shift the coordinates of an object and / or to retract an object. For example, the shift may occur if the object is located in an area of ​​the data corresponding to a malfunctioning or overused nozzle. The object may thus be shifted to an area where the corresponding nozzles are functioning, e.g., are not clogged and / or underused compared to the overused nozzles.

[0051] In some examples, the data may include a plurality of slice data, where each slice data, for example, agent delivery control data, represents a build area containing a two-dimensional slice of an object. Thus, each slice can be moved to a different location within its respective slice data area, allowing the coordinates of the object to be moved as a whole. Each slice can be moved by the same amount to ensure that the entire object is moved.

[0052] In other examples, the data may include three-dimensional object data, such as object design data, where the data represents a build volume in which the three-dimensional object is intended to be located. Thus, the object can be moved to a different location within the volume of data, allowing the coordinates of the object as a whole to be shifted.

[0053] In the example from Fig. 4, the data 400b is created based on modifications to the original data 400a. The object 402 is moved out of the area 406 corresponding to the non-functioning nozzles 404.

[0054] In the example from Fig. 5, the data 500b is created based on modifications to the original data 500a. The controller 210 may identify twenty objects 502. For example, the controller 210 may identify that the twenty objects 502 are separated from each other, e.g., that they do not contact other objects. The controller 210 may analyze three-dimensional data or a collection of slice data. The data may be a vector format or another format in which the controller 210 can identify that the objects 502 are separated. The twenty objects 502 are all shifted so that none of the objects 502 are located in the areas 506 corresponding to the non-functioning nozzles 504. In other examples, some of the objects are shifted, but others are not, to avoid the areas 506.

[0055] In the example from Fig. 6, the data 600b and 600c are created based on modifications to the original data 600a. In the data 600a, the item 602a is not located in the area 606 corresponding to non-functioning nozzles 604, and the item 602b is located in the area corresponding to non-functioning nozzles 602. However, there is not enough space in the area or volume to allow both items 602a and 602b to be created without using the nozzles 604 corresponding to the forbidden area 606. Thus, in the created data 600b used for a build process, one of the items, in this example 602b, is revoked. Meanwhile, the item 602a is not moved because it is not located in the area 606. In some examples, as in Fig. As shown in Figure 6, data 600c may be created representing another build to create the item 602b revoked in data 600b. Thus, two build processes may be performed in the build volume to create both items 602a and 602b.

[0056] In the example from Fig. 7, the data 700b is created based on modifications to the original data 700a. The eight objects 702 are each shifted such that none of the objects 702 are located in the areas 706 corresponding to the underused nozzles 704, rather than in the areas 707 corresponding to the overused nozzles 705. In other examples, some of the objects may be shifted but others not to avoid the areas 707.

[0057] Then iterations from 308 to 312 can be performed to create the three-dimensional object.

[0058] At 308, the layer 802b of building material may be provided as in Fig. 8a. For example, the controller 210 may control the build material distributor 224 to provide the layer 802b on a previously completed layer 802a on the support member 204 by causing the build material distributor 224 to move along the y-axis as discussed above. The completed layer 802a may include a solidified portion 806. Although a completed layer 802a in the Fig. 8a-d for illustrative purposes, it should be noted that 308 to 312 may be initially applied to create the first layer 802a.

[0059] At 310, as in Fig. As shown in Figure 8b, coalescing agent 804 can be selectively delivered to the surface of portions of layer 802b. As discussed above, the agent 804 can be delivered through the agent distributor 802, for example, in the form of fluids, such as liquid droplets.

[0060] The selective delivery of agent 804 can be performed in patterns on the portions of layer 802b that can define the data representing the three-dimensional object, e.g., data 400b, 500b, 600b, 600c, or 700b, to become solid to form a portion of the three-dimensional object being created. "Selective delivery" means that agent can be delivered to selected portions of the surface layer of the build material in various patterns.

[0061] In some examples, coalescing modifier agent may be similarly selectively delivered to portions of layer 602b.

