DESC:FIELD OF DISCLOSURE
The present disclosure relates to three-dimensional (3D) printing systems and methods, and more particularly to a dimensionally adaptive bed, system, and method for multi-material 3D printing.
BACKGROUND
Three-dimensional (3D) printing, also known as additive manufacturing, has revolutionized the way objects are designed, prototyped, and produced across various industries. This technology allows for the creation of complex three-dimensional objects by depositing materials layer by layer based on digital models.
Conventional 3D printing systems typically utilize a fixed-size print bed and operate with a single material at a time. These systems often require a minimum amount of raw material to be present in the print bed, regardless of the actual quantity needed for the object being printed. This can lead to significant material wastage, especially when printing smaller objects or when using expensive materials. Additionally, the inability to efficiently print with multiple materials in a single process limits the functionality and applications of 3D printed objects.
Current multi-material 3D printing solutions often involve complex mechanisms or multiple print heads, which can increase system complexity, cost, and maintenance requirements. Furthermore, these systems may struggle with material cross-contamination and precise control over material placement, affecting the quality and properties of the final printed object.
Therefore, there exists a need for a technical solution that solves the aforementioned problems of conventional systems and methods for three-dimensional printing. Such a solution should address material wastage, enable efficient multi-material printing, and provide greater flexibility in print bed utilization without compromising print quality or increasing system complexity.
SUMMARY
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
In an aspect of the present disclosure, a system is disclosed. The system includes a three-dimensional (3D) printer having a print bed. The system includes a material restricting mechanism disposed on the print bed. The material restricting mechanism includes a material restrictor configured to be moved to create an active region on the print bed. The active region is filled with the printing material based on a quantity of the printing material required to print an object.
In some aspects of the present disclosure, the material restrictor is configured to be moved in one of X-axis, Y-axis, or a combination thereof to create the active region on the print bed.
In some aspects of the present disclosure, the material restrictor is a rigid wiper configured to be moved to create the active region on the print bed.
In some aspects of the present disclosure, the material restrictor includes a plurality of interlinked parts. Each part of the plurality of interlinked parts is controlled independently to form the active region of a pre-selected shape.
In some aspects of the present disclosure, the material restricting mechanism includes one or more handles coupled to the material restrictor to move the material restrictor and create the active region.
In some aspects of the present disclosure, the system includes one or more sensors configured to sense signals representing one of a geometry of the print bed, an amount of a printing material in a storage, a type of a printing material in the storage, an amount of a printing material in the 3D printer, a printing material required to print an object, a current position of the material restricting mechanism on the print bed, or a combination thereof. The system includes one or more actuators coupled to the material restricting mechanism. The system includes processing circuitry coupled to the one or more sensors and the one or more actuators. The processing circuitry is configured to control each actuator of the one or more actuators to actuate the material restricting mechanism to create the active region based on the sensed signals.
In some aspects of the present disclosure, the processing circuitry is configured to control each actuator of the one or more actuators to actuate the material restricting mechanism to create the active region based on one or more input parameters provided by a user.
In some aspects of the present disclosure, the system includes a roller configured to level the printing material when the active region is filled with the printing material.
In some aspects of the present disclosure, the system includes a laser configured to scan and melt the printing material layer by layer to form the object.
In some aspects of the present disclosure, the processing circuitry is configured to generate an alert signal when an amount of a printing material in the storage is less than a predefined threshold value to replenish the corresponding printing material in the storage. The alert signal is displayed by way of a user interface.
In an aspect of the present disclosure, a method for three-dimensional (3D) printing is disclosed. The method includes providing a 3D printer having a print bed. The method includes disposing a material restricting mechanism on the print bed. The material restricting mechanism includes a material restrictor. The method includes moving the material restrictor to create an active region on the print bed. The method includes filling the active region with printing material based on a quantity of the printing material required to print an object.
In some aspects of the present disclosure, creating the active region on the print bed includes moving the material restrictor in one of X-axis, Y-axis, or a combination thereof.
