Additive manufacturing equipment

Abstract

SOLUTION: To provide an additive manufacturing apparatus, in which an electronic control unit is configured to cause one or a plurality of IP lamps to discharge energy when a print assembly or a recoat assembly crosses a build zone, receive a temperature value from one or a plurality of temperature sensors, determine whether the temperature value is within a prescribed range, and adjust the intensity of the one or plurality of IP lamps or the flow gas rate of the one or plurality of IP lamps when the temperature value is not within the prescribed range.SELECTED DRAWING: Figure 1B

Description

Technical Field

[0001] This specification generally relates to additive manufacturing apparatuses, and more particularly, to methods for operating and using additive manufacturing apparatuses.

Background Art

[0002] Additive manufacturing apparatuses can be utilized to "build" objects layer by layer from build materials such as organic or inorganic powders. Initial iterations of additive manufacturing apparatuses were used to prototype three-dimensional objects. However, as additive manufacturing technology has improved, there has been an increasing interest in utilizing additive manufacturing apparatuses for large-scale commercial manufacturing of objects. One problem with scaling additive manufacturing apparatuses for commercial manufacturing is to improve the processing capacity of the additive manufacturing apparatus while maintaining and increasing the machine's reliability to meet commercial demand.

Summary of the Invention

Problems to be Solved by the Invention

[0003] Therefore, alternative additive manufacturing apparatuses and components thereof that improve manufacturing throughput and reliability are needed.

Means for Solving the Problems

[0004] A first embodiment A1 comprises a process chamber having a length defined by at least a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate portions along the length of the process chamber; a support extending along the length of the process chamber in a first vertical plane; a print assembly including a plurality of nozzles for distributing binder into the build zone, movably coupled to the support via a first actuator configured to move forward or backward along the length of the support, and positioned in a second vertical plane parallel to the first vertical plane; a vision system configured to image the distributed binder pattern of the build zone; and the print assembly and the first actuator. Additive manufacturing apparatus includes, and an electronically controlled unit communicatively coupled to the vision system, wherein the electronically controlled unit is configured to traverse the build zone in a forward or reverse direction while distributing binder to the print assembly according to a programmed deposition pattern, receive image data from the vision system of the distributed binder pattern resulting from the programmed deposition pattern, analyze the image data to determine whether there is an anomaly in the distributed binder pattern, and, if an anomaly is determined to be present in the distributed binder pattern, adjust the programmed deposition pattern for subsequent traverses of the print assembly on the build zone to address the anomaly.

[0005] A second embodiment A2 includes an additive manufacturing apparatus according to the first embodiment A1, which supplements the distributed binder pattern image data as the print assembly traverses the build zone in the forward or reverse direction.

[0006] A third embodiment A3 includes an additive manufacturing apparatus according to any one of the first to second embodiments A1 to A2, wherein the abnormality is a region of the build layer of a build manufactured in the build zone in which a predetermined amount of binder is present, based on a comparison of the image data with the programmed deposition pattern.

[0007] A fourth embodiment A4 includes an additive manufacturing apparatus according to any one of the first to third embodiments A1 to A3, wherein the anomaly is a region of the build layer of a build manufactured in the build zone, where, based on a comparison of the image data with the programmed deposition pattern, there is a greater amount of binder than predetermined, or binder is detected at one or more locations where binder should not be deposited.

[0008] A fifth embodiment A5 includes an additive manufacturing apparatus according to any of the first to fourth embodiments A1 to A4, wherein the programmed map of the deposition pattern selects one of a plurality of nozzles to select pixels of the build layer of the build to be manufactured in the build zone.

[0009] A sixth embodiment A6 includes an additive manufacturing apparatus according to a fifth embodiment A5, wherein adjusting the programmed deposition pattern for subsequent crossings of the print assembly on the build zone includes updating the amount of binder defined for distribution by a selected nozzle among a plurality of nozzles.

[0010] A7th embodiment includes an additive manufacturing apparatus according to A5, wherein adjusting the programmed deposition pattern for subsequent crossings of the print assembly on the build zone involves updating the mapping of selected nozzles from a plurality of nozzles to select pixels in the subsequent build layer, and a first nozzle mapped to distribute binder to a first selected set of pixels during a first crossing of the print assembly is mapped to distribute binder to a second selected set of pixels during a second crossing of the print assembly on the build zone.

[0011] Eighth aspect A8 Adjusting the programmed deposition pattern for subsequent crossing of the print assembly on the build zone includes performing a sub-pixel shift to align the pixels defined by the programmed deposition pattern with a plurality of jet nozzles, comprising an additive manufacturing apparatus according to any of the first aspects A1 to seventh aspects A7.

[0012] The ninth embodiment A9 further includes an additive manufacturing apparatus according to any of the first embodiments A1 to eighth embodiments A8, wherein the cleaning station is configured to clean a plurality of the nozzles of the print assembly, and the electronic control unit is further configured to interface the print assembly with one or more cleaning elements of the cleaning station if it determines the presence of an anomaly in the distributed binder pattern.

[0013] The tenth embodiment A10 includes an additive manufacturing apparatus according to any of the first embodiments A1 to the ninth embodiment A9, wherein the electronic control unit is further configured to cause the print assembly to perform a purge operation in the cleaning zone when it determines the presence of an abnormality in the distributed binder pattern.

[0014] The eleventh embodiment A11 includes an additive manufacturing apparatus according to any of the first embodiments A1 to the tenth embodiment A10, wherein the vision system includes at least one of an electromagnetic radiation source, a camera, an infrared camera, or an X-ray imaging device.

[0015] The 12th embodiment A12 comprises a process chamber having a length defined by at least a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate portions along the length of the process chamber; a support extending along the length of the process chamber in a first vertical plane; and a doctor for distributing build material into the build zone. - Additive manufacturing apparatus comprising: a recoat assembly including at least one of a blade and a roller, movably coupled to the support via a second actuator configured to move forward or backward along the length of the support, and positioned on a second vertical plane parallel to the first vertical plane; a vision system configured to image a distributed layer of build material in the build zone; and an electronic control unit communicably coupled to the recoat assembly, the second actuator, and the vision system, wherein the electronic control unit is configured to cause the recoat assembly to traverse the build zone to distribute build material according to predetermined build material input parameters to form a new layer of build material in the build zone, receive image data from the vision system of the distributed build material in the build zone, analyze the image data to determine whether there is an abnormality in the distributed build material, and if an abnormality is determined to be present in the new layer of distributed build material, to perform corrective measures for subsequent distribution of build material by the recoat assembly.

[0016] The 13th embodiment A13 includes the additive manufacturing apparatus described in the 12th embodiment A12, wherein the corrective measure includes adjusting predetermined build material input parameters.

[0017] A 14th embodiment A14 includes an additive manufacturing apparatus according to A 13th embodiment A13, wherein a predetermined build material input parameter is at least one of the build material thickness, over-input amount, recoat assembly speed for traversing the build zone, rotational speed of the rollers of the recoat assembly, and rotational direction of the rollers of the recoat assembly.

[0018] A15th embodiment includes an additive manufacturing apparatus according to any of the 12th embodiment A12 to 14th embodiment A14, wherein the modification measure includes causing the recoat assembly to redistribute the build material onto the new layer before the print assembly distributes the binder onto the new layer of build material.

[0019] The 16th aspect A16 includes an additive manufacturing apparatus as described in any of the 12th aspect A12 to the 15th aspect A15, wherein the corrective measure includes stopping the build.

[0020] The seventeenth embodiment A17 further includes a cleaning station located in the cleaning zone or the supply zone, the cleaning station being configured to clean at least one of the doctor blade and the roller of the recoat assembly, and the electronic control unit being further configured to interface the recoat assembly with one or more cleaning elements of the cleaning station if it determines the presence of an abnormality in the new layer of the distributed build material, the additive manufacturing apparatus according to any of the twelveth embodiment A12 to the sixteenth embodiment A16.

[0021] The 18th embodiment A18 includes an additive manufacturing apparatus according to any of the 12th embodiment A12 to the 17th embodiment A17, wherein the electronic control unit receives a current draw value from a motor that drives the roller of the recoat assembly, determines whether the roller is operating according to predetermined build material input parameters, and determines the presence of an abnormality in the roller of the recoat assembly if it is determined that the roller is not operating according to predetermined build material input parameters.

[0022] The 19th embodiment A19 includes an additive manufacturing apparatus according to any of the 12th embodiment A12 to the 18th embodiment A18, wherein the vision system includes at least one of a camera, an infrared camera, and an X-ray imaging device.

[0023] The 20th embodiment A20 comprises a process chamber having a length defined by at least a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate portions along the length of the process chamber; a support extending along the length of the process chamber in a first vertical plane; a print assembly movably coupled to the support via a first actuator configured to move forward or backward along the length of the support and positioned in a second vertical plane parallel to the first vertical plane; a recoat assembly movably coupled to the support via a second actuator configured to move forward or backward along the length of the support and positioned in the second vertical plane parallel to the first vertical plane; and at least one of the print assembly and the recoat assembly configured to apply energy to the build material and binder in the build zone to stimulate a curing reaction. Additive manufacturing apparatus includes one or more IR lamps coupled to one side, one or more temperature sensors configured to monitor at least one of the gas temperature of the process chamber and the surface temperature of the build material, and an electronic control unit communicatively coupled to the print assembly, the first actuator, the recoat assembly, the second actuator, one or more of the IR lamps, and one or more of the temperature sensors, wherein the electronic control unit is configured to cause one or more of the IR lamps to release energy when the print assembly or the recoat assembly traverses the build zone, to receive temperature values ​​from one or more of the temperature sensors, to determine whether the temperature values ​​are within a predetermined range, and if the temperature values ​​are not within the predetermined range, to adjust the intensity of one or more of the IR lamps or the flow gas rate of one or more of the IR lamps.

[0024] The 21st embodiment A21 includes the additive manufacturing apparatus according to the 20th embodiment A20, wherein the intensity of one or more IR lamps is increased when the temperature value is determined to be below the predetermined range.

[0025] Aspect 22: A22 includes the additive manufacturing apparatus according to any one of Aspects 20 to 21, wherein when it is determined that the temperature value exceeds the predetermined range, the intensity of one or more of the IR lamps is reduced.

[0026] Aspect 23: A23 includes the additive manufacturing apparatus according to any one of Aspects 20 to 22, wherein a first IR lamp of one or more of the IR lamps is coupled to the print assembly, and a second IR lamp of one or more of the IR lamps is coupled to the recoat assembly.

[0027] Aspect 24: A24 includes the additive manufacturing apparatus according to any one of Aspects 20 to 23, wherein the electronic control unit controls the flow gas rate around one or more of the IR lamps.

[0028] Aspect 25: A25 includes the additive manufacturing apparatus according to any one of Aspects 20 to 24, wherein one or more of the temperature sensors are gas temperature sensors, and the electronic control unit is further configured to adjust the flow gas rate of the gas around one or more of the IR lamps when it is determined that the surface temperature value of the build material is not within the predetermined range.

[0029] Aspect 26: A26 includes the additive manufacturing apparatus according to any one of Aspects 20 to 25, wherein when it is determined that the surface temperature value is below the predetermined range, the flow gas rate around one or more of the IR lamps is increased.

[0030] Aspect 27: A27 includes the additive manufacturing apparatus according to any one of Aspects 20 to 26, wherein when it is determined that the surface temperature value exceeds the predetermined range, 1 the flow gas rate around one or more of the IR lamps is reduced.

[0031] The 28th embodiment A28 further includes an environmental control system fluidly coupled to the process chamber, wherein if the environmental control system determines that the process chamber temperature is not within a predetermined process chamber range, it delivers heated gas to the process chamber, the additive manufacturing apparatus according to any of the 20th embodiment A20 to the 27th embodiment A27.

[0032] The 29th embodiment A29 further includes a build plate heater thermally coupled to the build platform of the build zone, wherein if the temperature value of the surface temperature of the build material surface is determined to be below a predetermined range, the electronic control unit increases the amount of energy delivered to the build plate heater to the build material and the build plate of the build zone, as described in any of the 20th embodiment A20 to the 28th embodiment A28.

[0033] The 30th embodiment A30 includes an additive manufacturing apparatus comprising: a process chamber having a length defined by at least a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate sections along the length of the process chamber; an environmental control system connected to the process chamber and including one or more subsystems for controlling environmental conditions within the process chamber; one or more sensors configured to monitor at least one of the temperature, vapor content, and process gas concentration within the process chamber; and an electronic control unit communicatively connected to the environmental control system and one or more of the sensors, wherein the electronic control unit is configured to receive sensor data from one or more of the sensors, determine whether the sensor data from one or more of the sensors corresponds to a predetermined set of environmental conditions for the process chamber during build, and if it is determined that the sensor data is not within the predetermined set of environmental conditions, automatically adjust the settings of one or more of the environmental control systems.

[0034] A 31st embodiment A31 further includes the additive manufacturing apparatus according to A30th embodiment A30, wherein the electronic control unit is configured to cause the environmental control system to start flow to the process chamber through the heat exchanger of the environmental control system when the sensor data indicates that the temperature of the process chamber is below the predetermined set of environmental conditions, and to cause the environmental control system to stop flow to the process chamber through the heat exchanger of the environmental control system when the sensor data indicates that the temperature of the process chamber is above the predetermined set of environmental conditions.

[0035] The 32nd embodiment A32 includes an additive manufacturing apparatus according to any of the 30th embodiment A30 to the 31st embodiment A31, wherein the electronic control unit is further configured to cause the environmental control system to start flow through the heat exchanger, dehumidifier, or condenser of the environmental control system when the sensor data indicates that the steam content exceeds the predetermined set of environmental conditions, and to cause the environmental control system to stop flow through the heat exchanger, dehumidifier, or condenser of the environmental control system when the sensor data indicates that the steam content falls below the predetermined set of environmental conditions.

[0036] The 33rd aspect A33 is that the electronic control unit, when the sensor data indicates that the process gas concentration is below the predetermined set of environmental conditions, causes the environmental control system to start flow from the process gas supply of the environmental control system, and when the sensor data indicates that the process gas concentration is above the predetermined set of environmental conditions, causes the environmental control system to stop flow from the process gas supply of the environmental control system. Includes an additive manufacturing apparatus according to any of the 30th embodiment A30 to the 32nd embodiment A32, further configured to stop.

[0037] The 34th embodiment A34 further includes a particulate sensor configured to detect the concentration of airborne build material in the process chamber, wherein the electronic control unit is further configured to cause the environmental control system to start the air filtration system of the environmental control system if the sensor data indicates that the concentration of airborne build material exceeds the predetermined set of environmental conditions, and to cause the environmental control system to stop the flow from the air filtration system of the environmental control system if the sensor data indicates that the concentration of airborne build material falls below the predetermined set of environmental conditions, the additive manufacturing apparatus according to any of the 30th embodiment A30 to the 33rd embodiment A33.