[0062] In the examples of Fig. 8a-8d, the patterns of means 804 correspond, for illustrative purposes, to cross-sectional side views of the article 402 defined in 400b. However, other patterns, including the patterns defined in data 500b, 600b, 600c, or 700b, may be used.

[0063] Fig. 8c shows the coalescing agent 804 substantially completely penetrated into the portions of the build material layer 802b, but in other examples, the degree of penetration may be less than 100%. The degree of penetration may depend, for example, on the amount of agent delivered, the type of build material, the type of agent, etc.

[0064] At 312, a predetermined level of energy may be temporarily applied to the layer 802b of build material. In various examples, the applied energy may be infrared or near-infrared energy, microwave energy, ultraviolet (UV) light, halogen light, ultrasonic energy, or the like. The temporary application of energy may cause the portions of the build material to which coalescing agent 804 has been delivered to heat above the melting point of the build material and coalesce. In some examples, the energy source may be focused. In other examples, the energy source may be unfocused, and the temporary application of energy may cause the portions of the build material to which coalescing agent 804 has been delivered or penetrated to heat above the melting point of the build material and coalesce. For example, the temperature of all or a portion of layer 802b may reach approximately 220 degrees Celsius.Upon cooling, the parts may coalesce with coalescing agent 804, may solidify, and may form part of the three-dimensional article being created, as shown in . Fig. 8d shown.

[0065] As discussed above, such a solidified part 806 may have been created in a previous iteration. The heat absorbed during the application of energy may propagate to the previously solidified part 806 to cause a portion of the part 806 to heat above its melting point. This effect helps create a part 808 that has a strong interlayer bond between adjacent layers of solidified build material, as shown in Fig. 8d shown.

[0066] After a layer of build material has been processed as described above in steps 308 to 312, new layers of build material may be provided on top of the previously processed layer of build material. In this way, the previously processed layer of build material acts as a support for a subsequent layer of build material. The process of steps 308 to 312 may then be repeated to create a three-dimensional object layer by layer.

[0067] Fig. 9 is a flowchart illustrating a method 900 for creating a three-dimensional object according to some examples. Aspects of the method may be computer-implemented. In some examples, the illustrated orders may be varied so that some elements may occur simultaneously, some elements may be added, and some elements may be omitted.

[0068] When describing the Fig. 9 is on the Fig. 2, 4-7, 8a-c and 10a-b. As shown, the Fig. 10a-b the carrier 203a from Fig. 2b with center distributors 202a-b. In other examples, the methods herein may comprise the carrier 203b from Fig. 2c or other supports and center dividers. In addition, the Fig. 10a-b original data 1000a representing the three-dimensional object to be created and include data 1000b created based on modifications of the original data 1000a. Fig. Figure 10a shows a schematic view of the center distributors 202a-b and an xy cross section of the data 1000a-b. Fig. Figure 10b shows a schematic view of the center manifolds 202a-b and an xz cross section of the data 1000a-b.

[0069] At 902, data representing the three-dimensional object may be created or obtained by the controller 210.

[0070] Then iterations from 904 to 912 can be performed to create the three-dimensional object.

[0071] At 904, a layer 802b of building material may be provided, as in Fig. 8a. This can be done in a similar way as previously with respect to 308 from Fig. 3. Although for illustrative purposes in the Fig. 8a-d, a completed layer 802a is shown, it should be noted that 904 to 912 may be initially applied to create the first layer 802a.

[0072] At 906, data relating to the nozzles 205 of the center manifolds may be obtained and / or created by the controller 210. This may be done in a similar manner as previously described with respect to 304. Fig. 3, with the detections relating to the nozzles from the Fig. 4-7, as discussed above. For example, the data may represent dimensions measured by the nozzle sensors 207 of the nozzles 205 and / or may represent the usage of the nozzle 205. However, in this example, the data may be obtained during the build process during the creation of each layer. In this way, modifications to the build may be made spontaneously based on the nozzle data, as described below.

