US007766641B2

(12) Ulllted States Patent (10) Patent N0.: US 7,766,641 B2 Silverbrook (45) Date of Patent: *Aug. 3, 2010

(54) THREE DIMENSIONAL (3D) PRINTER 5,594,652 A 1/1997 Penn et a1. SYSTEM WITH PLACEMENT AND CURING 5,705,117 A 1/1998 O’Connor et a1. MECHANISMS 5,869,170 A 2/1999 Cima et 211.

6,025,012 A 2/2000 Matsuda et a1. 75 _ . . - 6,026,748 A * 2/2000 Reed et a1. ............. .. 101/4241

( ) Inventor. Kla Sllverbrook, Balmain (AU) 6,165,406 A 120000 Jang et a1‘

(73) Assignee: Silverbrook Research Pty Ltd, E221‘: et al' Balmam, New S°mhWa1eS(AU) 6,641,243 B2 11/2003 Anderson et a1.

6,658,314 B1 12/2003 G th 't ( * ) Notice: Subject' to any disclaimer, the term of this 6,994,412 B2 200% WZStSjJ-k et a1‘

patent 1s extended or adjusted under 35 6,997,698 B2 2/2006 Silverbrook U.S.C. 154(b) by 306 days. 7,077,502 B2 7/2006 Mitsuzawa

7,373,214 B2 5/2008 Silverbrook This patent is subject to a terminal dis- 2002/0067382 A1 6/2002 Vega et a1. C1aimer_ 2005/0263932 A1 12/2005 Heugel

(21) App1_ NO; 11/775,160 FOREIGN PATENT DOCUMENTS

. DE 10014682 Al 9/2001 (22) Filed: Jul. 9, 2007 GB 2360978 A 10/2001

JP 54036386 3/1979 (65) PI‘IOI‘ Publication Data JP 02439216 A 5/1991

US 2007/0252871 A1 Nov. 1, 2007 _ _ * cited by examiner

Related US‘ Application Data Primary ExamineriMaria Veronica D EWald

(63) Continuation of application No. 10/542,454, ?led as application No. PCT/AU2004/000023 on Jan. 9, 2004, (57) ABSTRACT noW Pat. No. 7,249,942.

A printer system is provided for developing a three dimen (30) Foreign Application Priority Data sional (3D) printed structure. The system includes a plurality Jan 1 6 2003 (AU) 2003900180 of spaced apart sets of printing devices. A conveyor system is

' ’ """""""""""""" " arranged to serially convey a print medium operatively With

(51) Int_ CL respect to each set so that printed voxels from each successive 3283 1/16 (200601) set can form successive layers of the 3D printed structure

(52) U 5 Cl 425/375 264/113_ 264/308 upon the print medium. A placement mechanism is con?g ' ' ' """"""""""" " ’ 347/47’_ 347/102’ ured to place an object upon layers of the 3D printed structure.

58 F, M f Cl ,? t, s h ’ 4 2 5 B7 5 The placement mechanism includes a translation mechanism ( ) 1e 0 425511;: ‘1911343742 14/1 13 308’ con?gured to translate the object at substantially the same

See a lication ?le‘ f’or Com l’ete séarcil histo ’ velocity as the conveyance of the print medium during place pp p 1y‘ ment of the object. A plurality of curing mechanisms is inter

(56) References Cited leaved betWeen the sets of printing devices and is con?gured to cure the printed voxels.

U.S. PATENT DOCUMENTS

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US 7,766,641 B2 1

THREE DIMENSIONAL (3D) PRINTER SYSTEM WITH PLACEMENT AND CURING

MECHANISMS

CROSS-REFERENCE TO RELATED APPLICATION

This Application is a continuation of US. application Ser. No. 10/542,454, ?led in Jul. 15, 2005, Which is a national phase application (371) of PCT/AU2004/00023, ?led on J an. 9, 2004 all of Which are herein incorporated by reference.

CO-PENDING APPLICATIONS

Various methods, systems and apparatus relating to the present invention are disclosed in the following co-pending applications ?led by the applicant or assignee of the present invention simultaneously With the present application:

PCT/AU2004/000024 PCT/AU2004/000026 PCT/AU2004/000034

he disclosures of these co-pending applications are incor porated herein by cross-reference

FIELD OF INVENTION

This invention relates to the creation of objects using digi tal additive manufacturing and more particularly to creating Working objects that may be electrically and/or mechanically active.