[0038] The 35th embodiment A35 comprises a process chamber having a length defined by at least a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate parts along the length of the process chamber; a support extending along the length of the process chamber in a first vertical plane; a print assembly movably coupled to the support and positioned in a second vertical plane parallel to the first vertical plane, including a plurality of nozzles for distributing binder into the build zone and configured to move forward or backward along the length of the support; a recoat assembly movably coupled to the support and positioned in a second vertical plane parallel to the first vertical plane, including at least one of a doctor blade and a roller for distributing build material into the build zone and configured to move forward or backward along the length of the support; a vision system configured to image the build zone; and the print assembly, the recoat assembly, the first actuator, the second actuator, and front The system includes an electronically controlled unit communicatively coupled to a vision system, the electronically controlled unit instructs the print assembly to traverse the build zone in the forward direction during a first interval, distributing binder according to a programmed deposition pattern; during a second interval following the first interval, the electronically controlled unit receives image data of the distributed binder pattern from the vision system, analyzes the image data to determine whether there is an anomaly in the distributed binder pattern during the second interval; the print assembly to traverse the build zone in the reverse direction during the second interval, distributing binder according to a programmed deposition pattern; the recoat assembly to traverse the build zone in the reverse direction, distributing build material supplied to the supply zone to form a new layer of build material in the build zone according to predetermined build material input parameters; and the recoat assembly, in accordance with the print assembly traversing the build zone during the second and third intervals, the electronically controlled unit instructs the print assembly to:The additive manufacturing apparatus includes a configuration that, during the third interval, causes at least one of a purging process and a wiping process to be performed while traversing the cleaning zone in both forward and reverse directions.

[0039] The 36th embodiment A36 includes the additive manufacturing apparatus according to the 35th embodiment A35, wherein the electronically controlled unit, during a fourth interval, distributes a binder according to a programmed deposition pattern on the new layer of build material, causing the recoat assembly to traverse the build zone in the forward direction, and the print assembly to traverse the build zone in the forward direction, following the recoat assembly traversing the build zone.

[0040] The 37th aspect A37 states that if the electronic control unit determines the presence of the anomaly in the distributed binder pattern, it will program the deposition pattern for subsequent crossing of the print assembly on the build zone in order to address the anomaly. Includes an additive manufacturing apparatus as described in any of the 35th aspect A35 to the 36th aspect A36, which is further configured to make adjustments.

[0041] The 38th embodiment A38 includes an additive manufacturing apparatus according to any of the 35th embodiment A35 to the 37th embodiment A37, wherein the electronic control unit is further configured to take corrective action for subsequent distribution of the build material by the recoat assembly if it determines the presence of the abnormality in the new layer of the distributed build material.

[0042] The 39th embodiment A39 includes an additive manufacturing apparatus according to any of the 35th embodiment A35 to the 38th embodiment A38, wherein the electronic control unit is further configured to cause the print assembly to perform subpixel indexing of the plurality of nozzles between the first interval and the second interval.

[0043] The 40th embodiment A40 includes an additive manufacturing apparatus according to any of the 35th embodiment A35 to the 39th embodiment A39, wherein a delay is performed before the recoat assembly begins to traverse the build zone in the reverse direction, following the print assembly that traverses the build zone during the second and third intervals.

[0044] The 41st aspect A41 includes an additive manufacturing apparatus according to any of the 35th aspect A35 to the 40th aspect A40, wherein the print assembly traverses the build zone in the forward and reverse directions at a first speed.

[0045] The 42nd embodiment A42 includes an additive manufacturing apparatus according to any of the 35th embodiment A35 to the 41st embodiment A41, wherein the print assembly traverses the cleaning zone in the forward and reverse directions at a second speed, the second speed being slower than the first speed.

[0046] The 43rd embodiment A43 further includes one or more IR lamps configured to apply energy to a binder and build material in a build zone to stimulate a curing reaction, wherein one or more of the IR lamps are coupled to at least one of the print assembly and the recoat assembly, comprising the additive manufacturing apparatus according to any of the 35th embodiment A35 to the 42nd embodiment A42.

[0047] The 44th embodiment A44 includes the additive manufacturing apparatus according to the 43rd embodiment A43, wherein two IR lamps are coupled to the recoat assembly, the first IR lamp being coupled to the front-facing surface of the recoat assembly and the second IR lamp being coupled to the rear-facing surface of the recoat assembly. [Brief explanation of the drawing]

[0048] [Figure 1A] Figure 1A depicts an exemplary process flowchart for building a component using a manufacturing apparatus and manufacturing method according to one or more embodiments shown and described herein. [Figure 1B]Figure 1B is a schematic diagram illustrating a manufacturing apparatus according to one or more embodiments shown and described herein. [Figure 2] Figure 2 schematically shows an exemplary architecture of a manufacturing apparatus according to one or more embodiments shown and described herein. [Figure 3] Figure 3 shows an exemplary flowchart of a printing method for improving reliability, according to one or more embodiments shown and described herein. [Figure 4] Figure 4 shows an exemplary flowchart of a recoating method for improving reliability, according to one or more embodiments shown and described herein. [Figure 5] Figure 5 shows a flowchart of an exemplary method relating to a curing method for improving build speed, according to one or more embodiments shown and described herein. [Figure 6] Figure 6 shows a flowchart of an exemplary method relating to an environmental control system operating method for improving reliability, according to one or more embodiments shown and described herein. [Figure 7] Figure 7 illustrates an exemplary schematic diagram of the motion of the printed and recoated assemblies in a build block according to one or more embodiments shown and described herein. [Modes for carrying out the invention]

[0049] Further features and advantages of the manufacturing apparatus described herein, as well as its components, are described in the following detailed description, some of which will be readily apparent to those skilled in the art from that description, or will be recognized by carrying out the embodiments described herein, including the following detailed description, claims, and accompanying drawings.

[0050] It should be understood that both the general description above and the detailed description below describe various embodiments and are intended to provide an overview or framework for understanding the nature and characteristics of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments and are incorporated herein and constitute part thereof. The drawings illustrate the various embodiments described herein and, together with the description, help to illustrate the principles and operation of the claimed subject matter.

[0051] Hereinafter, embodiments of the manufacturing apparatus and its components are given in detail, examples of which are shown in the accompanying drawings. Where possible, the same reference numerals are used throughout the drawings to refer to the same or similar parts.

[0052] One embodiment of an additive manufacturing apparatus comprises a process chamber defining a volume having height, length, and width. The length is defined by a plurality of processing zones. The process chamber includes a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate parts along the length of the process chamber. The process chamber includes an actuator assembly for distributing build material and depositing binder material within the additive manufacturing apparatus. The actuator assembly may generally include a support extending along the length of the process chamber in a first vertical plane. The actuator assembly may further include a recoat assembly for distributing build material and a print assembly for depositing binder material. The print assembly includes a plurality of nozzles for distributing binder 50 into the build zone. The print assembly is movably coupled to the support via a first actuator configured to move back and forth along the length of the support. The print head actuator may include a print actuation axis, where the print head actuator is actuated bidirectionally along the print actuation axis, thereby resulting in bidirectional motion of the print head. The print assembly is positioned in a second vertical plane parallel to the first vertical plane.

[0053] The recoat assembly includes one or more doctor blades and / or one or more rollers 142 for distributing build material 40 within the build zone BZ. The recoat assembly is movably coupled to the support via a second actuator configured to move back and forth along the length of the support. The recoat assembly may include a recoat actuation axis, where the recoat assembly is actuated bidirectionally along the recoat actuation axis, thereby resulting in bidirectional motion of the recoat head. The recoat assembly is positioned on a first vertical plane They may be arranged in a parallel second vertical plane. The recoat actuation axis and the print actuation axis may share the same axis, be parallel to each other, or be spaced apart from each other in the vertical direction. Embodiments of the print and recoat assemblies may further include a curing system, such as an infrared lamp, for applying energy to the build material and binder in the build zone to stimulate the curing reaction. Various embodiments of actuator assemblies for additive manufacturing apparatuses including actuator assemblies, additive manufacturing apparatuses and methods for using them are described in further detail herein with specific reference to the accompanying drawings.

[0054] The embodiments further include an environmental control system configured to control environmental conditions within a process chamber. The environmental control system may include one or more subsystems for controlling environmental conditions within the process chamber. One or more subsystems may include a heat exchanger, a dehumidifier, a condenser 182, or a similar system capable of removing vapor from the environment of the process chamber, a process gas supply source, an air filtration system (e.g., a cyclone separator), etc. The environmental control system is coupled to the process chamber via one or more ports, valves, ventilation conduits, etc. In some embodiments, the environmental control system is adapted to maintain environmental conditions within the process chamber preferred for a particular build. For example, the environmental control system can regulate the environment within a given set of environmental conditions, which may include operating ranges such as pressure, process gas concentration, relative humidity, vapor concentration in the air, build material concentration in the air, and process chamber temperature.

[0055] Furthermore, embodiments described herein more specifically disclose systems and methods for operating print assemblies, recoat assemblies, curing systems, environmental control systems, and their interactions in order to improve the reliability and speed of the build process. To further improve the reliability and speed of the build process, the manufacturing apparatus disclosed herein further implements one or more sensors and control systems configured to operate in a closed-loop control loop.

[0056] Various embodiments of the manufacturing apparatus are described in further detail herein, with particular reference to the accompanying drawings. It should be understood that the embodiments of the manufacturing apparatus shown and described herein may be configured and operable to build three-dimensional and / or non-three-dimensional objects or parts.

[0057] A range may be expressed herein as "about" one particular value and / or "about" another particular value. Where such a range is expressed, another embodiment includes one particular value and / or other particular values. Similarly, where the use of the antecedent "about" expresses a value as an approximation, it will be understood that the particular value forms another embodiment. The start and end points of a range are significant in relation to the other point (end and start point), and also have meaning independent of the other point.

[0058] The directional terms used herein, such as up, down, right, left, front, back, top, upward, bottom, forward, reverse, and back, are made solely with reference to the diagrams depicted and are not intended to imply absolute orientation unless otherwise explicitly stated.

[0059] Unless otherwise expressly stated, no method described herein is ever intended to be construed as requiring its steps to be performed in a specific order, nor as requiring any particular orientation of any apparatus. Therefore, if a method claim does not actually enumerate the order in which its steps should be followed, or if any apparatus claim does not actually enumerate the order or orientation of its individual components, or if the steps should be limited to a specific order, or if any particular orientation of the components of the apparatus is required, it is never intended to be construed as requiring its steps to be performed in a specific order, or as requiring any particular orientation of any apparatus. Unless otherwise specifically stated in the claims or description, the absence of a specific order or orientation is not intended to be inferred in any way. This applies to any possible implicit basis for interpretation, including logical issues relating to the arrangement of steps, the flow of operations, the order of components, or the orientation of components, plain meaning derived from grammatical organization or punctuation, and the number or type of embodiments described herein.

[0060] As used herein, the singular form "one," etc., includes multiple referents unless the context clearly indicates otherwise. Thus, for example, a reference to "one" component 70 includes embodiments having two or more such components unless the context clearly indicates otherwise.

[0061] The embodiments described herein relate to manufacturing equipment (e.g., additive manufacturing equipment) and components for such equipment, specifically, a print assembly for depositing binder 50, a recoat assembly for distributing build material, an environmental control system for controlling the environment within the process chamber, and one or more sensors configured to provide operational feedback to an electronic control unit to improve the reliability and speed of the build process. The embodiments described herein can implement machine vision, pattern testing, printhead maintenance, printhead index-based redundancy, etc., to establish closed-loop reliability and speed improvement processes. The control loops described herein generally include steps for detecting, analyzing, and compensating for build operations. While the technology developed and described herein relates to manufacturing, it is understood that aspects of this technology may be applied to related industries such as 2D printing.

[0062] Referring to Figure 1A, an exemplary process flowchart for building component 80 using the manufacturing apparatus 100 and manufacturing method is shown. Figure 1A is intended to provide a non-limiting overview of the manufacturing apparatus 100 and manufacturing method shown and described in detail herein. The apparatus 100 is configured to perform one or more predefined operations, such as those defined by build instructions executed by the control system 10.

[0063] As used herein, “build instructions” refer to control commands for manipulating the operation of the apparatus 100 to build component 80. Build instructions are defined, for example, by a design deposition pattern for each layer of component 80 to be built, and by a set of operational controls that define the ordered operation of motors, actuators, print assemblies, jet nozzles, and various other components of the apparatus 100 to build component 80. Build instructions are defined based on the component design or model and mechanical specifications of the apparatus 100. For example, the apparatus 100 may include a predetermined fixed distance between jet nozzles in the print head, referred herein as “jet spacing.”

[0064] The apparatus 100 further receives build material 40 and binder 50, which can be deposited layer by layer and drop by drop, respectively, according to build instructions for building component 80. For example, the apparatus 100 may use a recoat assembly 140 (Figure 1B) to form a layer of powder 60 (also referred to herein as a layer of build material 40) on a build plate 120 (Figure 1B), and then use a print assembly 150 (Figure 1B) in a pixel 31 to deposit one or more drops of binder 50, thereby forming a voxel 30. The “build material” may include binder 50, an energy source, and one or more organic and / or inorganic materials that, when combined, harden to form part of component 80.

[0065] As used herein, “pixel” refers to a two-dimensional spatial portion of an object or part printed by the apparatus 100, in particular, the current slice or layer of a three-dimensional portion relative to its positioning along the build plate 120. Each pixel corresponds to an image pixel defined in the design deposition pattern of the build instruction. An image pixel is a digital representation of a pixel. An image pixel includes a width defined by the jet spacing of the jet nozzles of the apparatus 100. As used herein, “voxel” refers to a three-dimensional spatial portion of powder in the build plate 120, defined by one or more drops of binder 50 deposited within a pixel forming the current slice or layer of a three-dimensional portion (e.g., component 80). It is understood that voxels do not have to be cubic, as the shape of the voxel depends on the wicking and curing behavior of the binder 50 having the build material 40 (e.g., a layer of powder on which the binder 50 is deposited).

[0066] The binder 50 may be deposited in varying amounts at various locations within a layer of powder 60 (e.g., build material 40) in the form of drops. The location and amount of the drops are defined in the “designed deposition pattern,” which refers to a set of image pixels that form a pattern of a desired slice of the build file, and when applied to the layer of powder 60 by the apparatus 100, it defines the “applied deposition pattern.” The design deposition pattern defines the amount (e.g., “drop volume”) and location (e.g., the location of the center of the binder 50 drops on the layer of powder 60), while the applied deposition pattern refers to the distribution of the binder 50 through the layer of powder, which may include overlaps between adjacent pixels or into the lower layer of powder. As used herein, “drop volume” refers to the volume of binder drops released from the jet at one time. Multiple drops may be released for a single pixel, and the number of drops varies in units of volume. After the formation of one or more layers of powder 60 and the attachment of one or more drops of binder 50, the apparatus 100 forms a component 80. More specific methods for forming the component 80 and embodiments of the apparatus 100 are described in detail below.