[0073] In the example from the Fig. 10a-b, nozzles 1004 may be detected as non-functional, e.g., partially clogged or completely clogged. Thus, controller 210 may identify a region 1006 in data 1000a corresponding to the non-functional nozzles 1004. If region 1006 includes an object, e.g., all or part of an object, such an object may be moved to different regions in the data, as described below.

[0074] At 908, the data representing the three-dimensional object may be modified based on the data representing the usage of the nozzles in order to shift the coordinates of an object and / or revoke an object. For example, the shift may occur when the object is located in a region of the data corresponding to a non-functioning or overused nozzle. The object may thus be shifted to a region where the corresponding nozzles are functioning and / or underused compared to the overused nozzles. This may be done in a similar manner as described above with respect to 306 of Fig. 3, with modifying three-dimensional object data or disc data and with the Fig. 4-7 specific examples shown.

[0075] Additionally, in some examples, detection of non-functioning or over-used nozzles occurs after part of the item has already been created, for example, initial slices have been created using nozzles identified as non-functioning. In these examples, the item may be revoked in the remaining data representing the item. This may be done, for example, so that no build material is wasted on an item that is expected to be faulty. In some examples, for example, if space is available, creation of the item may be restarted at the new layer using functioning and / or under-used nozzles.

[0076] For example, in Fig. 10a-b, the data 1000b is created based on modifications of the original data 1000a. The object 1002a is created due to errors in the xy-range 1006 of the Fig. 10a. For example, the object 1002 is revoked at a slice indicated by 1008, so that the remaining object 1002a above the slice 1008 is revoked. The object 1002a is then moved to create a duplicated moved object 1002b. The object 1002b is moved both in the x-direction to cover the area 1006 as in Fig. 10a, as well as upward in the z-direction due to previous slices that have already been created and that include the revoked item 1002a. In other examples, no further item, such as item 1002b, can be added to the data 1000b after the item 1002a has been revoked.

[0077] At 910, as in Fig. 8b, coalescing agent 804 can be selectively delivered to the surface of portions of layer 802b. This can be done in a similar manner as previously described with respect to 310 of Fig. 3. As previously discussed, in the examples of the Fig. 8a-8d, the patterns of means 804 are, for illustrative purposes, cross-sectional side views of the article 402 defined in 400b. However, other patterns may be used, including the patterns defined in data 500b, 600b, 600c, 700b, or 1000b.

[0078] At 912, a predetermined level of energy may be temporarily applied to the layer 802b of build material. This may be done in a similar manner as previously described with respect to 312 of Fig. 3 to create a solidified part 808.

[0079] After a layer of build material has been processed as described above in 904 through 912, new layers of build material may be provided on top of the previously processed layer of build material. In this way, the previously processed layer of build material acts as a support for a subsequent layer of build material. The process of 904 through 912 may then be repeated to (1) create a three-dimensional object layer by layer, and / or (2) modify data representing the three-dimensional object to shift the coordinates of the object and / or revoke the object.

[0080] All features disclosed in this specification (including accompanying claims, abstract and drawings) and / or all elements of methods or processes so disclosed may be combined in any combination, except for combinations in which at least some of the features and / or elements are mutually exclusive.

[0081] In the foregoing description, numerous details are set forth to provide 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 discussed above. The appended claims are intended to cover such modifications and variations.

