WO2020091753A1

WO2020091753A1 - Insertable devices for a build unit

Info

Publication number: WO2020091753A1
Application number: PCT/US2018/058367
Authority: WO
Inventors: Eduard GALDEANO CASTILLO; Jordi REIG ARMERO; Gerard GUIXE SIMON
Original assignee: Hewlett-Packard Development Company, L.P.
Priority date: 2018-10-31
Filing date: 2018-10-31
Publication date: 2020-05-07

Abstract

In one example, there is a device insertable into a build unit of a 3D printer. The device comprises a sidewall defining two open ends of the device and an interior chamber therebetween. A base is disposed in the interior chamber and is moveable relative to the sidewall.

Description

INSERTABLE DEVICES FOR A BUILD UNIT

BACKGROUND

[0001] Additive manufacturing systems that generate three-dimensional objects on a layer-by-layer basis have been proposed as a potentially convenient way to produce three-dimensional objects.

BRIEF DESCRIPTION OF DRAWINGS

[0002] Examples will now be described, by way of non-limiting example, with reference to the accompanying drawings, in which:

[0003] Figure 1 is a simplified schematic of an example device;

[0004] Figure 2 is a simplified schematic of an example device;

[0005] Figure 3 is a flowchart of an example method of printing an object;

[0006] Figures 4A-4E schematically indicate an example method;

[0007] Figure 5 is a simplified schematic of an example unit; and

[0008] Figure 6 is a simplified schematic of an example unit.

DETAILED DESCRIPTION

[0001 ] Additive manufacturing techniques may generate a three- dimensional object through the solidification of a build material. The build material may be powder-based and the properties of generated objects may depend on the type of build material and the type of solidification mechanism used. In a number of examples of such techniques including sintering techniques, build material is supplied in a layer-wise manner and the solidification method includes heating the layers of build material to cause melting in selected regions. In other techniques, chemical solidification methods may be used.

[0002] Additive manufacturing systems may generate objects based on structural design data. This may involve a designer generating a three- dimensional model of an object to be generated, for example using a computer aided design (CAD) application. The model may define the solid portions of the object. To generate a three-dimensional object from the model using an additive manufacturing system, the model data can be processed to generate slices of parallel planes of the model. Each slice may define a portion of a respective layer of build material that is to be solidified or caused to coalesce by the additive manufacturing system.

[0003] Some additive manufacturing systems comprise a build unit comprising a a moveable platform on which the build material is placed to then be solidified. The moveable platform may be raised and lowered so that the object may be solidified in layers. Once the object is solidified in the build unit, the build unit may then be set aside while the object is left to cool. This process can take, for example, hours, or a day or even days depending on the nature of the object being printed or the size of the build unit. Therefore, it can be some time before the build unit (once the solidified and cooled object is removed) can be returned to the additive manufacturing system for a subsequent print job.

[0004] Some examples herein relate to a device, or unit, that is insertable into, and removable from, a build unit of an additive manufacturing system (hereinafter referred to as a “3D printer”). Some examples herein relate to inserting such a device, or unit, into a build unit of a 3D printer, providing a build material (e.g. a powder-based build material) onto a moveable base of the device, or unit, and solidifying (e.g. by selective heating) the build material to form a solidified (or 3D-printed) object. In some examples, as the moveable platform of the build unit descends so that the next layer of build material may be provided and sintered, the moveable base of the device, or unit, may move with the moveable platform to lower the build material and therefore the object. This process may be repeated to form the completed object.

[0005] According to some examples, once the solidifying of the object is complete, the device, or unit, itself may be removed from the build unit to cool the newly-printed object at a location remote from the build unit, to thereby free up the build unit for a subsequent print job.

[0006] Figure 1 shows an example device 100. As will be explained below, the device 100 is insertable into, and removable from, a build unit (not shown in Figure 1 ) of a 3D printer. For example, the device 100 may be insertable into a build unit.