[0067] Referring here to Figure 1B, one embodiment of the manufacturing apparatus 100 is schematically shown. The apparatus 100 includes a process chamber 101. The process chamber 101 may be an hermetically sealed chamber and / or, otherwise, a pressurized or depressurized (e.g., maintained at or near vacuum) chamber for building components 70 under specific environmental conditions, such as those controlled by the environmental control system 180 (Figure 2). The process chamber 101 is defined by a volume having height, length, and width. The length is defined by a plurality of processing zones. The processing zones include a cleaning zone "CZ", a build zone "BZ", and a supply zone "SZ", which are sequentially arranged in separate parts along the length of the process chamber 101 (along the + / - X axis). The apparatus 100 includes a cleaning station 108, a build plate 120, a supply platform 130, a recoat assembly 140, and a print assembly 150. The cleaning zone "CZ" may include elements of the manufacturing equipment 100, such as a cleaning station 108 and a jet test / purge area 109. The build zone "BZ" may include elements of the manufacturing equipment 100, such as a build plate 120, a build plate heater 121, a build platform actuator 122, and a build receptacle 124. The supply zone "SZ" may include elements of the manufacturing equipment 100, such as a lower build material hopper 172 (Figure 2) that can receive build material 40 from an upper build material hopper 170 (Figure 2), and a supply platform 130 that can receive build material 40 from the lower build material hopper 172 (Figure 2).

[0068] The recoat assembly 140 and the print assembly 150 are coupled to the support 104 of the device 100 and operate in response to the operation of the first and second actuator assemblies 102 and 103. The rails are configured to translate along the support 104. For example, the support 104 may be a linear actuator in which one or more actuator assemblies 102, 103 can operate independently and simultaneously. In some embodiments, the support 104 may have a rectangular or square vertical cross-section (i.e., a cross-section in the YZ plane of the coordinate axes shown in the figure), and in other embodiments, the rail 104 may have an "i" shaped vertical cross-section (i.e., a cross-section in the YZ plane of the coordinate axes shown in the figure). The first actuator assembly 102 and the second actuator assembly 103 may be configured to facilitate independent control of the print assembly 150 and the recoat assembly 140, respectively, along the actuation axis 116 of the device 100. The actuation axis 116 is also referred to herein as the "longitudinal axis" (i.e., extending along the + / -X axis as shown in the figure). This allows the recoat assembly 140 and the print assembly 150 to traverse the actuation axis 116 of the apparatus 100 in the same and / or opposite directions, and to traverse the actuation axis 116 of the apparatus 100 at various speeds and / or the same speed. The independent actuation and control of the recoat assembly 140 and the print assembly 150 allows at least several steps of a manufacturing process (e.g., an additive manufacturing process) to be executed simultaneously, thereby making the total cycle time of the manufacturing process shorter than the sum of the cycle times for each individual step. In other embodiments, the apparatus 100 may include additional actuator assemblies coupled to the recoat assembly 140, the print assembly 150, etc.

[0069] In some embodiments, a third actuator assembly 105 may be built to facilitate independent control of the print assembly 150 along a transverse axis (e.g., extending along the + / -Y axis as shown in the figure) that is approximately perpendicular to the longitudinal axis (e.g., the actuation axis 116, + / -X axis as shown in the figure). As will be described in more detail herein, the third actuator assembly 105 can provide fine movements of the print assembly 150 along the transverse axis, which are referred to herein as indexes. The first actuator assembly 102 and the third actuator assembly 105 are generally referred to as a print head position control assembly. That is, a print head position control assembly includes a first actuator assembly 102 configured to move the print head along the longitudinal axis and a third actuator assembly 105 configured to move the print head along the transverse axis. The print head position control assembly may be controlled via signals generated by a control system 10, such as an electronic control unit 10. The electronic control unit 10 may include a processor 10a and non-temporary computer-readable memory 10b.

[0070] In some embodiments, the first actuator assembly 102 includes a position sensor 102a, and the second actuator assembly 103 includes a position sensor 103a that provides the electronic control unit 10 with position information of the recoat assembly 140 and / or print assembly 150 in a feedback control signal, so that the electronic control unit 10 can track the position of the recoat assembly 140 and / or print assembly 150 in response to the provided control signals. In some examples, the electronic control unit 10 can adjust the control signals provided to the first actuator assembly 102 and the second actuator assembly 103 based on the position information provided by the position sensors 102a and 103a. In embodiments, the position sensors 102a and 103a may be encoders, ultrasonic sensors, optical-based sensors, magnetic sensors, etc., embedded in or coupled to the first actuator assembly 102, the second actuator assembly 103, and / or the support 104.

[0071] As described above, in the embodiments described herein, both the recoat assembly 140 and the print assembly 150 are mounted on the operating axis 116 of the apparatus 100 (for example, on the second vertical plane) They are arranged (inside). Therefore, the movement of the recoat assembly 140 and the print assembly 150 on the actuation axis 116 occurs along the same axis and is therefore collinear. In this configuration, the recoat assembly 140 and the print assembly 150 can occupy the same space (or part of the same space) along the actuation axis 116 of the apparatus 100 at various times during a single build cycle. In other embodiments, components of the manufacturing apparatus 100 that cross the actuation axis 116, such as the recoat assembly 140 and the print assembly 150, do not need to be centered on the actuation axis 116. In this case, at least two of the components of the manufacturing apparatus 100 are positioned relative to the actuation axis 116 such that when the components cross the actuation axis 116, the components can occupy the same or overlapping volumes along the actuation axis 116.

[0072] The recoat assembly 140 is configured to facilitate the distribution of build material 40 from a supply source of build material 40 located on the supply platform 130 to the build plate 120. As described in more detail herein, the print assembly 150 is configured to facilitate the adhesion of binder material 50 and / or other jettable constituent materials (e.g., ink, fluid medium, nanoparticles, fluorescent microparticles, sintering aids, anti-sintering aids, etc.) onto the build plate 120 when the print assembly 150 traverses the BZ along the operating axis 116 of the apparatus 100. In the embodiments of the apparatus 100 described herein, the operating axis 116 of the apparatus 100 is parallel to the + / -X axis of the coordinate axes shown in the figure. In the embodiments described herein, the cleaning station 108, the build plate 120, and the supply platform 130 are arranged in series along the operating axis 116. The recoat assembly 140 and the print assembly 150 are also arranged in series along the operating axis 116 of the apparatus 100 and in parallel within the cleaning station 108, the build plate 120, and the supply platform 130. Furthermore, the recoat assembly 140 and the print assembly 150 are also arranged in series along the operating axis 116 of the apparatus 100, between the home position 151 of the print assembly 150, which is located near the -X end of the operating axis 116, and the home position 153 of the recoat assembly 140, which is located near the +X end of the operating axis 116. That is, the home position 151 of the print assembly 150 and the home position 153 of the recoat assembly 140 are spaced apart laterally parallel to the + / -X axes of the coordinate axes shown in the figure, with at least the build plate 120 and the supply platform 130 located between them. In this embodiment, the build plate 120 (e.g., BZ) is positioned along the operating axis 116 of the device 100 between the cleaning station 108 (e.g., CZ) and the supply platform 130 (e.g., SZ).

[0073] Referring further to Figure 1B, the cleaning station 108 is positioned close to one end of the operating shaft 116 of the apparatus 100 and is positioned at the same home position 151 where the print assembly 150 is located, or "parked" before and after the build material 50 is deposited on the build material 40 located on the build plate 120. The cleaning station 108 may include one or more cleaning units to facilitate the cleaning of the print assembly 150, in particular the cleaning of the multiple print heads 156 of the print assembly 150 during the deposit operation. The cleaning station 108 may include, but is not limited to, an immersion station containing a cleaning solution for dissolving excess binder material 50 from multiple print heads 156, a wiping station for removing excess binder material 50 and / or cleaning solution from multiple print heads 156, a jet test / purge area 109 for testing the binder deposition pattern and / or purging the binder material 50 and / or cleaning solution from multiple print heads 156, a capping station for maintaining moisture in multiple jet nozzles 158 of the multiple print heads 156, or various combinations thereof. The print assembly 150 is cleaned between the first actuator assembly 102. It may be transitioned. In some embodiments, the apparatus 100 may include a jet test / purge area 109 positioned close to one end of the operating shaft 116 adjacent to the cleaning station 108 and / or home position 151. It should be understood that the jet test / purge area 109 of the apparatus 100 may be configured to facilitate material deposition by the print assembly 150 before deposition along the build plate 120. When the jet test / purge area 109 functions as a jet test area, the print assembly 150 can distribute the material of the binder 50 in a predetermined pattern. The distributed pattern can then be captured by the vision system 14 and analyzed by the electronic control unit 10 to determine whether there is a problem with the nozzle 158 or print head 156 of the print assembly 150.

[0074] The build plate 120 is coupled to the build platform actuator 122 to facilitate raising and lowering the build plate 120 perpendicular to the operating axis 116 of the device 100 (for example, parallel to the + / -Z directions of the coordinate axes shown in the figure). The build platform actuator 122 can be, for example, a mechanical actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator, or any other actuator suitable for imparting linear motion to the build plate 120 in a vertical direction, but is not limited to these. Suitable actuators include, but are not limited to, worm-driven actuators, ball screw actuators, pneumatic pistons, hydraulic pistons, and electromechanical linear actuators. The build plate 120 and the build platform actuator 122 are located within the build receptacle 124, which is located below the operating axis 116 of the device 100 (i.e., in the -Z direction of the coordinate axes shown in the figure). During the operation of the apparatus 100, the build plate 120 is retracted into the build receptacle 124 by the operation of the build platform actuator 122 after each layer of binder material 50 has been deposited on the build material 40 placed on the build plate 120. In some embodiments, the build plate 120 may further include a build plate heater 121 coupled to it. The build plate heater 121 applies energy to the build material 40 and / or binder 50 on the build plate 120 to facilitate the deposition process and / or curing process. The faster the binder 50 and build material 40 in the layers cure, the more processing capacity the apparatus 100 can achieve, as new layers can be printed rapidly and continuously. As described herein, the apparatus 100 may also include other supply sources and forms of energy directed to the build material 40 and binder 50 in the build zone to accelerate the curing block.

[0075] Referring further to Figure 1B, the supply platform 130 is coupled to a supply platform actuator 132, which facilitates raising and lowering the supply platform 130 vertically (i.e., parallel to the + / -Z directions of the coordinate axes shown in the figure) relative to the operating axis 116 of the device 100. The supply platform actuator 132 can be, for example, a mechanical actuator, an electromechanical actuator, a pneumatic actuator, a hydraulic actuator, or any other actuator suitable for imparting linear motion to the supply platform 130 vertically, but is not limited to these. Suitable actuators include, but are not limited to, worm-driven actuators, ball screw actuators, pneumatic pistons, hydraulic pistons, and electromechanical linear actuators. The supply platform 130 and the supply platform actuator 132 are located in a supply container 134 situated below the operating axis 116 of the device 100 (i.e., in the -Z direction of the coordinate axes shown in the figure). During the operation of the apparatus 100, the supply platform 130 rises toward the operating axis 116 of the apparatus 100 relative to the supply container 134 by the action of the supply platform actuator 132, after a layer of build material 40 has been distributed from the supply platform 130 to the build plate 120, as will be further described herein. In this embodiment, please understand that the apparatus 100 does not include, for example, a supply platform 130, such as in an embodiment in which build material 40 is supplied to the build plate 120 using a build material hopper.

[0076] Embodiments of the additive manufacturing apparatus 100 include one or more energy sources 160 for heating and / or curing the build material 40 and the binder 50. In embodiments, the recoat assembly 140 and / or the print assembly 150 may include one or more energy sources 160 for accelerating the curing and / or phase change of the build material 40 and the binder 50. One or more energy sources 160 may include infrared lamps (IR lamps 160), ultraviolet sources, and / or other types of energy sources. The intensity, exposure duration, and other parameters of one or more energy sources 160 may be controlled by an electronic control unit 10, as well as related hardware components such as power circuits and control circuits. As shown, a first IR lamp 160A is coupled to a front-facing surface (e.g., facing in the +X direction) of the print assembly 150, a second IR lamp 160B is coupled to a back-facing surface (e.g., facing in the -X direction) of the recoat assembly 140, and a third IR lamp 160C is coupled to a front-facing surface of the recoat assembly 140.

[0077] The manufacturing apparatus 100 further includes sensors for monitoring the operation and environmental conditions of the apparatus 100's components. Sensor 20 is communicatively coupled to an electronic control unit 10. The electronic control unit 10 is configured to receive sensor data from the sensors, analyze the sensor data, and implement control functions such as build parameter compensation on the fly and adjustments to environmental conditions within the process chamber 101. Sensor 20 may include one or more temperature sensors 21 (e.g., a pyrometer, thermocouple, thermistor, or other types of temperature sensors configured to measure surface or bulk temperatures of liquids, solids, or gases), a relative humidity sensor 22, a process gas concentration sensor 23, a current sensor 24, a particulate sensor 25, a force sensor 26, a lower explosion limit (LEL) monitor 27, a volatile organic compound (VOC) sensor 28, or similar solvent vapor concentration sensors, an oxygen sensor (O2 sensor) 29, and other sensors. It should be understood that the sensor 20 may be statically mounted within the process chamber 101 or may be movably coupled to one or more movable assemblies within it (e.g., print assembly 150, recoat assembly 140, etc.). A movable sensor 20 can provide the advantage of the sensing area of ​​the process chamber 101 when the build process is in operation, where detection would be obstructed by moving components of the manufacturing apparatus 100. The operation of the sensor 20 will be described in more detail with reference to the flowchart disclosed herein.

[0078] Figure 1B shows at least two implementations of the vision system 14 (e.g., 14A and 14B). It should be understood that the vision system 14 is not limited to these two positions and configurations. The manufacturing apparatus 100 may include the vision system 14A coupled to the support 104. The vision system 14A may also be a field monitoring system used to capture image data of the build zone during the build process. Alternatively, the vision system 14A may be movably coupled to the support 104 so that it can move along the support when the print assembly 150 and recoat assembly 140 also move along the support 104. The vision system 14A may capture various angles and fields of view of zones (e.g., CZ, BZ, SZ) within the process chamber 101, more specifically, the BZ (e.g., the build on the build plate 120). The image data of the component 70) can be panned, tilted, and / or zoomed. The print assembly 150 or recoat assembly 140 is imaged while passing through the BZ so that it can be determined whether there are any anomalies in the distributed binder pattern or the distributed build material 40 of the new layer.

[0079] In some embodiments, the vision system 14 may be a vision system 14B coupled to either or both of the print assembly 150 and the recoat assembly 140. In such examples, the vision system 14B may be configured to capture image data of the BZ as the print assembly 150 and the recoat assembly 140 complete their pass through the BZ. As the speed at which the print assembly 150 and the recoat assembly 140 traverse the BZ increases, the time that a stationary mounted vision system 14A must capture a complete field of view image of the build plate 120 decreases or disappears. However, by implementing a vision system 14 (14A or 14B) that can move with and / or around the movement of the print assembly 150 and the recoat assembly 140, the vision system 14A or 14B may be able to capture a continuous, unobstructed image of the BZ as the print assembly 150 and / or the recoat assembly 140 pass over the BZ. The captured image data may then be combined to unfold a complete image of the active build on the build plate 120.

