3D printing system with resin container positioning system

Abstract

The three-dimensional (3D) printing system includes a print engine and a resin container. The print engine includes a pair of opposing support plates, between which a receiving space is defined. The pair of support plates include a pair of profile inclined sections and a pair of hooks extending into the receiving space. The outer surface of the resin container includes a plurality of fixed rollers and a pair of cam rollers. The plurality of fixed rollers are configured to partially engage with the pair of profile inclined sections as the resin container is translated into the receiving space. In response to rotation around a horizontal axis, the pair of cam rollers are configured to engage with a pair of hooks, lift and translate the plurality of fixed rollers, and fully engage with the pair of profile inclined sections.

Description

Cross-Reference to Related Applications

[0001] This non-provisional patent application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 591,139, filed October 18, 2023 by Eric M. Innes et al. and entitled "Three-Dimensional Printing System with Resin Vessel Positioning System"; the content of which is incorporated herein by reference under the benefit of 35 U.S.C. 119(e). TECHNICAL FIELD

[0002] The present disclosure relates to apparatus and methods for the digital manufacturing of three-dimensional (3D) articles by layer-wise solidification of build material. More specifically, the present disclosure relates to a method for accurately positioning a resin vessel within a print engine. BACKGROUND ART

[0003] 3D printing systems are widely used for prototyping and manufacturing of articles. One type of 3D printing system utilizes a process called stereolithography. A typical stereolithography system includes a resin vessel and a print engine. The resin vessel is very heavy and may be mounted on swivel wheels or casters. The resin vessel is pushed into the print engine before the manufacturing process is initiated. SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION

[0004] One problem arises when the factory floor under the resin vessel and the print engine is not flat. As a result, manufacturing accuracy issues due to relative vertical and angular positioning between the resin vessel and the print engine may occur. MEANS FOR SOLVING THE PROBLEMS

[0005] In a first aspect of this disclosure, a three-dimensional (3D) printing system includes a print engine and a resin container. The print engine includes a pair of opposing support plates between which a receiving space is defined. The pair of support plates include a pair of profiled ramps and a pair of hooks extending into the receiving space. The resin container has opposing inner and outer surfaces. The inner surface defines a reservoir configured to contain a photocurable resin. The outer surface includes a plurality of fixed rollers and a pair of cam rollers. The plurality of fixed rollers are configured to partially engage with the pair of profiled ramps as the resin container is initially translated into the receiving space, thereby partially loading the resin container into the print engine. The pair of cam rollers are connected to a horizontal axis and are configured to be received by a pair of hooks as the resin container is initially translated into the receiving space. In response to rotation around the horizontal axis, the pair of cam rollers are configured to engage with the pair of hooks, lift and translate the plurality of fixed rollers, and fully engage with the pair of profiled ramps when the resin container is fully loaded into the receiving space.

[0006] This system allows for the precise and easy positioning of very heavy resin containers relative to the print engine, even on uneven floors. The engagement between the profile inclination and the fixed roller provides stable and accurate positioning of the resin container. A cam roller that engages with a hook facilitates the mounting and removal of the resin container and fixed roller from the profile inclination.

[0007] In one implementation, the print engine further includes a build plate, a vertical movement mechanism connected to the build plate, an imaging subsystem, and a controller. The controller is configured, in particular, to operate the vertical movement mechanism and the imaging subsystem to produce a three-dimensional (3D) object in a layer-by-layer manner.

[0008] In another implementation, a pair of profile inclined sections each include a curved front section, a flat middle section, and a curved rear section. A pair of hooks can be positioned directly above the curved front section of the pair of profile inclined sections. Multiple fixed rollers include a pair of leading rollers and a pair of trailing rollers. Partial engagement of the multiple fixed rollers includes the pair of leading rollers individually engaging with the upper surface of the flat middle section and the pair of trailing rollers individually engaging with the upper surface of the curved front section. The pair of leading rollers are above the pair of trailing rollers, enabling partial engagement. Full engagement of the multiple fixed rollers includes the pair of leading rollers individually engaging with the upper surface of the curved rear section and the pair of trailing rollers individually engaging with the flat middle section.