In some aspects of the present disclosure, the material restrictor is a rigid wiper. Creating the active region includes moving the rigid wiper on the print bed.
In some aspects of the present disclosure, the material restrictor includes a plurality of interlinked parts. Creating the active region includes independently controlling each part of the plurality of interlinked parts to form the active region of a pre-selected shape.
In some aspects of the present disclosure, moving the material restrictor includes actuating one or more handles coupled to the material restrictor.
In some aspects of the present disclosure, the method includes sensing, by one or more sensors, signals representing one of a geometry of the print bed, an amount of a printing material in a storage, a type of a printing material in the storage, an amount of a printing material in the 3D printer, a printing material required to print an object, a current position of the material restricting mechanism on the print bed, or a combination thereof. The method includes controlling, by processing circuitry, one or more actuators coupled to the material restricting mechanism to actuate the material restricting mechanism to create the active region based on the sensed signals.
In some aspects of the present disclosure, the method includes controlling, by the processing circuitry, the one or more actuators to actuate the material restricting mechanism to create the active region based on one or more input parameters provided by a user.
In some aspects of the present disclosure, the method includes leveling the printing material with a roller when the active region is filled with the printing material.
In some aspects of the present disclosure, the method includes scanning and melting the printing material layer by layer with a laser to form the object.
In some aspects of the present disclosure, the method includes generating, by the processing circuitry, an alert signal when an amount of a printing material in the storage is less than a predefined threshold value to replenish the corresponding printing material in the storage. The method includes displaying the alert signal by way of a user interface.
The foregoing general description of the illustrative aspects and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.
BRIEF DESCRIPTION OF FIGURES
The following detailed description of the preferred aspects of the present disclosure will be better understood when read in conjunction with the appended drawings. The present disclosure is illustrated by way of example, and not limited by the accompanying figures, in which like references indicate similar elements.
FIG. 1 illustrates a block diagram of a system for dimensionally and geometrically adaptive 3D printing, according to aspects of the present disclosure;
FIG. 2A illustrates an isometric view of a 3D printer of the system of FIG. 1, according to aspects of the present disclosure;
FIG. 2B illustrates another isometric view of the 3D printer of the system of FIG. 1, according to aspects of the present disclosure;
FIG. 3A illustrates an isometric view of a 3D printer, according to aspects of the present disclosure;
FIG. 3B illustrates another isometric view of the 3D printer of FIG. 3A, according to aspects of the present disclosure; and
FIG. 4 illustrates a flowchart of a method for dimensionally and geometrically adaptive 3D printing, of the system of FIG. 1, according to aspects of the present disclosure.
DETAILED DESCRIPTION
The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.
FIG. 1 illustrates a block diagram of a system 100 for dimensionally and geometrically adaptive 3D printing. The system 100 comprises a 3D printer 102, a storage 104, a server 106, and a communication network 108 interconnecting these components.
The three-dimensional (3D) printer 102 may include a print bed 110. The 3D printer 102 may be configured to fabricate three-dimensional objects using additive manufacturing techniques. The 3D printer 102 may include a material restricting mechanism 112 disposed on the print bed 110. The material restricting mechanism 112 may include a material restrictor configured to be moved to create an active region on the print bed 110. The active region may be filled with the printing material based on a quantity of the printing material required to print an object.
The 3D printer 102 may further include one or more sensors 114 configured to sense signals representing one of a geometry of the print bed 110, an amount of a printing material in the storage 104, a type of a printing material in the storage 104, an amount of a printing material in the 3D printer 102, a printing material required to print an object, a current position of the material restricting mechanism 112 on the print bed 110, or a combination thereof. The 3D printer 102 may include one or more actuators 116 coupled to the material restricting mechanism 112. The one or more actuators 116 may be configured to move the material restrictor to create the active region on the print bed 110.