[0080] The vision system 14 is communicatively coupled to the electronic control unit 10. The vision system 14 may be any device having an array of sensing devices (e.g., pixels) capable of detecting radiation in the ultraviolet wavelength band, the visible light wavelength band, or the infrared wavelength band. The vision system 14 may implement one or more cameras or other imaging devices such as an X-ray apparatus. The vision system 14 may include one or more cameras that are sensitive to detecting electromagnetic radiation in the visible spectrum, the infrared spectrum, and / or the ultraviolet spectrum. Thus, the vision system 14 may include an electromagnetic radiation excitation source such as a lamp, an infrared emitter, or an ultraviolet light source, which directs electromagnetic radiation onto surfaces such as the build material 40 and binder 50 in the build zone BZ, which is reflected from the build zone BZ to one or more cameras and captured by one or more cameras of the vision system 14. In some embodiments, reflected light from a visible spectrum light source such as a lamp can illuminate powder gouging, short diffusion, missing areas, etc., of the binder 50 through contrast analysis of the captured image data. Generally, image data captured in visible light is useful for detecting large defect areas, but other electromagnetic radiation sources can be used to detect smaller defect areas. In some embodiments, a vision system 14 configured to detect and capture infrared radiation can be used to develop thermal imagery of the build material 40 and binder 50 within the build zone BZ. In such cases, the thermal imagery can be analyzed to determine the depth of penetration of the binder 50 into the build material 40, and / or other defects not visible through visible light inspection of the build zone BZ. In some embodiments, the vision system 14 may be configured to detect and capture image data of the build material 40 and binder 50 within the build zone BZ that is excited, for example, by ultraviolet light. The sensitivity of the vision system 14 to ultraviolet light provides image data with enhanced contrast between the binder 50 and the build material 40 within the build zone BZ.Image data with enhanced contrast between the binder 50 and the build material 40 includes a higher signal-to-noise ratio compared to other image data captured under various illumination sources. While the embodiments described above are described for the purpose of capturing image data and determining anomalies in the build from the image data, the embodiments described above can also be used in machine vision-enabled automated depowdering to determine whether a part is completely depowdered (e.g., the fluorescence surface intensity is greater than the threshold when powder is present).

[0081] One or more cameras may have any resolution. One or more cameras may be omnidirectional cameras or panoramic cameras. In some embodiments, one or more optical components, such as mirrors, fisheye lenses, or any other type of lens, may be optically coupled to each of the one or more cameras. In embodiments described herein One or more cameras can provide image data to the electronic control unit 10.

[0082] The electronic control unit 10 can perform one or more image analysis processes to determine the presence of anomalies in the distributed binder pattern or a new layer of distributed build material 40. These processes may include machine vision analysis, machine learning algorithms, artificial intelligence (AI), and the like. In some embodiments, the electronic control unit 10 can determine anomalies based on discrepancies in light levels (e.g., light intensity) or contrast differences in image data of the build material 40 on the build plate 120. A discrepancy in light intensity may indicate defects in the recoat layer, such as short spreads of binder 50, gouging, or missing areas. With respect to the binder deposition pattern, differences in light intensity can also be used to identify deposited binder patterns, and the electronic control unit 10 can compare the identified deposited binder pattern with expected or predefined binder patterns for a particular layer of the build.

[0083] In some embodiments, the electronic control unit 10 maintains a log of feedback parameters from various sensors and systems of the device 100. The log can be compiled and analyzed by the electronic control unit 10, along with examples of anomalies detected, in order to develop predictive analysis. Thus, the electronic control unit 10 can predict when an anomaly will occur based on a series of events or sensor readings prior to the anomaly occurring, by overtime. For example, if a layer-by-layer increase in current related to the rollers of the recoat assembly 140 exists before an anomaly is detected in the image data, the electronic control unit 10 can perform preventive maintenance or other corrective measures before the anomaly occurs. For example, if the system detects a defect, the first action is to record the defect and record the sensor data set of the device 100 for the instant layer and a predetermined number of previous layers. This recorded data can later be used for the development of predictive analysis.

[0084] The print assembly 150 comprises, among other features, a support bracket 152, a print head 154, and a plurality of print heads 156. The support bracket 152 is movably coupled to the support 104 and a first actuator assembly 102 of the apparatus 100, while the print head 154 is positioned along opposing ends of the support bracket 152 and movably coupled to it via a third actuator assembly 105 configured to movably index the print head along the lateral direction. As will be described in more detail herein, the print head 154 of the print assembly 150 may include two or more rows of a plurality of print heads 156, and in some embodiments, at least one of these is movable relative to another row of the plurality of print heads 156. This makes it possible to perform at least the material deposition step of a manufacturing block by changing the relative position of at least one movable print head row 156, thereby increasing jet reliability and jet resolution.

[0085] However, in some embodiments, the print assembly 150 includes multiple print heads 156, each containing a plurality of jet nozzles 158. The plurality of jet nozzles 158 are spaced apart from each other in a direction transverse to the longitudinal axis, and the distance from a first jet nozzle to a second jet nozzle located adjacent to the first jet among the plurality of jets defines the jet spacing.

[0086] Referring further to Figure 1B, the manufacturing apparatus 100 is a control system communicatively coupled to the first actuator assembly 102, the third actuator assembly 105 (collectively referred to herein as the print head position control assembly), the recoat assembly 140, the second actuator assembly 103, and / or the print assembly 150. The system may further include component 10. In some embodiments, the control system 10 may be coupled in particular to one or more actuators of the print assembly 150. In this example, the control system 10 is coupled to the device 100 via a communication conduit 12, but it should be understood that in other embodiments, the control system 10 may be communicably coupled to the device 100 via various other means or systems, such as via a wireless connection. The control system 10, sometimes referred to as the electronic control unit 10, comprises a processor 10a and a non-temporary memory 10b containing stored computer-readable and executable instructions. Any operation of the device 100, including the operations described herein, may be performed by computer-readable and executable instructions stored in the non-temporary memory 10b of the electronic control unit 10 (e.g., build instructions defining sliced ​​files and / or deposition patterns for layers of component 70 to be built, predefined build material input parameters, predefined environmental conditions, etc.) when performed by the processor 10a of the electronic control unit 10.

[0087] For example, one or more actuators of the first actuator assembly 102 (e.g., mechanical actuators, electromechanical actuators, pneumatic actuators, hydraulic actuators, worm-driven actuators, ball screw actuators, pneumatic pistons, hydraulic pistons, electromechanical linear actuators, etc.) can be operated by computer-readable and executable instructions stored in the non-temporary memory of the control system 10 when executed by the processor 10a of the electronic control unit 10, causing the print assembly 150 and / or recoat assembly 140 to move in the manner described herein. Furthermore, as will be described in more detail below, computer-readable and executable instructions stored in the non-temporary memory 10b, when executed by the processor 10a, can cause the electronic control unit 10 to perform various operations such as moving the print assembly 150, operating one or more actuators 105 of the print assembly 150 to move the row of print heads 156, depositing material on the build material 40 (e.g., powder or other material) in the build plate 120, etc.

[0088] In some embodiments, the electronic control unit 10 may be further coupled to a computing device 15, optionally, via a network 16, or directly via a communication link such as a wired or wireless connection. The computing device 15 may include a display 15a, a processing unit 15b (e.g., having at least a processor 10a and memory), and an input device 15c, each of which may be coupled together and / or to the network 16 for communication. The computing device 15 may be configured to perform processes such as generating executable instructions for building component 70 using the apparatus 100. This method may implement CAD or other related 3D drafting and rendering systems and a slicing engine, etc. The slicing engine may be configured to receive a model or drawing of component 70 for processing, build a model or drawing into build instructions that define a number of motion control operations, powder layer placement, deposition patterns for the binder, etc., performed by the apparatus 100 to build component 70. The slicing engine can determine the number of powder layers that the build should contain, and the position within the powder layers where the binder 50 should be distributed. The depositional form of the binder 50 may also include defining the size (volume) of the binder 50 distributed at specific locations within the powder layer.

[0089] In some embodiments, network 16 is a personal area network that utilizes Bluetooth® technology to connect the control system 10 in a communicative manner. In other embodiments, network 16 is one or more computer networks (e.g., a personal area network, a local area network, or a wide area network). This may include area networks, cellular networks, satellite networks, and / or global positioning systems, as well as combinations thereof. Thus, the control system 10 and / or device 100 may be communicably coupled to network 16 via wire, via a wide area network, via a local area network, via a personal area network, via a cellular network, via a satellite network, etc. A suitable local area network may include wired Ethernet® and / or wireless technologies such as Wi-Fi, for example. A suitable personal area network may include wireless technologies such as IrDA, Bluetooth®, Wireless USB, Z-Wave, ZigBee®, and / or other short-range communication protocols. A suitable personal area network may also include wired computer buses such as USB and FireWire®, for example. A suitable cellular network includes, but is not limited to, technologies such as LTE, WiMAX, UMTS, CDMA, and GSM®.

[0090] The apparatus 100 further includes one or more fluid reservoirs 110, 112 fluidically coupled to the print assembly 150 via one or more conduits. In some embodiments, the print assembly 150 may also include one or more local fluid manifolds 110A and 112A for locally storing fluid. In particular, one or more fluid reservoirs may be fluidically coupled to one or more local fluid manifolds 110A and 112A of the print assembly 150. In this case, each of the multiple jet nozzles 158 of the multiple print heads 156 are in fluid communication with the material stored in one or more local fluid manifolds 110A and 112A. Figure 1B shows one or more fluid reservoirs, such as one including a first fluid reservoir 110 containing a first material 114 stored therein, and a second fluid reservoir 112 containing a second material 115 stored therein, where the first material 114 is different from the second material 115. The first fluid reservoir 110 is in fluid communication with the plurality of print heads 156 via the first conduit 111, and the second fluid reservoir 112 is in fluid communication with the plurality of print heads 156 via the second conduit 113. In some embodiments, the first fluid reservoir 110 and the second fluid reservoir 112 may contain the same material. In some embodiments, the plurality of print heads 156 may be coupled to a single fluid reservoir containing the same material so that the plurality of print heads 156 are configured to deposit the same material.

[0091] As will be described in more detail herein, in some embodiments, a first fluid reservoir 110 is coupled to a plurality of printheads 156 of a subset (i.e., a first subset) different from a second fluid reservoir 112 (i.e., a second subset), and the plurality of printheads 156 collectively receive and distribute each of the first material 114 and the second material 115, while each of the plurality of printheads 156 of the print assembly 150 receives and distributes either the first material 114 or the second material 115. In other embodiments, a first conduit line 111 and a second conduit line 113 may be coupled to each other by a coupling mechanism such as a manifold or valve. In this example, fluid reservoirs 110, 112 are in fluid communication with the coupling mechanism via conduit lines 111, 113, and the coupling mechanism includes a third conduit line coupled to it and extending to the printhead 154. The coupling mechanism may be configured to selectively shift the fluid communication between the fluid reservoirs 110, 112 and the print heads 154 so that, depending on the operation of the coupling mechanism, multiple print heads 156 receive either the first material 114 or the second material 115. It should be understood that the coupling mechanism may be further configured to facilitate simultaneous fluid communication between the first fluid reservoir 110 and the second fluid reservoir 112 and the print assembly 150 so that multiple print heads 156 receive both materials 114, 115 simultaneously. In some embodiments, one or more valves, one or more pumps, or both are located in the conduit lines 111, 113 to control the flow of binder 50 to the print heads 156. The printhead 156 may be fluidically coupled to it. In some cases, the pump and valve may be operated to cause an increase in pressure on the flow of binder 50 in and / or distributed from the nozzles 158 of the printhead 156. Such operation is called a purging operation and can be used to clean the nozzles 158 and improve the operation of the printhead 156.

[0092] Referring here to Figure 2, an exemplary embodiment of the manufacturing apparatus 100 is shown. As described herein, the manufacturing apparatus 100 includes a process chamber 101, a support 104, a cleaning station 108, a build plate 120, a supply platform 130, a recoat assembly 140, a print assembly 150, a lower build material hopper 172, an upper build material hopper 170 that subsequently supplies to the supply platform 130, and an environmental control system 180. The process chamber 101 includes a cleaning zone CZ, a build zone BZ, and a supply zone SZ sequentially arranged in separate sections along the length of the process chamber 101. The process chamber 101 includes an actuator assembly for distributing build material 40 and depositing binder material 50 into the additive manufacturing apparatus 100. The actuator assembly may generally include a support 104 extending along the length of the process chamber 101 in a first vertical plane (e.g., along the + / -X axis). The actuator assembly may further include a recoat assembly 140 for distributing build material 40 and a print assembly 150 for depositing binder material 50. The print assembly 150 is movably coupled to the support 104 via a first actuator 102 (Figure 1B) configured to move in the forward (F) (+X axis) and backward (R) (-X axis) directions along the length of the support 104. The print assembly 150 is positioned in a second vertical plane parallel to the first vertical plane.

[0093] The recoat assembly 140 includes one or more powder spreading members, such as one or more doctor blades 141 (Figure 1B) and / or one or more rollers 142 (Figure 1B), to distribute the build material 40 onto the build plate 120 in the BZ. One or more rollers 142 may be motor-driven or passively rotating members to rotate and distribute the build material 40. In either case, the rotation of one or more rollers 142 can be monitored using the current sensor 24 to determine, for example, whether the recoat assembly 140 is resistant to the rotation of the rollers as it crosses the SZ and BZ. In some embodiments, the recoat assembly 140 includes a roller brush 143 (Figure 1B) that can be in contact with and rotated to clean one or more powder spreading members.

[0094] The recoat assembly 140 is movably coupled to the support 104 via a second actuator 103 (Figure 1B) configured to move forward (F) and backward (R) along the length of the support. The recoat assembly 140 may include a recoat actuation axis that allows the recoat assembly 140 to actuate bidirectionally along the recoat actuation axis, thereby giving rise to bidirectional motion of the recoat assembly 140. The recoat assembly 140 is positioned in a second vertical plane parallel to the first vertical plane. The recoat actuation axis and the print actuation axis may share the same axis, be parallel to each other, or be spaced apart from each other in the vertical direction.

[0095] The BZ includes a build plate 120. The build plate 120 may be located within a build receptacle 124 that is optionally airtight to the process chamber 101. The supply zone SZ includes a supply platform 130 configured to supply build material 40 to the recoat assembly 140 for distribution across the build zone BZ. The supply platform 130 may be coupled to a lower build material hopper 172 via one or more control and transport mechanisms that provide a continuous and stable supply of build material 40. The upper build material hopper 170 supplies build material 40 to the lower build hopper 1 The supply platform 130 may include an electrically or pneumatically operated valve (not shown) that can be released into the supply platform 130 to transfer the build material 40 onto the supply platform 130. The build material 40 on the supply platform 130 may be transferred from there to the build plate 120 as the recoat assembly 140 traverses the build plate 120. The supply platform 130 may be operated up and down (along the + / - Z axis) so that the lower build hopper 172 can transfer additional build material 40 onto the supply platform 130 (e.g., when in the lower position), and the recoat assembly 140 can push the build material 40 from the supply platform 130 onto the build plate 120 (e.g., when the supply platform 130 is in the upper position).