[0009] In yet another implementation, the pair of cam rollers include a handle, and the rotation of the handle around a horizontal axis causes the pair of cam rollers to rotate around the horizontal axis. The handle has two positions, including an up position and a down position. In the up position, the multiple fixed rollers are partially engaged with the pair of profile inclined sections. In the down position, the multiple fixed rollers are fully engaged with the pair of profile inclined sections.

[0010] In a second aspect of the present disclosure, a method for manufacturing a three-dimensional article comprises the steps of providing a 3D printing system of the first aspect, and then: (1) translating a resin container into a receiving space of a print engine, and (a) partially engaging a plurality of fixed rollers with a pair of profile inclined portions and (b) receiving a pair of cam rollers with a pair of hooks; and (2) fully loading the resin container into the receiving space, which includes rotating the pair of cam rollers to engage a pair of hooks with the pair of cam rollers, and thus lifting and translating the plurality of fixed rollers to fully engage with the pair of profile inclined portions. [Brief explanation of the drawing]

[0011] [Figure 1] This is a schematic diagram of an embodiment of a three-dimensional (3D) printing system including a print engine, a resin container, and a controller. [Figure 2] This is an isometric projection view of one embodiment of a resin container. [Figure 3] This is a side view showing a separated embodiment of a support plate that forms part of a printed engine. [Figure 4] This is a side view of one embodiment of a resin container. [Figure 5] This is a flowchart of one embodiment of a method for manufacturing 3D objects. [Figure 6A] This is an isometric projection view of one embodiment of a part of a print engine and a resin container arranged to be installed inside the print engine. [Figure 6B] This is an isometric projection view of one embodiment of a resin container partially installed within a print engine. [Modes for carrying out the invention]

[0012] Figure 1 is a schematic diagram of an embodiment of a three-dimensional (3D) printing system 2 configured to manufacture a 3D object 4. In describing System 2, mutually orthogonal axes X, Y, and Z are used, also referred to as the X-axis, Y-axis, and Z-axis. θ-X, θ-Y, or θ-Z refer to rotations around axes parallel to the X-axis, Y-axis, or Z-axis, respectively. Axes X and Y are generally horizontal transverse axes. Axe Z is a vertical axis generally aligned with gravity. The term "generally" means that the direction or magnitude is not necessarily exact but is to the specification. Terms such as horizontal, vertical, orthogonal, or aligned are generally due to engineering design and intent and are accurate within manufacturing tolerances.

[0013] Manufacturing tolerances can be influenced by factors such as the type of materials used to construct the system's components. Manufacturing tolerances can also be influenced by the specific processing sequence used when manufacturing and assembling the system's parts.

[0014] The 3D printing system 2 includes a print engine 6 and a resin container 8. The resin container 8 has an inner surface 10 defining a reservoir 12 configured to contain a photocurable resin 14. The photocurable resin 14 is, in particular, a liquid polymer resin comprising one or more monomers and one or more catalysts. The photocurable resin 14 is configured to polymerize during a radiation curing process and cure from a liquid state to a solid state. The radiation curing process involves exposure of the photocurable resin to blue, violet, and / or ultraviolet radiation, or a wavelength distribution in the range of 100 to 500 nanometers (nm). The radiation curing process can preferably utilize radiation having one or more spectral peaks optimized for the catalyst.

[0015] The print engine 6 includes a build plate 16 supported by a plate support 18. 3D articles 4 are manufactured by selectively forming a series of layers of cured photocurable resin 14 on the upper surface of the build plate 16. A vertical movement mechanism 20 is connected to the plate support 18. In one embodiment, the vertical movement mechanism 20 includes an electric lead screw screwed into a threaded bearing. The threaded bearing is mounted on the plate support 16. A motor fixed in place rotates the lead screw, thereby translating the plate support 16 up and down. In another embodiment, the vertical movement mechanism 20 may be based on cables and electric pulleys. Such movement mechanisms are known in the fields of stereolithography, as well as 2D and 3D printing. Any such movement mechanism may incorporate a gear reduction mechanism to improve torque and positioning accuracy.