The 3D printer 102 may include processing circuitry 118 coupled to the one or more sensors 114 and the one or more actuators 116. The processing circuitry 118 may be configured to control each actuator of the one or more actuators 116 to actuate the material restricting mechanism 112 to create the active region based on the sensed signals.
The storage 104 may be configured to store printing materials for use by the 3D printer 102. The storage 104 may include one or more containers or compartments for storing different types of printing materials. The storage 104 may be coupled to the 3D printer 102 to supply printing materials as needed.
The server 106 may include a database 120 and a processor 122. The database 120 may be configured to store data related to 3D printing operations, such as 3D models, printing parameters, and material information. The processor 122 may be configured to process data and control various operations of the system 100.
The communication network 108 may include suitable logic, circuitry, and interfaces that may be configured to provide a plurality of network ports and a plurality of communication channels for transmission and reception of data related to operations of various entities in the system 100. Each network port may correspond to a virtual address (or a physical machine address) for transmission and reception of the communication data. For example, the virtual address may be an Internet Protocol Version 4 (IPV4) (or an IPV6 address) and the physical address may be a Media Access Control (MAC) address. The communication network 108 may be associated with an application layer for implementation of communication protocols based on one or more communication requests from the 3D printer 102, the storage 104, and the server 106. The communication data may be transmitted or received, via the communication protocols. Examples of the communication protocols may include, but are not limited to, Hypertext Transfer Protocol (HTTP), File Transfer Protocol (FTP), Simple Mail Transfer Protocol (SMTP), Domain Network System (DNS) protocol, Common Management Interface Protocol (CMIP), Transmission Control Protocol and Internet Protocol (TCP/IP), User Datagram Protocol (UDP), Long Term Evolution (LTE) communication protocols, or any combination thereof.
The system 100 may further include an intelligent material recycling system. This recycling system may be configured to recycle unused material from earlier layers of the print and deposit it onto new layers for further printing. As used herein, "unused material" refers to powder or resin that was not sintered, cured, or adhered in previous layers. This recycling capability may significantly reduce the initial material requirement, enhancing the overall efficiency of the printing process.
The system 100 may incorporate a hybrid closed-loop feedback mechanism. This mechanism may accept computer-generated limitation parameters while also accepting human-induced parameters to actuate the material restricting mechanism 112. The computer-generated parameters may be intelligently acquired by the sensors 114 embedded in the 3D printer 102. These parameters may include the geometry of the print bed 110, the amount and type of material in stock, the material required for the print, and the current position of the material restricting mechanism 112 on the print bed 110.
In operation, the system 100 may enable dimensionally and geometrically adaptive 3D printing. The 3D printer 102 may receive a 3D model from the server 106 via the communication network 108. The processing circuitry 118 may analyze the 3D model and determine the required quantity of printing material. Based on this determination, the processing circuitry 118 may control the one or more actuators 116 to move the material restrictor of the material restricting mechanism 112, creating an active region on the print bed 110 that corresponds to the required quantity. The one or more sensors 114 may provide feedback on the position of the material restrictor and the amount of printing material in the storage 104. The 3D printer 102 may then fill the active region with the required amount of printing material from the storage 104 and proceed with the printing process.
FIG. 2A illustrates an isometric view of a 3D printer 102 with a dimensionally and geometrically adaptive bed. The 3D printer 102 comprises a print bed 110 with an adjustable volume. A material restricting mechanism 112 is positioned above the print bed 110. The material restricting mechanism 112 includes a material restrictor 200 that divides the print bed 110 into an active region 202 and an empty region 204.
The print bed 110 may be configured to support the printing material and the object being printed. The print bed 110 may have a flat surface and may be made of materials suitable for 3D printing, such as glass, aluminum, or specialized printing surfaces.
The material restricting mechanism 112 may be disposed on the print bed 110. The material restricting mechanism 112 may include a material restrictor 200 configured to be moved to create an active region 202 on the print bed 110. The material restrictor 200 may be a rigid wiper or a flexible barrier that can be adjusted to define the boundaries of the active region 202.