[0096] The cleaning zone CZ includes a cleaning station 108. The cleaning station 108 may include one or more cleaning units to facilitate cleaning of the print assembly 150, particularly the multiple print heads 156 of the print assembly 150, during binder deposition operations. The cleaning units may include, but are not limited to, an immersion station containing a cleaning fluid for dissolving excess binder material 50 from the multiple print heads 156, a wiping station for removing excess binder material 50 and / or cleaning fluid from the multiple print heads 156, a jet station for purging the binder material 50 (e.g., to re-establish the meniscus within the jet nozzles 158), and / or a jet station for purging the cleaning fluid from the multiple print heads 156, a capping station for maintaining moisture within the multiple jet nozzles 158 of the multiple print heads 156, or various combinations thereof. The print assembly 150 may be moved between cleaning units by the first actuator assembly 102. In some embodiments, the apparatus 100 may include a jet test / purge area 109 (for example, where a print assembly 150 can perform a purging process) positioned near one end of the operating shaft 116 adjacent to the cleaning station 108 and / or home position 151 (Figure 1B). The jet test / purge area 109 of the apparatus 100 may be configured to facilitate material deposition (e.g., purge blocks) by the print assembly 150 before deposition along the build plate 120. In some embodiments, the jet test / purge area 109 functions as a jet test area. In such examples, the print assembly 150 can distribute binder 50 material in a predetermined pattern referred to herein as a spit / test pattern. For example, the spit / test pattern may include a spatial arrangement of points and / or lines of binder 50 distributed by corresponding jet nozzles and spatially arranged in such a way that identification between individual jet nozzles is possible.Therefore, the distributed pattern, when captured by the vision system 14 and analyzed by the electronic control unit 10, can provide information such as the health of the jet nozzles, including volume output, trajectory alignment (e.g., straightness), and the spatial arrangement between the individual jet nozzles 158 of the multiple jets (e.g., yaw, offset, and / or overlap). The distributed pattern can then be captured by the vision system 14 and analyzed by the electronic control unit 10 to determine whether there is a problem with the nozzles 158 or print head 156 of the print assembly 150. To determine whether there is a problem with the nozzles 158 or print head 156 of the print assembly 150, the electronic control unit 10 can compare the captured image of the distributed pattern with historical image data or image data of the expected distributed pattern.

[0097] The manufacturing apparatus 100 further includes an environmental control system 180. The environmental control system 180 is connected to the process chamber 101 via one or more ports, valves, ventilation conduits, etc. The environmental control system 180 includes one or more subsystems for controlling the environmental conditions within the process chamber 101. One or more subsystems include heat exchange The subsystem may include a device 181, a dehumidifier and / or condenser 182, a process gas supply source 183, an air or process gas filtration system 184, and the like. Each subsystem may include one or more controllable valves that can be operated or deactivated electronically or pneumatically by the electronic control unit 10, so that the valves can be closed or the subsystem can be connected to or disconnected from the process chamber 101. In some embodiments, the environmental control system 180 is adapted to maintain environmental conditions within the process chamber 101 that are favorable for the build. For example, the environmental control system 180 can adjust the environment within a predetermined set of environmental conditions, which may include operating ranges such as pressure, process gas concentration, relative humidity, solvent vapor concentration, concentration of suspended build material 40, and temperature of the process chamber 101.

[0098] Next, referring to Figures 3 to 6, flowcharts illustrating exemplary methods of operating the manufacturing apparatus 100 are shown. More specifically, the exemplary methods disclose closed-loop control methods that improve the reliability and speed of building component 70. For example, generally, the methods include steps of detecting, analyzing, and compensating for build operations in order to improve reliability and increase the speed of operation. Figure 3 shows a flowchart related to a printing method for improving reliability. Figure 4 shows a flowchart related to a recoating method for improving reliability. Figure 5 shows a flowchart related to a curing method for improving build speed. Figure 6 shows a flowchart related to the operation method of the environmental control system 180 for improving reliability. It should be understood that each of these methods can be implemented as control logic and executed by the electronic control unit 10. Furthermore, although the methods are shown in separate flowcharts, the methods may be integrated together.

[0099] Referring to Figure 3, flowchart 300 illustrates a printing method that includes closed-loop control operations to improve the reliability of the build operation. In an embodiment, the electronic control unit 10 loads build instructions into the print assembly 150 for building component 70 (block 302). In some embodiments, the build instructions include compensation settings such as image shift settings and / or jet nozzle mapping to address defective nozzles 158. Multiple pixels and / or voxels defining the spatial portion of the build material 40 within the build plate 120 may be defined based on a digital build file of component 70 to be built by the apparatus 100 (e.g., defining the stored deposition pattern and / or apparatus 100 control instructions uploaded to the electronic control unit 10). The digital build file may be included in the build instructions. Layer-by-layer pixels of the build may be defined along a trajectory configured so that the print assembly 150 crosses the build zone BZ. Based on build commands, the electronic control unit 10 can map one or more jet nozzles 158 to the trajectory and / or pixels and corresponding design deposition patterns of the current layer of the build, so that the jet nozzles 158 deposit a predetermined drop volume of binder 50 at predetermined locations on the build material 40 within the build zone BZ.

[0100] In some embodiments, the print assembly 150 traverses the cleaning zone CZ in block 304 before the print assembly 150 begins to deposit the binder 50 onto the build material 40 in the build zone. It should be understood that some processes described herein may be performed in parallel to reduce turnover time. For example, loading build instructions and performing cleaning operations on the print assembly 150 may be performed in parallel. In the cleaning zone CZ, the print assembly 150 may traverse the wipers and / or other elements of the cleaning station 108 to clean the jet nozzles 158 and / or establish a meniscus on each of the jet nozzles 158. In some embodiments, the print assembly 150 may, for example, perform the cleaning operation on the jet nozzles as described in blocks 306 and 308, as described above. Depending on the condition, a cleaning operation can be performed. The print assembly 150 can also perform a spit / inspection pattern in the jet inspection / purge area 109 (block 304). In block 306, the vision system 14 can image the spit pattern and digitize the image data for analysis. The image data is analyzed to determine whether there is a defective nozzle 158 in the print assembly 150. If the electronic control unit 10 determines the presence of a defective nozzle 158, a corrective jet mapping can be determined in block 308. In some embodiments, the electronic control unit 10 may cause the print assembly 150 to perform a cleaning operation depending on the determination of the presence of a defective jet nozzle 158 to attempt to correct defects such as clogged nozzles so that the defective jet nozzle 158 can be removed from use during layer build, or so that the impact of the defective jet nozzle 158 can be minimized, or a corrective jet mapping may be implemented. Corrective jet mapping may include remapping the jet nozzle 158 from a planned trajectory for the next build pass (e.g., a binder deposition pass over a build zone BZ) to a corrected trajectory over the next build zone BZ. The trajectory refers to the path the jet nozzle takes across the build zone BZ as the print assembly 150 crosses the BZ. Corrective jet mapping may be performed in block 310 to update the control behavior of the print assembly 150 in response to the determination that a defective jet nozzle 158 is present. For example, adjustment to a programmed deposition pattern for subsequent crossings of the print assembly across build zones may include updating the mapping of a selected nozzle among several nozzles to select pixels for the subsequent build layer, so that a first nozzle, which was mapped to distribute binder to a first selected set of pixels during the first crossing of the print assembly, is mapped to distribute binder to a second selected set of pixels during the second crossing of the print assembly across build zones.In some embodiments, a first nozzle, which is mapped to distribute binder in a previous cross-section of a print assembly, may be remapped for a subsequent build layer so that it is mapped to an area of ​​the build layer where no pixels exist.

[0101] In some embodiments, this operation may be performed "on the fly," for example, before the print assembly 150 traverses the build zone BZ and distributes the binder 50 during the forward pass. "On the fly" refers to coordinating the operation of the print assembly 150 (or recoat assembly 140) while passing over the build layers of a build that are not predetermined adjustments loaded into the machine, before the build operation of the layers begins. In block 312, the electronic control unit 10 causes the print assembly 150 to traverse the build zone forward while distributing the binder 50 according to any adjustment settings, such as a programmed deposition pattern and a modified jet map defined by the build command. Note that the activity in block 312 may be synchronized with the activity in block 404 of the recoat process to ensure that the print assembly 150 and the recoat assembly 140 do not collide. Furthermore, note that the activity in block 312 may be synchronized with the activity in block 502 of the curing process.

[0102] When the print assembly 150 completes the forward pass of the build zone BZ, in block 314A, the print head 156 of the print assembly 150 may be indexed by an integer multiple of the subpixel increment before performing a second pass (e.g., a reverse pass) on the build zone BZ to improve the uniformity of binder deposition. In some embodiments, when the print assembly 150 completes the forward pass of the build zone BZ, the completion of the forward pass may trigger the build plate 120 to descend before the recoat assembly 140 performs a pass on the build zone BZ and distributes a new layer of build material 40 in block 314B. In some embodiments, blocks 314A and 31 Both of 4B are performed. In some cases, neither process in blocks 314A nor 314B is performed. That is, in block 312, the print assembly 150 completes a forward pass over the build zone BZ distribution binder 50, and then proceeds to block 316, where the print assembly 150 performs a reverse pass over the build zone BZ. Furthermore, if the build plate 120 is not lowered after the forward pass of the print assembly 150 has passed over the build zone BZ, then the build plate 120 is lowered after the reverse pass of the print assembly 150 has passed over the build zone BZ. While passing over the build zone BZ in the reverse direction, the print assembly 150 can distribute the binder 50 as described herein, or it can traverse the build zone BZ without distributing any further binder 50 onto the build layer.

[0103] In some embodiments, once the print assembly 150 has completed a forward and / or reverse pass of the build zone BZ, the vision system 14 can capture image data of the build zone BZ for analysis in block 318 and for analysis in block 317. In some embodiments, once the print assembly 150 has completed a first forward pass of the build zone BZ, the electronic control unit 10 can determine, in response to analysis of feedback from one or more sensors, that a subsequent forward pass is required to deliver the correct amount of binder 50 in case of a jet failure. In such an example, the electronic control unit 10 can return the print assembly 150 to the home position 151 side of the build zone BZ and optionally repeat a forward binder deposition through the build zone BZ using jet nozzle mapping adjusted so that one or more defective jet nozzles 158 do not align on the same trajectory as the first pass.

[0104] In block 316, the electronic control unit 10 causes the print assembly 150 to traverse the build zone in the reverse direction while distributing the binder 50 according to a programmed deposition pattern defined by the build command. Note that the activity in block 316 may be synchronized with the activity in block 502 for curing and, optionally, with the activity in block 404 for recoating. In block 318, either before or after the print assembly 150 traverses the build zone BZ in the reverse direction, the electronic control unit 10 analyzes the image data captured in block 317 to determine whether there are any jet defects or abnormalities in the distributed binder pattern. Depending on the determination of the presence of an abnormality in the distributed binder pattern, the electronic control unit 10 may, in block 320, adjust the programmed mapping of the jet nozzle 158 to the trajectory of the build deposition pattern and / or to the pixels for the subsequent traverse of the print assembly 150 on the build zone in order to address the abnormality. Any adjustments to the jet nozzle mapping may be performed in block 322 by the electronic control unit 10 and the print assembly 150, after which the process returns to block 302. In block 322, a pre-planned, for example, randomized index of the jet nozzles between build layers and / or build layer paths may be implemented in the build instructions. For example, the pre-planned index ensures that the same jet nozzle does not traverse the same trajectory across the build zone BZ, either between layers or between layer paths, thereby implementing a planned randomization of the portion of the build on which the jet nozzles distribute the binder. This randomization provides a level of redundancy in case a jet nozzle fails during the build. To prevent a faulty jet nozzle from continuing to traverse the same trajectory, the randomization shifts (e.g., by index) the jet nozzle to different trajectories at predetermined intervals or through, and thus exacerbates any problems caused by a faulty jet nozzle.Some adjustments may include grayscale modifications such as correcting jet nozzle mapping, or oversaturating the next layer to address defective binder deposition during the previous layer or other jet nozzle cleaning operations. Other jet nozzle cleaning operations are described in more detail, for example, with respect to block 324. This may include an aggressive purging operation in which the pressurized binder 50 is purged from the jet nozzle 158 into the jet test / purge area 109. In some examples, further corrective measures, such as cleaning or material purging operations, may be completed by the print assembly 150 in blocks 324 and 326 in response to determining the presence of anomalies in the binder pattern distributed in block 320. In operations in which the same jet nozzle or multiple jet nozzles 158 are repeatedly identified as being defective or requiring cleaning more frequently than others, the electronic control unit 10 may detect the increased frequency of problems with the jet nozzles and flagged jet nozzles to the operator or quality monitoring system so that replacement or repair may be scheduled and carried out.

[0105] For example, in block 324, the electronic control unit 10 can cause the print assembly 150 to perform a cleaning operation. The cleaning operation may include causing the print assembly 150 to traverse the wipers and / or other cleaning elements of the cleaning station 108 within the cleaning zone CZ. For example, valves associated with the print head for controlling the flow of binder 50 from binder supply lines 111 and 113 can be closed and the nozzles 158 can be pressurized. This operation may be performed optionally while the print assembly 150 is traversing the wipers of the cleaning station 108. The traverse of the CZ can be completed at a speed faster or slower than the speed at which the print assembly 150 traverses the BZ. The valves can then be opened in block 326 so that a rapid purge of the binder 50 into the jet test / purge area 109 can be achieved. Such an operation can, for example, clean the jet nozzles 158 and the print head 156 in response to determining anomalies in the distributed binder pattern. The purge and / or cleaning operations and their parameters may be adjusted based on machine learning based on an analysis of image data from previous layers. For example, the amount of pressure used during the cleaning process, or the amount of binder 50 flowing through the nozzle 158, can be adjusted to positively improve future cleaning processes.

[0106] The electronic control unit 10 is configured to repeat the operation of blocks 302-322 whenever it is specified that a new layer of binder 50 be deposited in the build zone BZ according to the build instruction.

[0107] Furthermore, in some embodiments, while the print assembly 150 is undergoing a cleaning operation, optionally immediately before or after printing, the supply of binder 50 to the print assembly 150 (e.g., one or more local fluid manifolds 110A and 112A) may be refilled in block 328. Additionally, in block 330, prior to further print assembly 150 deposition activity, a depressurization can be performed, for example, to re-establish binder 50 circulation within the print head following a pressurized purge operation, such as the purge operation described with respect to block 324. In block 332, the electronic control unit 10 can monitor the print head binder supply pressures in accordance with the processing in block 312 and / or block 330 and determine whether they are within acceptable limits. If they are outside acceptable limits, the electronic control unit 10 can implement corrective measures to adjust the pressure so that binder circulation to the nozzles 158 is within a predetermined acceptable range.

[0108] Referring here to Figure 4, flowchart 400 shows a recoating method that includes closed-loop control operation to improve the reliability of the recoating operation. In this embodiment, the electronic control unit 10 loads build instructions in block 402 for the recoating assembly 140 to build component 70, thereby configuring the height and crossing speed of the roller and / or doctor blade for the next distribution of build material 40. The build instructions specify the thickness of the build material for a new layer of build material 40, The system also includes predefined build material input parameters, which can optionally define an over-application to ensure good coverage by the recoat block, the recoat assembly speed for traversing the build zone, the rotation speed of the rollers of the recoat assembly 140, and the rotation direction of the rollers of the recoat assembly 140. The electronic control unit 10 can also determine in block 402 whether the powder supply process, dosing, is complete. Dosing involves the powder supply block activating the supply platform actuator 132 to move the supply platform 130 upward (e.g., in the +Z axis direction) to introduce the build material 40 into the recoat assembly 140 for distribution into the build zone BZ. Dosing is performed when the recoat assembly 140 is in the home position 153, for example, in block 402a. Furthermore, dosing is performed each time a new layer of build material 40 is distributed into the build zone BZ by the recoat assembly 140.