Claims

[1] A system (200) for creating a three-dimensional object, the system (200) comprising: a processor (212) for: Receiving nozzle data relating to a nozzle (205) of a medium distributor (202) used for dispensing the medium, the medium distributor (202) in a page-wide configuration having its length extending across the entire width of a support member (204); Modifying data (600a, 700a) representing a three-dimensional first object (602a, 702) and a three-dimensional second object (602b, 702) to cause the nozzle (205) associated with a prohibited area (606) not to be used to create the two three-dimensional objects (602a, 602b); wherein the three-dimensional first object (602a, 702) is not located in the forbidden area (606) and the three-dimensional second object (602b, 702) is located in the forbidden area (606), wherein the processor (212) is configured to modify the data (600a) to revoke or move the three-dimensional second object (602b, 702) located in the forbidden area (606) and not to move the three-dimensional first object (602a, 702) not located in the forbidden area (606), such that the nozzle (205) is not used to create the three-dimensional second object (602b, 702); and In the case of the postponement, causing the three-dimensional first object (602a, 702) and the three-dimensional second object (602b, 702) to be created in accordance with the modified data (600b, 600c) representing the two three-dimensional objects (602a, 602b, 702), or, in the case of revocation, causing only the three-dimensional first object (602a, 702) to be created in accordance with the modified data (600b) representing the three-dimensional first object (602a, 702). [2] The system (200) of claim 1, wherein the nozzle data represents the nozzle malfunction. [3] The system (200) of claim 2, further comprising a drop detector to detect whether the nozzle (205) is at least partially clogged, wherein the nozzle data is based on a measurement by the nozzle sensor (207). [4] The system of claim 1, wherein the nozzle data represents that the nozzle (205) is overused relative to other nozzles (205) of the center manifold (202). [5] The system (200) of claim 4, further comprising a nozzle sensor (207) for detecting usage of the nozzle (205), wherein the nozzle data is based on a measurement by the nozzle sensor (207). [6] The system (200) of claim 4, wherein the nozzle data is based on data representing previous use of the nozzle (205) on created three-dimensional objects. [7] The system (200) of claim 1, wherein the data (600a, 700a) representing the three-dimensional objects (602a, 602b, 702) are design data for three-dimensional objects. [8] The system (200) of claim 1, wherein the data representing the three-dimensional data is slice data. [9] The system (200) of claim 1, wherein the data represents a plurality (600a, 700a) of three-dimensional objects (602a, 602b, 702), wherein the processor (212) is to modify the data representing the plurality of three-dimensional objects (602a, 602b, 702) to shift the coordinates of the plurality of three-dimensional objects (602a, 602b, 702) such that the nozzle (205) is not used to create the three-dimensional objects (602a, 602b, 702). [10] The system (200) of claim 1, wherein the processor (212) is to receive the nozzle data and modify the data representing the three-dimensional objects (602a, 602b, 702) before the three-dimensional objects (602a, 602b, 702) are created. [11] The system (200) of claim 1, wherein the processor (212) is to receive the nozzle data and modify the data representing the three-dimensional objects (602a, 602b, 702) during a build process in which the three-dimensional objects (602a, 602b, 702) are created. [12] The system (200) of claim 11, wherein the processor (212) is to modify the data representing the three-dimensional objects to revoke the three-dimensional objects (602a, 602b, 702) while the three-dimensional objects are being created, and to shift the coordinates of the three-dimensional objects (602a, 602b, 702) such that the nozzle (205) is not used to create the three-dimensional objects (602a, 602b, 702). [13] Method comprising: Obtaining, by a processor (212), nozzle data relating to a nozzle (205) of a medium distributor (202) used for dispensing medium, the medium distributor (202) in a page-wide configuration having its length extending across the entire width of a support member (204), the nozzle (205) being associated with a prohibited area (606); Converting, by the processor (212), data (600a) to obtain modified data (600b, 600c) representing a three-dimensional first object (602a, 702) and a three-dimensional second object (602b, 702) to cause the three-dimensional second object (602b, 702) to be revoked or postponed so that the nozzle (205) is avoided during the creation of the three-dimensional objects (602a, 602b, 702); wherein the three-dimensional first object (602a, 702) is not in the forbidden area (606) and the three-dimensional second object (602b, 702) is in the forbidden area (606) so that the nozzle (205) is not used to create the three-dimensional second object (602b, 702); and in case of revocation, creating the three-dimensional first object (602a, 702) in accordance with the modified data (600b) or in case of displacement, creating the three-dimensional objects (602a, 602b, 702) in accordance with the modified data (600b, 600c).

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