The material restrictor 200 may be configured to be moved in one of X-axis, Y-axis, or a combination thereof to create the active region 202 on the print bed 110. This movement may allow for precise control of the size and shape of the active region 202, enabling efficient use of printing materials.
The active region 202 may be the area of the print bed 110 that is filled with printing material and used for the actual printing process. The size and shape of the active region 202 may be adjusted based on the quantity of printing material required for a specific object.
The empty region 204 may be the area of the print bed 110 that is not used for printing in a particular job. By creating an empty region 204, the system 100 can reduce material waste and improve efficiency.
The material restricting mechanism 112 may include one or more handles 206 coupled to the material restrictor 200. These handles 206 may be used to manually adjust the position of the material restrictor 200, providing an alternative or backup method for creating the active region 202.
A roller 208 may be configured to level the printing material when the active region 202 is filled with the printing material. The roller 208 may ensure an even distribution of printing material across the active region 202, which is crucial for print quality.
A laser 210 may be positioned above the print bed 110. The laser 210 may be configured to scan and melt the printing material layer by layer to form the object. The laser 210 may be a key component in the sintering or melting process used in many metal 3D printing techniques.
The processing circuitry 118 may be configured to control each actuator of the one or more actuators 116 to actuate the material restricting mechanism 112 to create the active region 202 based on one or more input parameters provided by a user. This feature allows for manual override or fine-tuning of the printing process, providing flexibility for experienced users to optimize prints based on their expertise.
In operation, the material restrictor 200 may be adjusted to create an active region 202 of the appropriate size and shape for a specific print job. The active region 202 may then be filled with printing material. The roller 208 may level the printing material, and the laser 210 may begin the printing process, selectively melting the material to form the desired object.
FIG. 2B illustrates an isometric view of a 3D printer 102 with a dimensionally and geometrically adaptive print bed. The 3D printer 102 comprises a print bed 110, which is divided into an active region 202 and an empty region 204. The active region 202 is where the printing material is deposited and processed.
The print bed 110 may be the foundation upon which the 3D printed object is built. It may be designed to provide a stable and level surface for the printing process. The print bed 110 may be made of materials that can withstand the high temperatures involved in metal 3D printing, such as ceramic or specialized metal alloys.
The material restricting mechanism 112 may be incorporated into the system 100. This mechanism may include a material restrictor 200, which may be adjustable to control the size of the active region 202. The material restrictor 200 may be a physical barrier that can be moved to define the boundaries of the active region 202.
The material restrictor 200 may be manipulated using a first handle 206a, allowing for dynamic adjustment of the print bed volume. This handle 206a may provide a manual method for adjusting the size of the active region 202, which may be useful for quick adjustments or in case of automated system failure.
Positioned above the print bed 110 may be a laser 210, which may serve as the power source for sintering or melting the printing material in the active region 202. The laser 210 may be a high-power laser capable of reaching the temperatures required to melt metal powders. It may be precisely controlled to selectively melt the printing material according to the 3D model being printed.
Adjacent to the laser 210 may be a roller 208, which may be used for leveling and distributing the printing material across the active region 202. The roller 208 may ensure an even layer of printing material, which is crucial for the accuracy and quality of the final printed object.
The empty region 204 may be the portion of the print bed 110 that is not currently in use for printing. This area can be expanded or reduced by adjusting the material restrictor 200, providing flexibility in print bed size and material usage.
In operation, the material restrictor 200 may be adjusted using the handle 206a to create an active region 202 of the appropriate size for the object being printed. Printing material may then be deposited in the active region 202 and leveled by the roller 208. The laser 210 may then selectively melt the material according to the 3D model, building the object layer by layer. This process may be repeated, with new layers of material being added and melted, until the object is complete.