[0016] The print engine 6 includes a coater 22 which includes an electric wiper module. In one embodiment, the wiper module is a rectangular block having a wiper blade that extends downward toward the build plane 24 and along the X-axis. The wiper module is constrained to translate along the Y-axis by one or two linear bearings and is movable up and down along the Z-axis by a motor or solenoid valve. In an alternative embodiment, the linear bearing constraining the wiper module can be moved up and down by an actuator. Such actuators may be based individually on electric screws and threaded bearings, motor-driven cams, solenoid valves, or other similar vertical movement mechanisms. A belt and pulley system translates the wiper module along the Y-axis. The belt is tensioned between two pulleys, one of which is connected to a motor. The wiper module is connected to a portion of the tensioned belt. As the motor rotates one of the two pulleys, the wiper module is translated along the Y-axis. Other mechanisms are possible for translating the wiper module, such as an electric lead screw housed within a threaded bearing supported by the wiper module. Various wiper modules, including stereolithography, are known in 3D printing.

[0017] The imaging system 26 is configured to irradiate the build plane 24 with radiation and selectively cure a layer of photocurable resin 14 on the build plane 24 and on the upper surface (or initially on the build plate 16) of the partially formed 3D article 4. In one embodiment, the imaging system 26 includes a laser that is sequentially reflected by two galvanometer mirrors and scans the irradiated laser beam 28 along the X and Y axes on the build plane 24. In another embodiment, the imaging system 26 may employ an array of light-emitting diodes or lasers scanned on the build plane 24. Further other imaging subsystems may employ a light source and an optical modulator. The light source may emit blue, violet, and / or ultraviolet (100-500 nm) to selectively cure the layer of photocurable resin 14. Various types of imaging systems 26 are known in the art with respect to stereolithography and other 3D printing systems.

[0018] The controller 30 is connected to the vertical movement mechanism 20, the coater 22, the imaging subsystem 26, and the other parts of the print engine 6. The controller 30 includes a non-temporary or non-volatile information storage device 32 connected to the processor 34. The controller 30 may be a single microcontroller located in the same place as the print engine 6, or it may include multiple computers, which may include two or more of the following: microcontrollers, desktop computers, laptop computers, server computers, and other computing devices. When executed by the processor 34, the information storage device 32 stores software instructions for operating the vertical movement mechanism 20, the coater 22, the imaging subsystem 26, and the other parts of the print engine 6.

[0019] Figure 2 is an isometric projection view of one embodiment of a resin container 8 configured to be installed inside a print engine 6 (Figure 1), having opposing inner surfaces 10 and outer surfaces 36. The inner surface 10 defines a reservoir 12 configured to contain a photocurable resin 14.

[0020] The outer surface 36 includes a plurality of fixed rollers 38, 40 and a pair of cam rollers 42. The plurality of fixed rollers 38, 40 includes a pair of leading rollers 38 and a pair of trailing rollers 40. The terms "leading" and "trailing" are relative terms with respect to the installation direction (D) parallel to the Y-axis. In other words, when the resin container 8 is translated into the print engine 6, the leading rollers 38 enter the print engine 6 first, followed by the trailing rollers 40. Each pair of rollers 38, 40, and 42 extends outward from the outer surface 36 in opposite directions (-X and +X).