[0007] The device 100 comprises a sidewall 1 10. For example, the device 100 may comprise a cylindrical sidewall. In one example, the device 100 comprises a set of sidewalls. The sidewall 1 10 defines two open ends 1 1 1 , 1 12 (e.g. first 1 1 1 and second 1 12 open ends) of the device 100, and an interior chamber 1 13. The interior chamber 1 13 is in between the sidewall 1 10 and the open ends 1 1 1 , 1 12 of the device.

[0008] The device 100 comprises a base 1 15. The base 1 15 is disposed between the two open ends 1 1 1 , 112 and is moveable relative to the sidewall 1 10. The base 1 15 is therefore a moveable base 1 15. In use the first open end 1 1 1 may be an upper end of the device 100 and the second open end 1 12 may be a lower end of the device 1 12.

[0009] The interior chamber 1 13 comprises a width W. The width W of the interior chamber 1 13 may be defined as the distance between two opposing points of the sidewall 1 10. A length L of the moveable base 1 15 may, in one example, be substantially equal to the width of the interior chamber 1 13 such that the edges of the base substantially abut the edges of the sidewall 1 10 when the base 1 15 is received in the interior chamber 1 13.

[0010] In some examples the sidewall 1 10 may be cylindrical, defining a substantially cylindrical-prism interior chamber 1 13 therebetween. In this example, the cross-sections of the interior chamber 1 13 may comprise circles (or, in one example, ovals). In other examples the sidewall 1 10 may comprise two sets of opposing faces, thereby defining a rectangular-prism interior chamber 1 13. In the latter example, the base 1 15 may be substantially rectangular. In this example, cross sections of the interior chamber 1 13 may comprise rectangles (e.g. squares).

[0011] The base 1 15 may not be attached to the sidewall 1 10, but may contact the sidewall 1 10. For example, the dimensions of the sidewall 1 10 and base 1 15 may be so that the base touches the sidewall 1 10 but is not so large as to be held in place with a friction fit. For example, the base 1 15 may be sized such that, upon insertion into the interior chamber 1 13, the base 1 15 is slideable relative to the sidewall 1 10. The base 1 15 may therefore be slidably disposed within the interior chamber 1 13. The two ends 1 1 1 , 1 12 may define, in use, uppermost and lowermost ends of the device 100.

[0012] As will be explained below, the device 100 is insertable into a build unit of a 3D printer and the moveable base 1 15 is engageable with the moveable platform of the 3D printer such that a build material may be placed, and an object solidified therefrom, on the moveable base 1 15. Thereafter, the device 100 (and the printed objet contained in the interior chamber 1 13 thereof) may be removed from the build unit and set aside to cool.

[0013] Figure 2 shows an example of the device 100. The device 100 of the example of Figure 2 is shown inserted in a build unit 250 of a 3D printer. For example, the device 1 10 is inserted into an internal chamber 270 of the build unit 250.

[0014] The device 100 in the example of Figure 2 comprises a removable lid 1 16. The removable lid 1 16 is to close the open end 1 1 1 of the device 100 to seal the interior chamber 1 13. The lid 1 16 in this example comprises two handles 1 17a, 1 17b. In one example however the lid 1 16 may comprise one handle. The handles 1 17a, 1 17b may be to allow a human and/or machine to lift the device 100, when the lid 1 16 is secured to the device 110 out of the build unit 250 and out of the 3D printer. For example, two handles 1 17a, 1 17b may be sized and/or spaced to receive the prongs of a forklift truck so that a forklift may engage the device 100 and lift the device 100 out of the build unit 250 following a print job.

[0015] The base 1 15 comprises a lock, schematically indicated by 1 18. The lock 1 18 is to fix the position of the base 1 15 relative to the sidewall 1 10.

[0016] The sidewall 1 10 in the example of Figure 2 comprises a stop 120. The stop 120 is to engage the moveable base 1 15 to prevent movement of the base 1 15 past the stop 120. In one example the stop 120 is provide in order to prevent movement of the base 1 15 past the open end 1 12. For example, the stop 120 may be provided at the open end 112 of the device 100, e.g. at the bottom of the device 100 in use. For example, the stop 120 may be provided to prevent the base 1 15 falling (or sliding) out of the device 1 10 (e.g. via the open end 1 12). The stop 120 may therefore prevent the base 1 15 being moved out of the internal chamber 1 13 (e.g. when the device 100 is empty and being carried to the build unit 250 for a print job). When the device 100 is out of the build unit (e.g. removed from the build unit), the moveable base 1 15 may move to a lowermost end of the device, e.g. the end 1 12, under gravity alone.