FIG. 3A illustrates an isometric view of a 3D printer (102) with a dimensionally and geometrically adaptive bed for intelligent multi-material 3D printing. The 3D printer (102) comprises a print bed (110) that forms the base of the printing area. Within the print bed (110) is an active region (202) where the actual printing takes place.
The print bed 110 may be designed to provide a stable and level surface for the 3D printing process. It may be made of materials that can withstand the high temperatures involved in metal 3D printing, such as ceramic or specialized metal alloys. The print bed 110 may also incorporate heating elements to maintain a consistent temperature throughout the printing process, which may be crucial for preventing warping or other defects in the printed object.
The material restricting mechanism 112 may be positioned above the print bed 110. This mechanism may include a material restrictor 300 composed of a plurality of interlinked parts 302. The first part 302a and the nth part 302n of the material restrictor 300 are visible in the figure, representing the beginning and end of the interlinked structure.
The material restrictor 300 with its plurality of interlinked parts 302 may offer greater flexibility in shaping the active region 202 compared to a single rigid wiper. Each part of the plurality of interlinked parts 302a-302n may be controlled independently to form the active region 202 of a pre-selected shape. This may allow for the creation of complex geometries in the active region 202, potentially enabling more efficient use of printing materials for objects with irregular shapes.
A laser 210 may be positioned above the active region 202. This laser 210 may be used for sintering or melting the printing material during the 3D printing process. The laser 210 may be a high-power laser capable of reaching the temperatures required to melt metal powders. It may be precisely controlled to selectively melt the printing material according to the 3D model being printed.
Adjacent to the laser 210 may be a roller 208, which may be used for leveling and distributing the printing material across the active region 202. The roller 208 may ensure an even layer of printing material, which is crucial for the accuracy and quality of the final printed object. The roller 208 may be designed to work in conjunction with the material restrictor 300, adapting to the potentially complex shapes of the active region 202 created by the interlinked parts 302.
The material restrictor 300 may be designed to adjust the size and shape of the active region 202, allowing for efficient use of printing materials and adaptability to different print sizes and geometries. The interlinked parts 302 of the material restrictor 300 can be adjusted to modify the boundaries of the active region 202 as needed for each print job. This adaptability may be particularly useful for multi-material printing, as it may allow for the creation of separate regions for different materials within the same print bed.
In operation, the processing circuitry 118 may analyze the 3D model to be printed and determine the optimal shape and size of the active region 202 for the print job. It may then control the individual parts of the material restrictor 300 to create this optimized active region 202. The appropriate printing material(s) may then be deposited in the active region 202 and leveled by the roller 208. The laser 210 may then selectively melt the material according to the 3D model, building the object layer by layer. For multi-material prints, this process may be repeated with different materials in different sections of the active region 202.
The system's multi-material printing capabilities may extend to materials that may not seem feasible or possible to be integrated under normal conditions. This can be achieved by utilizing the intelligent material recycling system to draw from the unused material from previous layers via the recycling system, and then accurately depositing one or multiple materials in the same layer. The laser 210 may then sinter these materials in one or multiple passes.
The multi-material 3D print fabrication can be controlled in such a way that the materials used can either be bonded to have no relative motion or not be bonded to have a relative motion. This flexibility in material bonding can be achieved through precise control of the laser 210 parameters and the material deposition process.
In some aspects of the present disclosure, post-processing techniques may be employed to further enhance the multi-material printing capabilities. These techniques may include, but are not limited to, vibration application, selective dissolving, mechanical separation, laser ablation, or the application of release agents. These post-processing methods may enable the creation of complex multi-material objects with varying levels of structural integration and functionality, while maintaining independent motion between the materials where desired.
FIG. 3B illustrates an isometric view of a 3D printer (102) with a dimensionally and geometrically adaptive bed for intelligent multi-material 3D printing. The 3D printer (102) comprises a print bed (110) that forms the base of the printing area. Within the print bed (110) is an active region (202) where the printing takes place, and an empty region (204) that is not used for printing.