[0021] The pair of cam rollers 42 is attached to a horizontal shaft 44. The horizontal shaft 44 is parallel to the X-axis. Thereby, the pair of cam rollers 42 can rotate around the horizontal shaft 44 having a θ-X rotation vector (around an axis parallel to the X-axis). A handle 46 is attached to the pair of cam rollers 42. The handle 46 enables manual and lever-operated rotation of the pair of cam rollers 42. The pair of cam rollers 42 is attached at a first radius (R1) from the shaft 44 (Figure 4). The handle 46 is attached at a second radius (R2) from the axle 44. The first radius (R1) and the second radius (R2) are perpendicular to the rotation axis. The second radius (R2) is larger than the first radius (R1), and provides a lever action to the user who is lowering or raising the handle. Preferably, R2 is at least twice or three times equal to R1 to provide effective lever action.

[0022] The resin container 8 is attached to a plurality of rotating wheels or casters 48. The casters 48 allow the resin container 8 to be manually advanced and translated into the print engine 6.

[0023] Figure 3 is a side view separately showing an embodiment of the support plate 48 forming a part of the print engine 6. The print engine 6 includes a pair of inward-facing support plates 48, and partially encloses a receiving space 49 (Figure 6A) for receiving the resin container 8 along the direction D.

[0024] A pair of support plates 48 include a pair of profile inclined sections 50 that extend into the receiving space. Each profile inclined section 50 includes a curved front section 52, a flat middle section 54, and a curved rear section 56. Element numbers 52, 54, and 56 indicate the upper surfaces of the curved front section 52, the flat middle section 54, and the curved rear section 56 of the profile inclined section 50, respectively. A pair of hooks 58 are located above the pair of curved front sections 52, and these also extend into the receiving space 49.

[0025] Figure 4 is a side view of one embodiment of a resin container 8 with the handle 46 in the raised or disengaged position. As the resin container 8 is initially or partially advanced or translated into the receiving space along D, a pair of leading rollers 38 engage with a pair of flat intermediate sections 54. Simultaneously, a pair of trailing rollers 40 engage with a pair of curved front sections 52. At the same time, the cam roller 42 is also received by the hook 58.

[0026] Next, the user (of the print system 2) can pull down the handle 46 to the lowered and engaged position. When the handle 46 is lowered, a pair of cam rollers 42 rotate around the shaft 44 and push a pair of hooks 58. This moves the resin container 8 until it is fully engaged with the print engine 6. At the same time, a pair of leading rollers 38 engage with the curved rear portions 56 of the pair of profile inclined sections 50. Also at the same time, a pair of trailing rollers 40 are lifted onto and engage with the flat middle portions 54 of the pair of profile inclined sections 50. When the handle 46 is in the lowered and engaged position, the resin container 8 is fully installed, supported, and positioned within the print engine 6.

[0027] To release the resin container 8, the handle 46 is moved from the lowered position to the raised and released position. When the handle 46 is lifted, a pair of cam rollers 42 rotate around the shaft 44 and push a pair of hooks 58. This moves the resin container 8 from fully engaged to partially engaged. At the same time, a pair of leading rollers 38 move from the curved rear portion 56 to the flat middle portion 54 of the pair of profile inclined sections 50. Also at the same time, a pair of trailing rollers 40 move from the flat middle portion 54 to the curved front portion 52 of the pair of profile inclined sections 50. The user can then translate the resin container 8 completely out of the receiving space in the -D direction.

[0028] In an alternative embodiment (or additionally), a pair of cam rollers 42 can be motorized. Instead of the user lowering and raising the arm 46, the motor can rotate the shaft 44 and rotate the cam rollers 42 in the same manner as described above. The motor can be coupled to the shaft 44 with a reduction gear train that increases torque and provides the appropriate angular velocity of the shaft 44.

[0029] Figure 5 is a flowchart for manufacturing a 3D object 4 using the printing system 2. According to 102, the printing engine 6 and the resin container 8 are initially separated as shown in Figure 6A. Figure 6A is an isometric view including a frame 60 that supports a pair of support plates 48 in a face-to-face relationship and partially encloses the receiving space 49. Other elements of the printing system 6 are omitted for simplification. The arm 46 is in the up or disengaged position.