[0109] Occasionally, additional powder supply processes may be performed. For example, when a powder supply sensor indicates that the level of build material 40 on the supply platform 130 falls below a threshold, the electronic control unit 10 can initiate one or more processes to replenish the build material 40 on the supply platform. In some embodiments, in block 402b, the lower build material hopper 172 can supply build material to the supply platform 130. This can be achieved by lowering the supply platform 130 to a certain level so that the build material 40 stored in the lower build material hopper 172 can flow onto the supply platform 130. The supply platform 130 can then be raised again to perform dosing. In some embodiments, for example, in block 402c, a material processing system including an upper build material hopper 170 is required to replenish the lower build material hopper, thereby supplying further build material to the supply platform 130 via the lower build material hopper 172 for building and dosing. The frequency of the replenishment process in block 402b may occur every few layers (e.g., every 20-40 layers), but further depends on the thickness of individual layers, the size of the hopper, and the cross-sectional area of ​​the build box. Furthermore, the frequency of the replenishment process in block 402c may occur after more than 100 layers have been built (e.g., ~100-500 layers, but further depends on the thickness of individual layers, the capacity of the lower and upper build material hoppers 172 and 170, which can be monitored by sensors to indicate the current fill level of hoppers 172 and 170 to the electronic control unit 10). It should be understood that the supply processing in blocks 402b and 402c may be performed at various points during the build operation and does not need to be performed while the recoat assembly 140 is in its home position 153.

[0110] Once dosing is complete, or while dosing is taking place, the electronic control unit 10 can execute block 404. In block 404, the electronic control unit 10 determines that the print assembly 150 has started or completed passing through the build zone BZ, for example in block 316, and then, in block 406, causes the recoat assembly 140 to traverse the supply zone SZ, which pushes the powder mounted on the supply platform 130. For example, the recoat assembly 140 may wait for the print assembly 150 to complete its reverse pass, and optionally, an additional delay may be waited in block 404. In some embodiments, the exhaust valve may be completely or partially closed so that suction from the environmental control device (system) 180 can be generated in the recoat assembly 140. This suction facilitates the collection of floating build material 40 to be collected and removed from the process chamber 101. It should be noted that the activity in block 406 may be synchronized with the activity in block 506 of the curing process. In some embodiments, the roller brush 143 (Figure 1B) within the recoat assembly 140 is located in block 408 and the recoat assembly 140 is located in the build zone BZ. Before crossing, the roller 142 can be rotated to clean it. In some embodiments, the roller 142 may rotate relative to the roller brush 143. In some embodiments, the roller brush 143 may be moved to engage with the roller 142 so that the roller brush 143 can clean the roller 142.

[0111] In some embodiments, the recoat assembly 140 can directly follow the print assembly 150 across the build zone BZ, but in some examples, the electronic control unit 10 can implement a delay before causing the recoat assembly 140 to cross the build zone BZ and distribute a new layer of build material 40. In block 410, the electronic control unit 10 causes the recoat assembly 140 to cross the build zone BZ and distribute (e.g., push) the build material 40 onto it (e.g., in the reverse direction R, -X axis direction). One or more rollers 142 and / or doctor blades 141 of the recoat assembly 140 push the build material across the build zone BZ during the first pass (e.g., in the reverse direction). The rollers 142 can rotate at a rotational speed and / or direction, and the rotational speed and / or direction may be the same for each roller in the multi-roller system or may be different speeds and / or directions. Note that the activity in block 410 may be synchronized with the activity in block 506 of the curing process. When the recoat assembly 140 reaches the opposite end of the build zone BZ (for example, the opposite end of SZ), block 412 can lift the rollers and / or doctor blades of the recoat assembly 140 to move it over any residual mounds of build material 40 from the first pass ("hop over").

[0112] In block 414, the electronic control unit 10 causes the recoat assembly 140 to build in the reverse direction, again traversing the build zone BZ (for example, in the forward direction F), and pushing any remaining build material 40 across the build zone BZ to generate the defined thickness of build material 40 for the new layer. Note that the activity in block 414 may be synchronized with the preheating process in block 510 of the curing process. In block 416, the electronic control unit 10 further causes the recoat assembly 140 to traverse the supply zone SZ, and push any remaining build material 40 back onto the build material supply platform 130, or optionally, into a build material return bin located adjacent to the supply platform 130.

[0113] The electronic control unit 10 is configured to repeat the operation of blocks 402-416 each time it is specified that a new layer of build material 40 be distributed to the build zone BZ according to the build instructions.

[0114] In the above description, the process of distributing the build material 40 to the build zone BZ using the recoat assembly 140 was described, but the electronic control unit 10 may also perform recoat defect detection and correction processing. In block 418, the electronic control unit 10 loads a build command including predetermined build material dispensing parameters. In block 402, the electronic control unit (system) 10 can facilitate the loading of the build command to the recoat assembly 140 or update the build command based on any corrective measures determined based on the results of blocks 420 to 424 described herein. In block 420, the electronic control unit 10 captures and receives image data from the vision system 14 of the build zone BZ before or during the forward and / or reverse passes by the print assembly 150, as described with reference to blocks 312 and 316 of Figure 3. The electronic control unit 10 analyzes the image data to determine the presence of anomalies in the recoat (for example, in a new layer of material distributed within the build zone BZ). In addition, during the first pass of the recoat assembly 140 (for example, in the reverse R direction), the electronic control unit 10 controls the force sensor 26 associated with the roller 142, the doctor blade 141, and / or other sensors in 422. The electronic control unit 10 also monitors one or more sensors associated with the recoat assembly 140, such as a current sensor 24 configured to monitor current draw on a sensor, a force sensor 26 associated with the doctor blade 141, and / or other sensors in the return path (e.g., forward path) of the recoat assembly 140.

[0115] In response to sensor data and / or image data received by the electronic control unit 10, the electronic control unit 10 performs an analysis of the sensor data and / or image data in block 422 to determine the presence of any anomalies in the new layer of the distributed build material 40. In block 424, in response to the determination of the presence of an anomaly, the electronic control unit 10 implements corrective measures. Corrective measures may include adjusting predetermined build material input parameters, causing the recoat assembly 140 to redistribute the build material 40 onto the new layer before the print assembly distribution binder 50 onto the new layer of build material 40, stopping the build block, interfacing the recoat assembly 140 with one or more cleaning elements of the cleaning station 108, and so on.

[0116] Referring here to Figure 5, flowchart 500 illustrates a recoating method that includes closed-loop control operation of a curing block, improving the speed of curing and / or preheating of the build material 40 and / or the build material 50 during the adhesion of the binder 50 and / or distribution of the build material 40. As described herein, the manufacturing apparatus 100 includes one or more energy sources 160, such as IR lamps 160, to facilitate the curing process and / or evaporation of the solvent from the build material 40. In some embodiments, one or more energy sources 160 may be coupled to the print assembly 150 and / or the recoating assembly 140. The following technique describes an embodiment in which a first IR lamp 160A is coupled to the forward-facing surface of the print assembly 150 and a second IR lamp 160B is coupled to the reverse-facing surface of the recoating assembly 140.

[0117] Moving to block 502, as the print assembly 150 traverses the build zone BZ in the reverse direction (for example, in block 316), the first IR lamp 160A applies the energy of the first height and / or flow gas 161A to the build material 40 and the binder 50 in the build zone BZ to accelerate the curing reaction and / or phase change. In block 504, after the print assembly 150 has traversed the build zone BZ in block 316, the electronic control unit 10 optionally activates a build plate heater 121 that provides heat to the build on the build plate 120 to accelerate solvent evaporation. In other embodiments, the build plate heater 121 provides heat to the build on the build plate 120 to accelerate solvent evaporation throughout the build process and is not intermittently activated and deactivated. The build plate heater 121 can be actively switched on and off repeatedly near a temperature setpoint so that the build plate 120 can maintain a predetermined temperature during the build. In some examples, as the build grows in layers, the distance of the build surface from the surface of the build plate 120 increases as the build progresses, so the setpoints may increase so that the surface temperature of the build material 40 on the build plate 120 remains at a predetermined temperature (e.g., within a predetermined range).

[0118] In some embodiments, the electronic control unit 10 causes the environmental control device 180 to flow gas 161B through or around the IR lamp 160B in block 506 to replace the binder vapor with hot air and provide an additional energy source (e.g., a heat source) to the binder 50 on the build material 40 and build plate 120 in order to accelerate the curing block. The IR lamp 160B may also supply IR energy to the binder 50 on the build material 40 and build plate 120 in order to accelerate the curing process in block 506. It should be understood that the IR lamps 160A, 160B, and 160C, as well as the flow gases 161A, 161B, and 161C, introduce heat to cure or preheat the build material 40 and binder 50 at various timings during the build. Furthermore, the flow gas 161B passing through or around the IR lamp 160B can cool the lamp and extend its lifespan. Additionally, in block 508, when the recoat assembly 140 traverses the build zone BZ in the reverse direction R (for example, in block 410), the second infrared lamp 160B applies the energy of the first height to the build material 40 and the binder 50 in the build zone to accelerate the curing reaction and / or phase change. Similarly, as the recoat assembly 140 traverses the build zone BZ in the forward direction F (for example, in block 414 during the return path to the supply zone SZ), the second infrared lamp 160B applies energy of a second height to the build material 40, and the binder 50 in the build zone preheats the build material 40 in block 510. The flow gas 161B is discussed in relation to the operation of the IR lamp 160B, but it is understood that each energy source (for example, each IR lamp 160A, 160B, or 160C) may include flow gas 161A, 161B, and 161C (Figure 1B) flowing through or around the IR lamp 160A, 160B, or 160C (Figure 1B).

[0119] The electronic control unit 10 is configured to repeat the operation of blocks 502-510 each time it is specified that a new layer of build material 40 be distributed to the build zone BZ according to the build instructions.

[0120] The aforementioned block describes a process for implementing a curing mechanism such as an IR lamp 160, a flow gas 161 (e.g., a heated flow gas generated by the heat from the IR lamp 160), and a build plate heater 121. However, the electronic control unit 10 may also implement a closed-loop control system that ensures one or more energy sources 160 provide the heating necessary to facilitate the curing process, phase change, and / or solvent evaporation.

[0121] In some embodiments, the electronic control unit 10 loads a build command in block 512 that includes a predetermined energy level of an IR lamp 160, a flow gas 161 rate, and / or process gas temperature (e.g., the average ambient temperature in the process chamber 101) and a surface temperature range (e.g., the surface temperature of the build material 40 on the build plate 120, which is optionally monitored using a pyrometer). In block 514, (e.g., in block 404) during the jet / recote delay, or as a continuous operation during the build, the electronic control unit 10 monitors sensor data from one or more sensors. For example, the electronic control unit 10 may receive the surface temperature of the build material 40 in the build zone BZ using a pyrometer and / or process gas temperature in the process chamber 101. In block 516, while the recoat assembly 140 passes through the build zone for the first time and return (e.g., in blocks 410 and 414), the electronic control unit 10 monitors the flow gas 161 temperature and / or surface temperature of the build material 40 on the build plate 120. The electronic control unit 10 analyzes the sensor data to determine whether the temperature of the flow gas 161 (which may be a function of the IR lamp intensity and the flow gas 161 velocity) and the surface temperature are within a predetermined temperature range defined in block 518. In response to the determination that the temperature values ​​are not within the predetermined range, the electronic control unit 10 may raise or lower the temperature by adjusting the intensity of one or more IR lamps 160, the velocity of the flow gas 161, the on / off cycle time of the build plate heater 121, and / or the delivery time of the heating process gas from the environmental system.

[0122] Referring to Figure 6, flowchart 600 shows an environmental control system including closed-loop control operation to improve the reliability of the recoat operation (for example, by controlling the humidity in the process chamber 101) and to provide better control of the curing process. The method is shown below. The environmental control system 180 described herein includes a plurality of subsystems for controlling the environment within the process chamber 101. Depending on the type of component 70 and the materials used within the process chamber 101, various environmental conditions must be met in order to deliver a reliable component 70. One or more subsystems may include a heat exchanger 181, a dehumidifier or condenser 182, or other means for removing vapor from the process gas, a process gas supply 183, an air filtration system 184, and the like. Each subsystem may include one or more controllable valves that can be electronically operated or stopped by the electronic control unit 10, so that the valves can be opened and closed, or the subsystem can be connected to or disconnected from the process chamber 101.

[0123] In block 602, the electronic control unit 10 loads a predetermined set of environmental conditions for environmental control within the process chamber 101 from the build command. The predetermined set of environmental conditions may include a predetermined temperature, relative humidity level, solvent concentration level, acceptable concentration of airborne build material 40, and gas concentration level within the process chamber 101.

[0124] In block 604, the electronic control unit 10 loads a predetermined set of environmental conditions into the environmental control system 180. Once the predetermined set of environmental conditions is loaded into the environmental control system 180, the environmental control system 180 can adjust the process chamber 101 according to the predetermined conditions. In some embodiments, during the build, in block 606, the electronic control unit 10 partially or completely closes the discharge valve to the process chamber 101 to create suction into the process chamber 101 around the recoat assembly 140, thereby extracting the floating build material 40, while the recoat assembly 140 distributes a new layer of build material 40. Note that the activity in block 606 may be synchronized with the activity in block 404 of the recoat process. In block 608, the electronic control unit 10 flows heated process gas into the process chamber 101. The heated (or cooled) process gas in the process chamber 101 may be further controlled to maintain a predetermined average temperature and / or humidity within the process chamber 101. In some embodiments, the environmental control processes disclosed herein may be performed in parallel or sequentially. Note that the activities in block 608 may be synchronized with the activities in block 506 of the recoating process.

[0125] In block 610, during the first pass of the recoat assembly 140, the electronic control unit 10 maintains suction in the process chamber 101 around the recoat assembly 140 by partially or completely closing the exhaust valve, so that the build material 40 in the air is extracted and filtered using a filter. The activity in block 610 can be synchronized with the activity in block 406 of the recoat process. Once the recoat assembly 140 has completed its return pass across the build zone BZ to the supply zone SZ, the suction level and heating flow gas can be adjusted in block 612. Once completed, in block 614, the heating flow gas valve can be shut off and the exhaust valve of the process chamber 101 can be opened by the electronic control unit 10. Furthermore, once the print assembly 150 is completed and passes over the build zone BZ, the gas flow is adjusted via the control unit 616. The activity in block 616 can be synchronized with the activity in blocks 312 and 316 of the print process.

[0126] When the build process is executed, the electronic control unit 10 receives sensor data regarding the environment of the process chamber 101. In addition to providing control signals and / or environmental conditions to the environmental control system 180, the electronic control unit 10 also monitors the sensor data and issues commands to correct environmental conditions that are not within a predetermined range defined by the build instructions. The system generates data. For example, in block 618, the electronic control unit 10 can receive one or more datasets from one or more sensors. The data may include sensor data indicating the temperature of the process chamber 101, the relative humidity inside the process chamber 101, the concentration of the process gas inside the process chamber 101, the concentration of the suspended build material 40, and / or other conditions inside the process chamber 101.