The print bed 110 may be designed to provide a stable and level surface for the 3D printing process. It may be made of materials that can withstand the high temperatures involved in metal 3D printing, such as ceramic or specialized metal alloys. The print bed 110 may also incorporate heating elements to maintain a consistent temperature throughout the printing process, which may be crucial for preventing warping or other defects in the printed object.
The material restricting mechanism 112 may be positioned above the print bed 110. This mechanism may include a material restrictor 300 composed of a plurality of interlinked parts 302. The first part 302a and the nth part 302n of the material restrictor 300 are visible in the figure, representing the beginning and end of the interlinked structure.
The material restrictor 300 with its plurality of interlinked parts 302 may offer greater flexibility in shaping the active region 202 compared to a single rigid wiper. Each part of the plurality of interlinked parts 302a-302n may be controlled independently to form the active region 202 of a pre-selected shape. This may allow for the creation of complex geometries in the active region 202, potentially enabling more efficient use of printing materials for objects with irregular shapes.
The active region 202 may be the area of the print bed 110 that is filled with printing material and used for the actual printing process. The size and shape of the active region 202 may be adjusted based on the quantity and geometry of printing material required for a specific object.
The empty region 204 may be the area of the print bed 110 that is not used for printing in a particular job. By creating an empty region 204, the system 100 can reduce material waste and improve efficiency. The size and shape of the empty region 204 may be dynamically adjusted for each print job based on the requirements of the object being printed.
A laser 210 may be positioned above the active region 202. This laser 210 may be used for sintering or melting the printing material during the 3D printing process. The laser 210 may be a high-power laser capable of reaching the temperatures required to melt metal powders. It may be precisely controlled to selectively melt the printing material according to the 3D model being printed.
Adjacent to the laser 210 may be a roller 208, which may be used for leveling and distributing the printing material across the active region 202. The roller 208 may ensure an even layer of printing material, which is crucial for the accuracy and quality of the final printed object. The roller 208 may be designed to work in conjunction with the material restrictor 300, adapting to the potentially complex shapes of the active region 202 created by the interlinked parts.
In operation, the processing circuitry 118 may analyze the 3D model to be printed and determine the optimal shape and size of the active region 202 for the print job. It may then control the individual parts of the material restrictor 300 to create this optimized active region 202, simultaneously defining the empty region 204. The appropriate printing material(s) may then be deposited in the active region 202 and leveled by the roller 208. The laser 210 may then selectively melt the material according to the 3D model, building the object layer by layer. For multi-material prints, this process may be repeated with different materials in different sections of the active region 202. The empty region 204 remains free of printing material, reducing waste and potentially allowing for easier removal of the finished object.
FIG. 4 illustrates a flowchart of a method 400 for dimensionally and geometrically adaptive 3D printing. The method 400 begins with step 402, where a 3D printer 102 with a print bed 110 is provided. In step 404, a material restricting mechanism 112 is disposed on the print bed 110.
At step 402, the system 100 provides a 3D printer 102 having a print bed 110. The 3D printer 102 may be configured for metal 3D printing using techniques such as Direct Metal Laser Sintering (DMLS), Electron Beam Melting (EBM), or binder jetting. The print bed 110 may be designed to withstand the high temperatures involved in metal 3D printing and may incorporate heating elements to maintain a consistent temperature throughout the printing process.
At step 404, the system 100 disposes a material restricting mechanism 112 on the print bed 110. The material restricting mechanism 112 may include a material restrictor 200 or 300. The material restrictor 200 or 300 may be a rigid wiper or a series of interlinked parts that can be adjusted to define the boundaries of an active region 202 on the print bed 110.
The method 400 then proceeds to step 406, where signals representing one or more parameters are sensed. These signals are used in step 408 to control actuators and move a material restrictor 200 or 300, creating an active region 202 on the print bed 110 based on the sensed signals.