[0017] In one example, a gasket 121 is provided between the moveable base 1 15 and the sidewall 1 10. The gasket 121 may have a lower coefficient of friction than the base 1 15 and therefore may facilitate smoother movement between the base 115 and the sidewall 1 10. In the example of Figure 2 the base 1 15 is dimensioned so as not to touch the sidewalls when in the interior chamber 1 13, and engagement between the base 1 15 and sidewalls 1 10 is instead via the gasket 121 . The gasket 121 may comprise plastic.

[0018] The build unit 250, into which the device 100 is shown inserted in Figure 2, comprises a moveable build unit platform 260. The moveable base 1 15 of the device 100 is moveable with the moveable build unit platform 260.

[0019] The stop 120 is depicted in the Figure 2 as a flange, or protruding lip, from the sidewall 1 10. In this example, the base 1 15 is engageable with the flange so as to prevent the base 1 15 moving past the flange. However, another kind of stop may be used rather than a flange (e.g. a dog or lug, received in a corresponding hole, or an electronically-controlled stopping mechanism).

[0020] The moveable base 1 15 comprises an attachment mechanism, shown schematically at 1 19, the attachment mechanism 1 19 being to secure the base 1 15 to the moveable build unit platform 260. For example, the attachment mechanism 1 19 may comprise a lock, or dog or lug, or a magnetic element).

[0021] As will be explained with further reference to the example of Figures 3 and 4, when the device 100 is in inserted into the build unit 250, as depicted in Figure 2, the moveable base 1 15 may engage the moveable platform 260 of the build unit 250. Build material to be solidified may be deposited onto the moveable base 1 15, and the moveable platform 260 may be raised to a position to begin a print job. If the moveable platform 260 is under the moveable base 1 15, then the two may be raised together. The attachment mechanism 1 19 may attach the moveable base 1 15 to the moveable platform 260 so that the two may be moved (e.g. lowered) together, e.g. during a print job in which the base 1 15 is to be lowered for solidifying subsequent layers of the object being printed. Movement of the base 1 15 during the print job may be affected by virtue of engagement between the gasket 121 and the sidewall 1 10. [0022] At the conclusion of the print job, the position of the base 1 15 may be at an intermediate location between the two device ends 11 1 , 1 12. In this example, the locking mechanism 1 18 may be actuated to fix the base 1 15 in its current position so that the newly-solidified object thereon is not damaged by a sudden downward movement of the base (e.g. under the influence of gravity) when the device 100 is lifted from the build unit 250. Alternatively, the stop 120 may prevent the base 1 15 being moved out of the internal chamber 1 13 defined by the sidewall 1 10 if the dimensions of the object are such that the base 1 15 has moved to an end 1 12 of the device 1 10 proximate the floor of the build unit (e.g. a lowermost end) during a print job.

[0023] Figure 3 shows an example method 300. The method 300 may be a method of 3D printing an object (or printing a 3D object). The method 300 may be a method of printing an object and cooling the printed object. The method 300 may utilise the devices described with reference to Figures 1 and 2, respectively.

[0024] The method 300 comprises, at block 302, inserting a device comprising a moveable base into a build unit of a 3D printer. For example, the device may comprise a moveable base and inserting the device, at block 302, may comprise engaging the moveable base with a moveable platform of the build unit. For example, the device may be inserted into the build unit such that a lower face of the moveable base of the device may engage an upper face of the moveable platform of the build unit.