[0127] In block 620, the electronic control unit 10 can implement one or more corrective measures to adjust environmental conditions that have been determined to be outside a predetermined set of environmental conditions. For example, if sensor data indicates that the temperature of the process chamber 101 is below a predetermined set of environmental conditions, the electronic control unit 10 can cause the environmental control system 180 to start flow from its heat exchanger, and if sensor data indicates that the temperature of the process chamber is above a predetermined set of environmental conditions, the electronic control unit 10 can cause the environmental control system 180 to stop flow from its heat exchanger. In some embodiments, the electronic control unit 10 causes the environmental control system 180 to start a cooling flow through the process chamber 101 to remove excess heat.

[0128] In some embodiments, the electronic control unit 10 causes the environmental control system 180 to start flow from its dehumidifier if sensor data indicates that the relative humidity is above a predefined set of environmental conditions, and causes the environmental control system 180 to stop flow from its dehumidifier if sensor data indicates that the relative humidity is below a predefined set of environmental conditions. The electronic control unit 10 causes the environmental control system 180 to start flow from its process gas supply if sensor data indicates that the process gas concentration is below a predetermined set of environmental conditions, and causes the environmental control system 180 to stop flow from its process gas supply if sensor data indicates that the process gas concentration is above a predetermined set of environmental conditions.

[0129] Similarly, the electronic control unit 10 causes the environmental control system 180 to start the flow from the condenser 182 of the environmental control system 180 if the sensor data indicates that the solvent concentration is outside a predetermined set of environmental conditions, and causes the environmental control system 180 to stop the flow from the condenser 182 of the environmental control system 180 if the sensor data indicates that the solvent concentration is within a predetermined set of environmental conditions. In some embodiments, the electronic control unit 10 causes the environmental control system 180 to activate (start) the air filtration system of the environmental control system 180 if the sensor data indicates that the concentration of the air build material 40 is above a predetermined set of environmental conditions, and causes the environmental control system 180 to stop the flow from the air filtration system of the environmental control system 180 if the sensor data indicates that the concentration of the air build material 40 is below a predetermined set of environmental conditions.

[0130] In some further embodiments, a build instruction may require that the environment within the process chamber 101 be an inert environment or maintained as at least an inert environment during a specified build process. Therefore, in block 622, the electronic control unit 10 can cause the environment control system 180 to generate and / or maintain an inert environment within the process chamber 101. The electronic control unit 10 may monitor one or more O2 sensors configured to generate and / or maintain an inert atmosphere within the process chamber 101 by monitoring the oxygen level within the process chamber 101.

[0131] It should be understood that the steps of the process described above may be omitted or performed in various orders while still achieving the objectives of this disclosure. Functional blocks and / or flowchart elements described herein may be converted into machine-readable instructions. As a non-limiting example, machine-readable instructions can be parsed from descriptive text (e.g., hypertext markup languages, extensible languages). The code can be written using any programming protocol, such as (i) a markup language, (ii) assembly language, (iii) object code generated from source code by a compiler, (iv) source code written using syntax from any suitable programming language for execution by an interpreter, or (v) source code for compilation and execution by a just-in-time compiler. Alternatively, machine-readable instructions can be written in a hardware description language (HDL), such as logic implemented via either a field-programmable gate array (FPGA) configuration or an application-specific integrated circuit (ASIC), or their equivalents. Thus, the functions described herein can be implemented in any conventional computer programming language as pre-programmed hardware elements or as a combination of hardware and software components.

[0132] Referring here to Figure 7, an exemplary schematic diagram of the operation of the print assembly 150 and recoat assembly 140 during the build process is shown. As described herein, the additive manufacturing apparatus 100 includes a process chamber 101 having a length defined by at least a cleaning zone CZ, a build zone BZ, and a supply zone SZ arranged in a continuous manner in separate sections along the length of the process chamber 101. In some embodiments, there may be additional zones referred herein as auxiliary zones (auxiliary zones or AZs). The AZs may include other elements such as an overflow bin for the build material 40 or a binder deposition test area. However, the additive manufacturing apparatus 100 does not necessarily include AZs. The additive manufacturing apparatus 100 also includes a support extending along the length of the process chamber 101 in a first vertical plane, the print assembly 150, the recoat assembly 140, a vision system 14, and an electronic control unit 10. The print assembly 150 includes a plurality of nozzles 158 for distributing the binder 50 into the build zone. The print assembly 150 is configured to move back and forth along the length of the support and is movably coupled to the support via a first actuator located on a second vertical plane parallel to the first vertical plane. The recoat assembly 140 may include one or more doctor blades 141 or rollers 142 for distributing the build material 40 into the build zone. The recoat assembly 140 is configured to move back and forth along the length of the support and is movably coupled to the support via a second actuator located on a second vertical plane parallel to the first vertical plane. Furthermore, the vision system 14 is configured to image the build zone.

[0133] The following build process is described with reference to time intervals T1, T2, T3, and T4. Time intervals indicated by a plus sign "+" are intended to indicate further movement within the build process during a defined time interval. The electronic control unit 10 is communicably coupled to the print assembly 150, the recoat assembly 140, the first and second actuators, one or more energy sources 160, and the vision system 14, as well as other elements of the additive manufacturing apparatus 100 described herein. The electronic control unit 10 is configured to cause the print assembly 150 to traverse the build zone in the forward direction F (e.g., toward the supply zone) while distributing the binder 50 according to a programmed deposition pattern during the first interval T1. In some examples, the electronic control unit 10 receives image data from the vision system 14 of the distributed binder pattern either when the print assembly 150 traverses the build zone in the forward direction F during the first interval T1, or when the print assembly 150 has completed traversing the build zone in the forward direction F. Image data and other sensor data may be recorded and stored in the memory of the electronic control unit 10 or other storage device for post-analysis or analysis during subsequent build processing steps to adjust and improve the build speed and / or quality. During the second interval T2 following the first interval T1, the electronic control unit 10 loads the binder 50 onto the print assembly 150 according to the programmed deposition pattern during the second interval T2. While distributing the binder, the build zone is traversed from the opposite direction (for example, away from the supply zone). During the second interval T2 following the first interval T1, the electronic control unit 10 receives image data of the administered binder pattern from the vision system 14. In some embodiments, for example, the vision system 14 is configured to move with the print assembly 150, or coupled to it, and when the print assembly 150 traverses the build zone in the forward direction F, image data of the distributed binder pattern may be captured during the first interval T1. In other embodiments, the vision system 14 may capture image data of the distributed binder pattern when the print assembly 150 has completed traversing the build zone. For example, when the print assembly 150 is cleared from the field of view of the vision system 14 to the build zone, image data can be captured.

[0134] Between the second interval T2 and the third interval T3, the electronic control unit 10 causes the recoat assembly 140 to traverse the build zone in the reverse direction (for example, away from the supply zone) from which the build material 40 supplied into the supply zone is distributed, and to form a new layer of build material 40 within the build zone according to predetermined build material input parameters. The recoat assembly 140 follows the print assembly 150 across the build zone. As the recoat assembly 140 traverses the build zone, the electronic control unit 10 can analyze image data to determine whether there are any abnormalities in the distributed binder pattern.

[0135] During the third interval T3, the electronic control unit 10 can cause the print assembly 150 to perform at least one of purging or wiping operations while traversing the cleaning zone in the forward and / or reverse directions. The print assembly 150 can perform one or more cleaning operations within the cleaning zone CZ when the recoat assembly 140 completes the reverse pass of the build zone BZ, for example, during the latter half of the third interval T3+. In some embodiments, the maintenance of the print assembly 150 described above may be performed based on the analysis of image data of the supplied binder pattern. For example, maintenance of the print assembly 150, such as a cleaning operation, may be performed when it is determined that there is an anomaly in the distributed binder pattern. In some embodiments, this may be performed in response to the determination of the presence of an anomaly in the distributed binder pattern (e.g., through image data analysis) in the print head redundancy or lateral index jets within the print assembly 150. For example, the analysis of image data may show that one or more jet nozzles 158 of one or more print heads failed to properly distribute the binder 50 during traversal and distribution of the binder 50 on the previous layer of build material 40.

[0136] During the fourth interval T4, the electronic control unit 10 causes the recoat assembly 140 to traverse the build zone forward (for example, toward the supply zone), and the print assembly 150 to traverse the build zone forward (towards the supply zone), distributing the binder 50 across the build zone, following the recoat assembly 140, onto a new layer of build material 40 according to a programmed deposition pattern.

[0137] In some embodiments, the electronic control unit 10 is further configured to adjust the jet nozzle mapping for the subsequent traverse of the print assembly 150 on the build zone in response to the detection of the presence of anomalies in the distributed binder pattern. The electronic control unit 10 is further configured to implement corrective measures for the subsequent distribution of the build material 40 by the recoat assembly 140 in response to the detection of the presence of anomalies in a new layer of the distributed build material 40. In some embodiments, the electronic control unit 10 causes the print assembly 150 to perform subpixel indexing of multiple nozzles 158 between a first interval T1 and a second interval T2. Furthermore, in some embodiments, the electronic control unit 10 causes the print assembly 150 to perform subpixel indexing of multiple nozzles 158 between third and fourth intervals T3, T4 The subpixel index of nozzle 158 is executed. In some embodiments, a delay may be implemented until the recoat assembly 140 begins to traverse the build zone in the reverse direction, following the print assembly 150 traversing the build zone, during the second and third intervals T2 and T3. The delay may be implemented to allow the binder 50 to be immersed in the build material 40, the build plate 120 to be reduced in the -Z direction, the print assembly 150 to remove the build zone, and / or the like.

[0138] Referring to the movement of the print assembly 150, the print assembly 150 traverses the build zone back and forth at a first speed. In some embodiments, the print assembly 150 traverses the cleaning zone forward and backward at a second speed, where the second speed is slower than the first speed.

[0139] Based on the above, it should be understood that embodiments of additive manufacturing apparatus are described herein. The additive manufacturing apparatus may include a process chamber 101 defining a volume having height, length, and width. The length defines a plurality of processing zones. The process chamber includes a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate parts along the length of the process chamber 101. The process chamber 101 includes an actuator assembly for distributing build material and depositing binder material within the additive manufacturing apparatus. The actuator assembly may generally include a support extending along the length of the process chamber 101 in a first vertical plane. The actuator assembly may further include a recoat assembly 140 for distributing build material and a print assembly 150 for depositing binder material. The print assembly 150 includes a plurality of nozzles 158 for distributing binder 50 into the build zone. The print assembly 150 is movably coupled to the support via a first actuator configured to move back and forth along the length of the support. The printhead actuator may include a print actuation axis, where the printhead actuator is capable of acting bidirectionally along the print actuation axis, thereby resulting in bidirectional motion of the printhead. The print assembly 150 is positioned in a second vertical plane parallel to the first vertical plane.

[0140] Furthermore, embodiments described herein more specifically disclose a print assembly 150, a recoat assembly 140, a curing system, an environmental control system 180, and systems and methods for operating their interactions to improve the reliability and speed of the build process. To improve the reliability and speed of the build process, the manufacturing apparatus disclosed herein further implements one or more sensors and control systems configured to operate in a closed-loop control loop.

[0141] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Accordingly, this specification is intended to encompass various modifications and variations to the embodiments described herein, provided that such modifications and variations fall within the scope of the appended claims and their equivalents.