At step 406, the system 100 senses, by one or more sensors 114, signals representing one of a geometry of the print bed 110, an amount of a printing material in the storage 104, a type of a printing material in the storage 104, an amount of a printing material in the 3D printer 102, a printing material required to print an object, a current position of the material restricting mechanism 112 on the print bed 110, or a combination thereof. These sensors 114 may include, but are not limited to, optical sensors, weight sensors, position sensors, and material composition sensors.
At step 408, the system 100 controls, by processing circuitry 118, one or more actuators 116 coupled to the material restricting mechanism 112 to actuate the material restricting mechanism 112 to create the active region 202 based on the sensed signals. The processing circuitry 118 may analyze the sensed signals and the 3D model to be printed to determine the optimal size and shape of the active region 202. It may then send commands to the actuators 116 to move the material restrictor 200 or 300 to create this optimized active region 202.
At decision step 410, the method 400 checks if printing material is in stock. If not, the process moves to step 418, where an alert signal is generated and displayed to replenish printing material. If printing material is available, the method 400 continues to step 412, where the active region 202 is filled with printing material based on the required quantity.
At step 410, the system 100 checks if the required printing material is available in the storage 104. This check may be based on the signals sensed by the sensors 114 in step 406. If the required material is not available, the method 400 proceeds to step 418.
At step 418, the system 100 generates, by the processing circuitry 118, an alert signal when an amount of a printing material in the storage 104 is less than a predefined threshold value to replenish the corresponding printing material in the storage 104. The system 100 then displays the alert signal by way of a user interface. This alert may prompt the user to refill the storage 104 with the required printing material.
The processing circuitry 118 may be configured to generate an alert signal when an amount of a printing material in the storage 104 is less than a predefined threshold value to replenish the corresponding printing material in the storage 104. The alert signal may be displayed by way of a user interface. This user interface may be a part of the 3D printer 102 itself, or it may be a separate device connected to the system 100 via the communication network 108. The user interface may display not only the alert for low material levels, but also provide options for the user to initiate material replenishment, adjust printing parameters, or pause the printing process if necessary.
If printing material is available, at step 412, the system 100 fills the active region 202 with printing material based on the quantity of the printing material required to print an object. The amount of material deposited may be precisely controlled based on the volume of the active region 202 and the requirements of the 3D model to be printed.
In step 414, the printing material is leveled with a roller 208. At step 414, the system 100 levels the printing material with a roller 208 when the active region 202 is filled with the printing material. The roller 208 ensures an even distribution of the printing material across the active region 202, which is crucial for the accuracy and quality of the final printed object.
Finally, in step 416, the printing material is scanned and melted layer by layer with a laser 210. At step 416, the system 100 scans and melts the printing material layer by layer with a laser 210 to form the object. The laser 210 selectively melts the printing material according to the 3D model, building the object layer by layer. This process may be repeated, with new layers of material being added and melted, until the object is complete.
The method 400 outlines a process for adaptive 3D printing, incorporating material restriction, parameter sensing, and material management. It allows for efficient use of printing material by creating an active region 202 based on sensed parameters and includes steps for material replenishment when necessary. This method 400 may be particularly useful for multi-material printing, as it allows for precise control of material deposition and can potentially create separate regions for different materials within the same print bed.
The dimensionally and geometrically adaptive bed system for intelligent multi-material 3D printing as described herein offers several advantages. These may include reduced material wastage and cost, improved efficiency and scalability, higher quality prints, faster printing times, versatility and customization, improved sustainability, and competitive advantage. The system's ability to adapt the print bed volume and efficiently recycle unused material may lead to significant cost savings for manufacturers. The multi-material printing capabilities may improve efficiency by reducing the need for multiple printers and enable the production of more complex, functional objects. Furthermore, the system's adaptability and precision may contribute to more sustainable manufacturing practices by reducing material waste and improving overall efficiency.