BACKGROUND

Digital additive manufacturing is a process by Which an object is de?ned three dimensionally by a series of volume elements (hereinafter referred to as voxels). The object is then produced by creating/ laying doWn each voxel one at a time, in roWs at a time, sWaths at a time or layers at a time.

There exists systems that use modi?ed inkj et type technol ogy to ‘print’ material onto a substrate, so building the object. HoWever, these systems typically utiliZe a single scanning printhead and are only useful for producing non-Working models.

SUMMARY OF INVENTION

In the present invention We digitally de?ne objects as a series of voxels and have a production line that creates objects by creating each voxel. The production line simultaneously creates different portions of objects With each portion pro duced by a separate sub system. In the preferred embodiments each portion is for different products and so the system builds up multiple objects simultaneously. The ?nished objects may be of identical or of different designs. The portions may be of any shape that may be digitally described. Portions produced by different subsystems may have different shapes.

In the preferred embodiments each and every voxel has the same dimension. HoWever, a product may be de?ned by vox els of more than one siZe.

The portions are preferably created or laid doWn onto one or more substrates. In the preferred embodiments one or more

substrates are provided, each having a substantially planar surface upon Which material is deposited. Each of the sur faces preferably moves in it’s oWn plane past the subsystems but does not otherWise move relative to the subsystems. Each

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2 substrate need not have a planar surface upon Which material is deposited and the surface may be of any shape desired. The substrate may move past the subsystems at a constant velocity along a path or may move in steps. The substrate may also be caused to rotate about one or more axes, as it moves betWeen

subsystems, as it moves past subsystems, as it is stationary or in combinations of these. In the preferred embodiments a continuous substrate moves past the subsystems of the pro duction line at a substantially constant velocity. The portions of the object produced by successive sub

systems preferably lie on top of each other but could be spaced apart from each other, positioned end on end, adjacent to each other or in any other con?guration. As an example, a substrate having a cylindrical surface may be caused to rotate about its axis as it moves past a subsystem, so that material deposited extends in a helix on the cylindrical surface. The portions are preferably layers of the object and the

layers are preferably tWo dimensional, i.e. they lie in a ?at plane. HoWever, the layers need not be planar. The layers may have a constant thickness. Layers having differing thickness Within the one layer are Within the scope of the invention. Similarly objects may be made With multiple layers that do not have the same thickness characteristics.

In the preferred embodiments each layer is planar, is made up of voxels of constant siZe and all layers have the same dimensions. Alternate layers may be offset relative to each other. Preferably alternate layers are offset by half a voxel in one or both of tWo mutually orthogonal directions.

Because voids may be formed in the object, When We refer to a ‘layer’ We mean a layer as de?ned, Which may include voids, not a continuous layer of material or materials.

In preferred embodiments each layer is created by one or more printheads. In the preferred embodiments the print heads are arranged along a longitudinally extending produc tion line and one or more substrates move past the printheads, and apart from the ?rst layer, the printheads print onto a previously printed layer of material(s). The printheads for all layers operate simultaneously and so Whilst the ?rst printhead is printing a ?rst layer of a ?rst set of one or more products, the second printhead is printing a second layer of a second set of one or more products and the third printhead is printing a third layer of a third set. Thus if We have a product 1000 layers high We have 1000 different subsystems, one for each layer. These 1000 subsystems operate to simultaneously produce 1000 different layers of 1000 sets of products.

In the preferred embodiments the printheads extend across the Width of the substrate and are capable of printing across the full substrate Width simultaneously i.e. they do not scan or raster When printing but are stationary. This enables a sub strate to be moved past the printheads at a substantially con stant speed, With the printheads printing roWs of material onto the substrate. The substrate speed is matched to the roW Width and printhead cycle time so that the substrate has moved the Width of the roWs printed for each printhead cycle. Thus the next roW or roWs printed by each printhead Will be printed next to a previously printed roW or roWs. In the preferred embodiments the printheads each print tWo roWs simulta neously for increased substrate speed.

Whilst substrate Width printheads are preferred, scanning type printheads may be utiliZed to simultaneously produce multiple layers of objects. The terms “printhead”, “print” and derivatives thereof are

to be understood to include any device or technique that deposits or creates material on a surface in a controlled man ner.

Each layer is printed by one or more printheads. We refer to the printhead or printheads for a layer as a ‘layer group’. As