[0025] The method 300 comprises, at block 304, printing a 3D object onto the moveable base of the device. Block 304 may comprise depositing a build material into the device. For example, block 304 may comprise depositing a build material onto a moveable platform of the device. Block 304 may comprise solidifying part of the build material layer-by-layer to form a solidified object on the moveable part of the device. Block 304 may comprise sequentially moving the moveable base of the device downwards so that a subsequent layer of build material may be solidified. For example, block 304 may comprise moving a moveable build unit platform downward, which may cause the moveable base of the device to move downward with the moveable platform.

[0026] The method 300 comprises, at block 306, removing the device from the build unit of the 3D printer. Block 306 may comprise sealing the device.

[0027] An example of the method 300 is schematically illustrated in Figures

4A-4E. [0028] Figure 4A depicts inserting a device 400 comprising a moveable base 415 into a build unit 450 of a 3D printer 490. A build material (not shown) is deposited onto the moveable base 415 to be solidified (e.g. by sintering via laser).

[0029] Figure 4B depicts raising the moveable build unit platform 460 of the build unit 450 to begin a 3D print job. The moveable base 415 of the device 400 moves with the moveable platform 460 of the build unit 450. Therefore, to begin the print job, the build material (deposited onto the moveable base 1 15) is raised to a position remote from the base of the built unit 450 (e.g. an uppermost position).

[0030] Figure 4C depicts the device during a print job. For example, Figure 4C depicts a snapshot of the solidifying process of the build material to become a printed object 435 on the moveable base of the device. The moveable platform 460 moves downward during a print job so that a subsequent layer of build material may be deposited onto the object 435 and then solidified to form the subsequent layer of the printed object 435.

[0031] Figure 4D depicts sealing the device 400 with a removable lid 416. The seal formed by the lid 416 may be an air-tight seal. In Figure 4D the print job is complete and the 3D printed object 435 occupies substantially all of the device 400 (e.g. an internal space thereof). As shown in Figure 4D, at the end of the print job the moveable base 415 is proximate the floor of the build unit 450.

[0032] Figure 4E depicts removing the device 400 from the build unit 450 of the 3D printer 490. In one example this may free the build unit 450 for a subsequent print job. For example, after removing the device 400, another similar device may be inserted into the build unit 450 for another print job.

[0033] The device 400 may be the example device 100 as depicted with reference to Figures 1 or 2, respectively, or the example device 500 as will now be described with reference to Figures 5 and 6.

[0034] Figure 5 depicts an example unit 500. The unit may be insertable into a build unit of a 3D printer.

[0035] The unit 500 comprises a frame 510 comprising first and second open ends 51 1 , 512 and a platform 515 moveably coupled to the frame 510 between the first and second open ends 51 1 , 512. In use, the first end 51 1 may be an upper end of the frame 510 and the second end 512 may be a lower end of the frame 510. [0036] The unit 500 is engageable with a moveable build platform of a build unit, or build bed, of a 3D printer such that the platform 515 is moveable with the moveable build platform.

[0037] Although the frame 510 is depicted in Figure 5 as not enclosed in one example it may be enclosed. For example, the frame 510 may define a container enclosing the moveable platform 515. The frame 510 may be any shape to define an area therebetween for the platform 515.

[0038] Figure 6 depicts an example of the unit 500 of Figure 5. The unit 500 in Figure 6 comprises a lid 16. The lid 516 is to close the first open end 51 1.The lid 516 comprises a handle 517 to move the unit 500. For example, the unit 500 may be sealed, via the lid 516, enclosing a printed job therein and then moved by the handle 517.

[0039] The platform 515 comprises a lock 519 to secure the platform 515 relative to the frame 510. The lock 519 may be a hook that may engage an opening in the frame 510. In this way the position of the platform 515 may be fixed relative to the frame 515, e.g. if the platform 515 has moved during a print job to an intermediate position between the ends 51 1 , 512 and the print job then concludes, the lock 519 may secure the platform 515 so that its position does not change when the unit 500 is moved.

[0040] The frame 510 comprises a securing feature 520 at a first location on the frame 510. The securing feature 520 is to engage the platform 515 so as to prevent the platform 515 from moving past the first location on the frame 510, e.g. falling out or sliding out of the frame (for example sliding past a lowermost open end 512 under the force of gravity). The securing feature 520 may comprise a protrusion from the frame 510 and the platform 515 may engage the protrusion so that it is prevent from moving further. The first location may be at the bottom of the frame, in use, for example proximate the second end 512.