[0030] According to 104, the resin container 8 is filled with the photocurable resin 14. Alternatively, the resin container 8 can be filled with the photocurable resin 14 at any point before 110, for example, after 108 but before 110.

[0031] According to 106, the user translates the resin container along the D direction (Figure 6A) and to a partially engaged position (Figure 6B). This positions the leading roller 38 on the flat middle section 54, the trailing roller 40 on the curved front section 52, and the cam roller 42 within the hook 58. Figure 6B is an isometric projection view of the partially engaged state.

[0032] According to 108, the arm 46 is lowered to rotate the cam roller 42, fully engaging the resin container 8 within the print engine 6. This positions the leading roller 38 on the curved rear section 56 and the trailing roller 40 on the flat middle section 54.

[0033] According to 110, the 3D printing system 2 (see Figure 1) is operated to produce the 3D article 4 in a layer-by-layer manner. The steps include, among other things: (1) operating the vertical movement mechanism 20 to position the upper surface of the build plate 16 (and the upper surface of the subsequent 3D article 4) one layer thickness below the build plane 24 (which corresponds to the upper surface of the photocurable resin 14); (2) operating the coater to provide a new layer of photocurable resin 14 onto the 3D article 4 or the upper surface of the build plate 16; (3) operating the imaging system 26 to selectively cure the new layer of photocurable resin 14; and (4) repeating steps (1) to (3) to complete the production of the 3D article 4. 110 may also include the step of removing the 3D article 4 from the 3D printing system 2.

[0034] According to 112, the arm 46 is raised to rotate the cam roller 42 and move the resin container 8 so as to partially engage with the print engine 6. This positions the leading roller 38 on the flat intermediate section 54 and the trailing roller 40 on the curved leading section 52. According to 114, the resin container 8 is translated in the -D direction and removed from the print engine 6. Thus, 116 indicates the end of the process. Note that step 110 may be repeated multiple times before the removal steps 112 and 114.

[0035] The specific embodiments and their applications described above are for illustrative purposes only and do not preclude modifications and variations that are included in the appended claims.

Claims

1. A three-dimensional (3D) printing system, Print engine; A resin container having opposing inner and outer surfaces, the inner surface defining a reservoir configured to contain a photocurable resin. Equipped with, The aforementioned print engine is A pair of support plates facing each other, defining a receiving space between them, and including a pair of profiled inclined portions and a pair of hooks extending within the receiving space, Includes, The aforementioned outer surface is, Multiple fixed rollers, configured to partially engage with the pair of profile inclined portions when the resin container is initially translated into the receiving space and thereby partially loaded into the receiving space and the print engine; A pair of cam rollers, connected to a horizontal axis, configured to receive the resin container by the pair of hooks when the container is first translated into the receiving space. Includes, In response to rotation around the horizontal axis, the pair of cam rollers are configured to engage with the pair of hooks, lift and translate the plurality of fixed rollers, and fully engage with the pair of profile inclined portions when the resin container is fully loaded into the receiving space. A three-dimensional (3D) printing system characterized by the following.

2. The aforementioned print engine further, Modeling plate; A vertical movement mechanism connected to the molding plate; Imaging subsystem; and controller The controller is configured, in particular, to operate the vertical movement mechanism and the imaging subsystem to produce a three-dimensional (3D) article in a layer-by-layer manner. A three-dimensional (3D) printing system according to claim 1, characterized in that it is the same as described in claim 1.

3. The three-dimensional (3D) printing system according to claim 1, characterized in that the pair of profile inclined portions each individually include a curved front portion, a flat middle portion, and a curved rear portion.

4. The three-dimensional (3D) printing system according to claim 3, characterized in that the pair of hooks are positioned directly above the curved front portions of the pair of profile inclined portions.