[0142] Further aspects of the present invention are provided by the following appended subject matter. (Note 1) A process chamber having a length defined by at least a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate sections along the length of the process chamber, A support extending along the length of the process chamber in the first vertical plane, A print assembly comprising a plurality of nozzles for distributing a binder within the build zone, configured to move forward or backward along the length of the support. A print assembly is movably coupled to the support via a first actuator and positioned on a second vertical plane parallel to the first vertical plane. A vision system configured to capture the distributed binder pattern of the build zone, The printed assembly, the first actuator, and the electronic control unit which is communicatively coupled to the vision system, Includes, The aforementioned electronic control unit is The build zone is traversed in the forward or reverse direction while distributing the binder to the print assembly according to a programmed deposition pattern. The vision system receives image data of the distributed binder pattern resulting from the programmed deposition pattern, In order to determine whether there is an abnormality in the distributed binder pattern, the image data is analyzed, If the presence of an anomaly in the distributed binder pattern is determined, the programmed deposition pattern is adjusted for subsequent crossings of the print assembly on the build zone in order to address the anomaly. It is structured in such a way. Additive manufacturing equipment. (Note 2) As the print assembly traverses the build zone in the forward or reverse direction, the distributed image data of the binder pattern is supplemented. Additive manufacturing equipment as described in any of the above appendices. (Note 3) The additive manufacturing apparatus according to any of the above appendices, wherein the abnormality is a region of the build layer of a build manufactured in the build zone, where a smaller amount of a predetermined binder is present, based on a comparison of the image data with the programmed deposition pattern. (Note 4) The additive manufacturing apparatus according to any of the above appendices, wherein the anomaly is a region of the build layer of a build manufactured in the build zone, where, based on a comparison of the image data with the programmed deposition pattern, there is a greater amount of binder than predetermined, or binder is detected at one or more locations where binder should not be deposited. (Note 5) The additive manufacturing apparatus according to any of the above appendices, wherein the programmed map of the deposition pattern selects one of the plurality of nozzles to select pixels of the build layer of the build to be manufactured in the build zone. (Note 6) Adjusting the deposition pattern programmed for subsequent crossings of the print assembly on the build zone includes updating the amount of binder defined for distribution by a selected nozzle among a plurality of nozzles, as described in any of the above appendices. (Note 7) Adjusting the deposition pattern programmed for subsequent crossings of the print assembly on the build zone involves updating the mapping of selected nozzles among a plurality of nozzles to select pixels in the subsequent build layer, and a first nozzle mapped to distribute binder to a first selected set of pixels during a first crossing of the print assembly is mapped to distribute binder to a second selected set of pixels during a second crossing of the print assembly on the build zone, as described in any of the appendices above. (Note 8) Adjusting the programmed deposition pattern for subsequent crossing of the print assembly on the build zone includes performing a sub-pixel shift to align the pixels defined by the programmed deposition pattern with a plurality of jet nozzles, as described in any of the above appendices, in an additive manufacturing apparatus. (Note 9) The cleaning zone further includes a cleaning station located in the cleaning zone, The cleaning station is configured to clean a plurality of the nozzles of the print assembly, The aforementioned electronic control unit is If an abnormality is detected in the distributed binder pattern, the print assembly is instructed to interface with one or more cleaning elements of the cleaning station. An additive manufacturing apparatus as described in any of the above appendices, further configured as follows. (Note 10) The additive manufacturing apparatus according to any of the above appendices, wherein the electronic control unit is further configured to cause the print assembly to perform a purge operation in the cleaning zone when it determines the presence of an abnormality in the distributed binder pattern. (Note 11) The vision system is an additive manufacturing apparatus as described in any of the above appendices, comprising at least one of an electromagnetic radiation source, a camera, an infrared camera, or an X-ray imaging device. (Note 12) A process chamber having a length defined by at least a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate sections along the length of the process chamber, A support extending along the length of the process chamber in the first vertical plane, A recoat assembly comprising at least one of a doctor blade and a roller for distributing build material within the build zone, wherein the recoat assembly is movably coupled to the support via a second actuator configured to move forward or backward along the length of the support, and is positioned on a second vertical plane parallel to the first vertical plane, A vision system configured to image the distributed layers of build material in the aforementioned build zone, The recoat assembly, the second actuator, and the electronic control unit which is communicatively coupled to the vision system, Includes, The aforementioned electronic control unit is The recoat assembly is subjected to a process that distributes build material according to predetermined build material input parameters, traversing the build zone to form a new layer of build material within the build zone. The system receives image data from the vision system of the build materials distributed within the build zone. The image data is analyzed to determine whether or not there is an abnormality in the distributed build material. If an abnormality is detected in the new layer of the distributed build material, corrective measures will be taken for the subsequent distribution of the build material by the recoat assembly. It is structured in such a way. Additive manufacturing equipment. (Note 13) The modification measures include adjusting predetermined build material input parameters, as described in any of the above appendices, in the additive manufacturing apparatus. (Note 14) Additive manufacturing apparatus according to any of the above appendices, wherein the predetermined build material input parameter is at least one of the build material thickness, over-input amount, recoat assembly speed for traversing the build zone, rotational speed of the rollers of the recoat assembly, and rotational direction of the rollers of the recoat assembly. (Note 15) The additive manufacturing apparatus according to any of the above appendices, wherein the corrective measure includes causing the recoat assembly to redistribute the build material onto the new layer before the print assembly distributes the binder onto the new layer of build material. (Note 16) The aforementioned corrective measures include stopping the build process, as described in any of the above appendices for the additive manufacturing apparatus. (Note 17) Further includes a cleaning station located in the cleaning zone or the supply zone, The cleaning station is configured to clean at least one of the doctor blade and the roller of the recoat assembly. The aforementioned electronic control unit is If the presence of an anomaly in the new layer of the distributed build material is detected, the recoat assembly is to interface with one or more cleaning elements of the cleaning station. An additive manufacturing apparatus as described in any of the above appendices, further configured as follows. (Note 18) The aforementioned electronic control unit is The current draw value of the motor that drives the roller of the recoat assembly is received. The system determines whether the roller is operating according to predetermined build material input parameters. If it is determined that the roller is not operating according to the predetermined build material input parameters, then it is determined that there is an abnormality in the roller of the recoat assembly. Additive manufacturing equipment as described in any of the above appendices. (Note 19) The additive manufacturing apparatus according to any of the above appendices, wherein the vision system includes at least one of a camera, an infrared camera, and an X-ray imaging device. (Note 20) A process chamber having a length defined by at least a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate sections along the length of the process chamber, A support extending along the length of the process chamber in the first vertical plane, A print assembly is movably coupled to the support via a first actuator configured to move forward or backward along the length of the support, and is positioned on a second vertical plane parallel to the first vertical plane. A recoat assembly is movably coupled to the support via a second actuator configured to move forward or backward along the length of the support, and is positioned on the second vertical plane parallel to the first vertical plane. One or more IR lamps, configured to apply energy to the build material and binder in the build zone to stimulate a curing reaction, and coupled to at least one of the print assembly and the recoat assembly, One or more temperature sensors configured to monitor at least one of the gas temperature of the process chamber and the surface temperature of the build material, The print assembly, The first actuator, The recoat assembly, The An electronic control unit communicatively coupled to two actuators, one or more IR lamps, and one or more temperature sensors, Includes, The aforementioned electronic control unit is As the print assembly or recoat assembly traverses the build zone, one or more of the IR lamps are made to emit energy. Receiving temperature values ​​from one or more of the temperature sensors, Determine whether the temperature value is within a predetermined range. If the temperature value is not within the predetermined range, adjust the intensity of one or more of the IR lamps or the flow gas rate of one or more of the IR lamps. It is structured in such a way. Additive manufacturing equipment. (Note 21) Additive manufacturing apparatus according to any of the above appendices, wherein if the temperature value is determined to be below the predetermined range, the intensity of one or more IR lamps is increased. (Note 22) Additive manufacturing apparatus according to any of the above appendices, wherein the intensity of one or more IR lamps is reduced when it is determined that the temperature value exceeds the predetermined range. (Note 23) One or more of the IR lamps, the first IR lamp, is coupled to the print assembly. One or more of the IR lamps, the second IR lamp, is coupled to the recoat assembly. Additive manufacturing equipment as described in any of the above appendices. (Note 24) Additive manufacturing apparatus according to any of the above appendices, wherein the electronic control unit controls the flow gas rate around one or more IR lamps. (Note 25) One or more of the temperature sensors are gas temperature sensors, The aforementioned electronic control unit is If it is determined that the surface temperature of the build material is not within the predetermined range, the gas flow rate around one or more IR lamps is adjusted. It is further structured in the following way: Additive manufacturing equipment as described in any of the above appendices. (Note 26) Additive manufacturing apparatus according to any of the above appendices, wherein if the surface temperature value is determined to be below the predetermined range, the flow gas rate around one or more IR lamps is increased. (Note 27) Additive manufacturing apparatus according to any of the above appendices, wherein if the surface temperature value is determined to exceed the predetermined range, the flow gas rate around one or more IR lamps is reduced. (Note 28) The process chamber further includes an environmental control system fluidically coupled to it. If the process chamber temperature is determined to be outside a predetermined range, the environmental control system delivers heated gas to the process chamber. Additive manufacturing equipment as described in any of the above appendices. (Note 29) The build plate heater is further thermally coupled to the build platform of the build zone, If the temperature value of the surface temperature of the build material surface is determined to be below the predetermined range, the electronic control unit shall instruct the build plate heater to increase the amount of energy delivered to the build material and the build plate in the build zone. Additive manufacturing equipment as described in any of the above appendices. (Note 30) A process chamber having a length defined by at least a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate sections along the length of the process chamber, An environmental control system comprising one or more subsystems connected to the process chamber and controlling the environmental conditions within the process chamber, One or more sensors configured to monitor at least one of the temperature of the process chamber, the vapor content, and the process gas concentration within the process chamber, The environmental control system and one or more of the sensors are communicated with an electronic control unit, Includes, The aforementioned electronic control unit is Receiving sensor data from one or more of the aforementioned sensors, Determine whether the sensor data from one or more of the sensors corresponds to a predetermined set of environmental conditions in the process chamber during the build process. If the sensor data is determined to be outside the predetermined set of environmental conditions, the system automatically adjusts one or more environmental control settings of the environmental control system. It is structured in such a way. Additive manufacturing equipment. (Note 31) The aforementioned electronic control unit is If the sensor data indicates that the temperature of the process chamber is below the predetermined set of environmental conditions, the environmental control system is instructed to start the flow to the process chamber through the heat exchanger of the environmental control system. If the sensor data indicates that the temperature of the process chamber exceeds the predetermined set of environmental conditions, the environmental control system will stop the flow from the environmental control system through the heat exchanger to the process chamber. It is further structured in the following way: Additive manufacturing equipment as described in any of the above appendices. (Note 32) The aforementioned electronic control unit is If the sensor data indicates that the vapor content exceeds the predetermined set of environmental conditions, the environmental control system is instructed to start the flow through the heat exchanger, dehumidifier, or condenser of the environmental control system. If the sensor data indicates that the vapor content is below the predetermined set of environmental conditions, the environmental control system will stop the flow through the heat exchanger, dehumidifier, or condenser of the environmental control system. It is further structured in the following way: Additive manufacturing equipment as described in any of the above appendices. (Note 33) The aforementioned electronic control unit is If the sensor data indicates that the process gas concentration is below the predetermined set of environmental conditions, the environmental control system is instructed to start the flow from the process gas supply of the environmental control system. If the sensor data indicates that the process gas concentration exceeds the predetermined set of environmental conditions, the environmental control system will be instructed to use the process gas supply of the environmental control system. Stop the flow from I. It is further structured in the following way: Additive manufacturing equipment as described in any of the above appendices. (Note 34) The system further includes a particulate sensor configured to detect the concentration of airborne build material within the process chamber, The aforementioned electronic control unit is If the sensor data indicates that the concentration of the airborne build material exceeds the predetermined set of environmental conditions, the environmental control system will start the air filtration system of the environmental control system. If the sensor data indicates that the concentration of the airborne build material falls below the predetermined set of environmental conditions, the environmental control system will stop the flow from the air filtration system of the environmental control system. It is further structured in the following way: Additive manufacturing equipment as described in any of the above appendices. (Note 35) A process chamber having a length defined by at least a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate sections along the length of the process chamber, A support extending along the length of the process chamber in the first vertical plane, A print assembly is movably coupled to the support via a first actuator configured to move forward or backward along the length of the support, and is positioned on a second vertical plane parallel to the first vertical plane, and includes a plurality of nozzles for distributing a binder within the build zone. A recoat assembly comprising at least one of a doctor blade and a roller for distributing build material within the build zone, movably coupled to the support via a second actuator configured to move forward or backward along the length of the support, and positioned on the second vertical plane parallel to the first vertical plane, A vision system configured to image the aforementioned build zone, The printed assembly, the recoated assembly, the first actuator, the second actuator, and an electronic control unit communicatively coupled to the vision system, Includes, The aforementioned electronic control unit is During the first interval, the build zone is traversed in the forward direction while distributing the binder to the print assembly according to a programmed deposition pattern. During the second interval following the first interval, image data of the distributed binder pattern is received from the vision system. The image data is analyzed to determine whether or not there is an abnormality in the binder pattern distributed during the second interval. During the second interval, the build zone is traversed in the reverse direction while distributing the binder according to the programmed deposition pattern in the print assembly. The recoat assembly is directed to traverse the build zone in the reverse direction to distribute the build material supplied to the supply zone in order to form a new layer of build material in the build zone according to predetermined build material input parameters, and the recoat assembly is directed to traverse the build zone according to the print assembly during the second and third intervals. The print assembly is instructed to perform at least one of a purging process and a wiping process while traversing the cleaning zone in both forward and reverse directions during the third interval. It is structured in such a way. Additive manufacturing equipment. (Note 36) The aforementioned electronic control unit is During the fourth interval, the recoat assembly is made to traverse the build zone in the forward direction, distributing the binder according to the programmed deposition pattern on the new layer of build material, and the print assembly is made to traverse the build zone in the forward direction, following the recoat assembly traversing the build zone. Additive manufacturing equipment as described in any of the above appendices. (Note 37) Additive manufacturing apparatus as described in any of the above appendices, wherein the electronic control unit is further configured to adjust the programmed deposition pattern for subsequent crossing of the print assembly on the build zone in order to address the anomaly when it determines the presence of the anomaly in the distributed binder pattern. (Note 38) The additive manufacturing apparatus according to any of the above appendices, wherein the electronic control unit is further configured to take corrective action for subsequent distribution of the build material by the recoat assembly when it determines the presence of the abnormality in the new layer of the distributed build material. (Note 39) The additive manufacturing apparatus according to any of the above appendices, wherein the electronic control unit is further configured to cause the print assembly to perform subpixel indexing of the plurality of nozzles between the first interval and the second interval. (Note 40) The additive manufacturing apparatus according to any of the above appendices, wherein a delay is performed before the recoat assembly begins to traverse the build zone in the reverse direction, following the print assembly that traverses the build zone, during the second and third intervals. (Note 41) The print assembly is an additive manufacturing apparatus according to any of the above appendices, which traverses the build zone in the forward and reverse directions at a first speed. (Note 42) The print assembly traverses the cleaning zone in the forward and reverse directions at a second speed. The second speed is slower than the first speed. Additive manufacturing equipment as described in any of the above appendices. (Note 43) The system further includes one or more IR lamps configured to apply energy to the binder and build material within the build zone in order to stimulate the curing reaction. One or more of the IR lamps are coupled to at least one of the print assembly and the recoat assembly. Additive manufacturing equipment as described in any of the above appendices. (Note 44) Two IR lamps are coupled to the recoat assembly, The first IR lamp is coupled to the front surface of the recoat assembly. The second IR lamp is coupled to the rear-facing surface of the recoat assembly. Additive manufacturing equipment as described in any of the above appendices.

[0143] (Cross-reference of related applications) This specification asserts the rights of U.S. Patent Provisional Application No. 63 / 108,549, filed on 2 November 2020, entitled “Additive Manufacturing Apparatus and Method of Operating the Same,” which is incorporated herein by reference in its entirety.

Claims

1. A process chamber having a length defined by at least a cleaning zone, a build zone, and a supply zone, which are sequentially arranged in separate sections along the length of the process chamber, A support extending along the length of the process chamber in the first vertical plane, A print assembly is movably coupled to the support via a first actuator configured to move forward or backward along the length of the support, and is positioned on a second vertical plane parallel to the first vertical plane. A recoat assembly is movably coupled to the support via a second actuator configured to move forward or backward along the length of the support, and is positioned on the second vertical plane parallel to the first vertical plane. One or more IR lamps, configured to apply energy to the build material and binder in the build zone to stimulate a curing reaction, and coupled to at least one of the print assembly and the recoat assembly, One or more temperature sensors configured to monitor at least one of the gas temperature of the process chamber and the surface temperature of the build material, The printed assembly, the first actuator, the recoat assembly, the second actuator, one or more IR lamps, and one or more temperature sensors are communicateably coupled to an electronic control unit, Includes, The aforementioned electronic control unit is As the print assembly distributes the binder across the build zone, energy is released to an IR lamp coupled to the print assembly, and / or as the recoat assembly distributes the build material across the build zone, energy is released to an IR lamp coupled to the recoat assembly. A temperature value is received from one or more of the temperature sensors. Determine whether the temperature value is within a predetermined range. If the temperature value is not within the predetermined range, the intensity of one or more of the IR lamps or the flow gas rate around one or more of the IR lamps is adjusted; if the temperature value is within the predetermined range, the intensity of one or more of the IR lamps and the flow gas rate around one or more of the IR lamps are not adjusted. It is structured in such a way. Additive manufacturing equipment.

2. The additive manufacturing apparatus according to claim 1, wherein if the temperature value is determined to be below the predetermined range, the intensity of one or more IR lamps is increased.

3. The additive manufacturing apparatus according to claim 1, wherein if the temperature value is determined to exceed the predetermined range, the intensity of one or more IR lamps is reduced.

4. One or more of the first IR lamps are coupled to the print assembly. One or more of the IR lamps, the second IR lamp, is coupled to the recoat assembly. The additive manufacturing apparatus according to claim 1.

5. The additive manufacturing apparatus according to claim 1, wherein the electronic control unit controls the flow gas rate around one or more IR lamps.

6. One or more of the temperature sensors are gas temperature sensors, The aforementioned electronic control unit is If it is determined that the surface temperature of the build material is not within the predetermined range, the flow gas rate around one or more IR lamps is adjusted. It is further structured in the following way: The additive manufacturing apparatus according to claim 5.

7. The additive manufacturing apparatus according to claim 6, wherein if it is determined that the surface temperature value falls below the predetermined range, the flow gas rate around one or more IR lamps is increased.

8. The additive manufacturing apparatus according to claim 6, wherein if the surface temperature value is determined to exceed the predetermined range, the flow gas rate around one or more IR lamps is reduced.

9. The process chamber further includes an environmental control system fluidically coupled to it. If the process chamber temperature is determined to be outside a predetermined range, the environmental control system delivers heated gas to the process chamber. The additive manufacturing apparatus according to claim 1.

10. The build plate heater is further thermally coupled to the build platform of the build zone, If the temperature value of the build material surface temperature is determined to be below the predetermined range, the electronic control unit shall increase the amount of energy delivered to the build plate heater in the build zone and to the build plate. The additive manufacturing apparatus according to claim 1.

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