[0041] Examples in the present disclosure may store print jobs as they are printed, without transfer from one container to another while the build material is still hot from the print job (which could lead to print quality deficiencies, deformations, or broken parts). Printer components may not therefore interact during the job unloading process, since the device or unit may be lifted from the build bed and moves elsewhere to let the printed object cool. Powder leaks may also be minimised during normal user workflows. The hardware of the build unit (e.g. motor) is no longer forced to lift a full printed object to another location, thereby improving the lifespan of such components.

[0042] A user also need not be concerned with correct placement of the device or unit as the moveable base or platform is engageable with the moveable platform of the build unit.

[0043] Examples in the present disclosure can be provided as methods, systems or machine readable instructions, such as any combination of software, hardware, firmware or the like. Such machine readable instructions may be included on a computer readable storage medium (including but is not limited to disc storage, CD-ROM, optical storage, etc.) having computer readable program codes therein or thereon.

[0044] The present disclosure is described with reference to flow charts and/or block diagrams of the method, devices and systems according to examples of the present disclosure. Although the flow diagrams described above show a specific order of execution, the order of execution may differ from that which is depicted. Blocks described in relation to one flow chart may be combined with those of another flow chart.

[0045] While the method, apparatus and related aspects have been described with reference to certain examples, various modifications, changes, omissions, and substitutions can be made without departing from the spirit of the present disclosure. It is intended, therefore, that the method, apparatus and related aspects be limited only by the scope of the following claims and their equivalents. It should be noted that the above-mentioned examples illustrate rather than limit what is described herein, and that those skilled in the art will be able to design many alternative implementations without departing from the scope of the appended claims.

[0046] The word“comprising” does not exclude the presence of elements other than those listed in a claim,“a” or“an” does not exclude a plurality, and a single processor or other unit may fulfil the functions of several units recited in the claims.

[0047] The features of any dependent claim may be combined with the features of any of the independent claims or other dependent claims.

Claims

1. A device insertable into a build unit of a 3D printer, the device comprising: a sidewall defining two open ends of the device and an interior chamber therebetween;

a base disposed in the interior chamber;

wherein the base is moveable relative to the sidewall.

2. A device according to claim 1 wherein the base comprises a lock to fix its position relative to the sidewall.

3. A device according to claim 1 wherein the sidewall comprises a stop to engage the moveable base to prevent movement of the base past the stop.

4. A device according to the claim 1 the device further comprising:

a removable lid to close one of the open ends of the device to seal the interior chamber.

5. A device according to claim 1 wherein the base is movable with a moveable build platform of the build unit.

6. A device according to claim 5 wherein the base comprises an attachment mechanism to secure the base to the moveable build platform.

7. A method comprising:

inserting a device comprising a moveable base into a build unit of a 3D printer;

printing a 3D object onto the moveable base of the device;

removing the device from the build unit of the 3D printer.

8. A method according to claim 7 wherein the moveable base of the device moves with a moveable platform of the build unit of the 3D printer.

9. A method according to claim 9 further comprising:

sealing the device with a removable lid.

10. A method according to claim 9 wherein the removable lid comprises a handle and wherein removing the device comprises lifting the device from the build unit by the handle.

1 1 . A unit comprising:

a frame comprising two open ends; and

a platform moveably coupled to the frame between the two open ends; wherein the unit is engageable with a moveable build platform of a build unit of a 3D printer such that the platform is moveable with the moveable build platform.

12. A unit according to claim 1 1 wherein the frame comprises a securing feature at a first location on the frame to engage the platform so as to prevent the platform from moving past the first location on the frame.

13. A unit according to claim 1 1 wherein the frame comprises a lock to secure the platform relative to the frame.

14. A unit according to claim 1 1 further comprising a lid to close one of the open ends.

15. A unit according to claim 15 wherein the lid comprises a handle to move the unit.