5. The three-dimensional (3D) printing system according to claim 3, wherein the plurality of fixed rollers include a pair of leading rollers and a pair of trailing rollers, and the partial engagement of the plurality of fixed rollers includes the pair of leading rollers individually engaging with the upper surface of the flat intermediate portion and the pair of trailing rollers individually engaging with the upper surface of the curved front portion.

6. The three-dimensional (3D) printing system according to claim 5, characterized in that the pair of leading rollers are located above the pair of trailing rollers, enabling the partial engagement.

7. The three-dimensional (3D) printing system according to claim 5, characterized in that the complete engagement of the plurality of fixed rollers includes the pair of leading rollers individually engaging with the upper surface of the curved rear portion and the pair of trailing rollers individually engaging with the flat intermediate portion.

8. The three-dimensional (3D) printing system according to claim 1, characterized in that the pair of cam rollers include a handle, and the rotation of the handle around the horizontal axis causes the pair of cam rollers to rotate around the horizontal axis.

9. The three-dimensional (3D) printing system according to claim 8, characterized in that the handle has two positions, including an up position and a down position, in the up position the plurality of fixed rollers are partially engaged with the pair of profile inclined portions, and in the down position the plurality of fixed rollers are fully engaged with the pair of profile inclined portions.

10. A method for manufacturing a three-dimensional (3D) article, A process for providing a three-dimensional (3D) printing system, wherein the printing system is A print engine comprising a pair of support plates, the pair of support plates being in an opposing relationship, defining a receiving space between them, and comprising a pair of profile inclined portions and a pair of hooks extending within the receiving space; A resin container having opposing inner and outer surfaces, wherein the inner surface defines a reservoir configured to contain a photocurable resin, and the outer surface is Multiple fixing rollers, configured to partially engage with the pair of profile inclined portions when the resin container is initially and partially loaded into the receiving space; A pair of cam rollers, connected to a horizontal axis, configured to be received by the pair of hooks when the resin container is initially and partially translated into the receiving space. Includes, In response to rotation around the horizontal axis, the pair of cam rollers are configured to engage with the pair of hooks, lift and translate the plurality of fixed rollers, and fully engage with the pair of profile inclined portions when the resin container is fully loaded into the receiving space. Plastic container; A process comprising; A step of moving the resin container parallel within the receiving space of the print engine; A step of partially engaging the plurality of fixed rollers with the pair of profile inclined portions; A step of receiving the pair of cam rollers by the pair of hooks; A process for fully loading the resin container into the receiving space, comprising rotating the pair of cam rollers, engaging the pair of hooks with the pair of cam rollers, thereby lifting and translating the plurality of fixed rollers and fully engaging them with the pair of profile inclined portions. A method characterized by including

11. The method according to claim 10, wherein the 3D printing engine further comprises a build plate, a vertical movement mechanism connected to the build plate, and an imaging system, and the method further comprises, in particular, the step of operating the vertical movement mechanism and the imaging system to produce a 3D article.

12. The method according to claim 10, wherein the pair of profile inclined portions each include a curved front portion, a flat middle portion, and a curved rear portion, the plurality of fixed rollers each include a pair of leading rollers and a pair of trailing rollers, and the partial engagement of the plurality of fixed rollers includes the pair of leading rollers each engaging with the upper surface of the flat middle portion and the pair of trailing rollers each engaging with the upper surface of the curved front portion.

13. The method according to claim 12, characterized in that the complete engagement of the plurality of fixed rollers includes the pair of leading rollers individually engaging with the upper surface of the curved rear portion and the pair of trailing rollers individually engaging with the flat intermediate portion.

14. The method according to claim 10, wherein the pair of cam rollers includes a handle, and the rotation of the handle around the horizontal axis causes the pair of cam rollers to rotate around the horizontal axis, and the rotation of the pair of cam rollers and the engagement of the pair of hooks by the pair of cam rollers, and thus the complete loading of the resin container into the receiving space, includes lifting and translating the plurality of fixed rollers and fully engaging them with the pair of profile inclined portions.

Images