Thus, the system 100 and the method 400 provide several significant technical advantages. The dimensionally adaptive print bed enables precise control over material usage, substantially reducing waste and associated costs in 3D printing processes. The multi-material printing capability enhances production efficiency by eliminating the need for multiple specialized printers, while also enabling the creation of more complex and functionally diverse objects. The system's intelligent material recycling mechanism further optimizes resource utilization, contributing to improved sustainability in manufacturing. The adaptive nature of the print bed 110, coupled with advanced sensor and actuator systems, allows for real-time adjustments during printing, resulting in higher quality prints with improved dimensional accuracy. Additionally, the system's ability to handle multiple materials in a single print job significantly reduces overall production time, enhancing manufacturing throughput. Finally, the integration of automated material monitoring and alert systems minimizes downtime and ensures continuous operation, further improving overall production efficiency.
Aspects of the present disclosure are discussed here with reference to flowchart illustrations and block diagrams that depict methods, systems, and apparatus in accordance with various aspects of the present disclosure. Each block within these flowcharts and diagrams, as well as combinations of these blocks, can be executed by computer-readable program instructions. The various logical blocks, modules, circuits, and algorithm steps described in connection with the disclosed aspects may be implemented through electronic hardware, software, or a combination of both. To emphasize the interchangeability of hardware and software, the various components, blocks, modules, circuits, and steps are described generally in terms of their functionality. The decision to implement such functionality in hardware or software is dependent on the specific application and design constraints imposed on the overall system. Person having ordinary skill in the art can implement the described functionality in different ways depending on the particular application, without deviating from the scope of the present disclosure.
The flowcharts and block diagrams presented in the figures depict the architecture, functionality, and operation of potential implementations of systems, methods, and apparatus according to different aspects of the present disclosure. Each block in the flowcharts or diagrams may represent an engine, segment, or portion of instructions comprising one or more executable instructions to perform the specified logical function(s). In some alternative implementations, the order of functions within the blocks may differ from what is depicted. For instance, two blocks shown in sequence may be executed concurrently or in reverse order, depending on the required functionality. Each block, and combinations of blocks, can also be implemented using special-purpose hardware-based systems that perform the specified functions or tasks, or through a combination of specialized hardware and software instructions.
Although the preferred aspects have been detailed here, it should be apparent to those skilled in the relevant field that various modifications, additions, and substitutions can be made without departing from the scope of the disclosure. These variations are thus considered to be within the scope of the disclosure as defined in the following claims.
Features or functionalities described in certain example aspects may be combined and re-combined in or with other example aspects. Additionally, different aspects and elements of the disclosed example aspects may be similarly combined and re-combined. Further, some example aspects, individually or collectively, may form components of a larger system where other processes may take precedence or modify their application. Moreover, certain steps may be required before, after, or concurrently with the example aspects disclosed herein. It should be noted that any and all methods and processes disclosed herein can be performed in whole or in part by one or more entities or actors in any manner.
Although terms like "first," "second," etc., are used to describe various elements, components, regions, layers, and sections, these terms should not necessarily be interpreted as limiting. They are used solely to distinguish one element, component, region, layer, or section from another. For example, a "first" element discussed here could be referred to as a "second" element without departing from the teachings of the present disclosure.
The terminology used here is intended to describe specific example aspects and should not be considered as limiting the disclosure. The singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "includes," "comprising," and "including," as used herein, indicate the presence of stated features, steps, elements, or components, but do not exclude the presence or addition of other features, steps, elements, or components.
As used herein, the term "or" is intended to be inclusive, meaning that "X employs A or B" would be satisfied by X employing A, B, or both A and B. Unless specified otherwise or clearly understood from the context, this inclusive meaning applies to the term "or."
Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the relevant art. Terms should be interpreted consistently with their common usage in the context of the relevant art and should not be construed in an idealized or overly formal sense unless expressly defined here.
The terms "about" and "substantially," as used herein, refer to a variation of plus or minus 10% from the nominal value. This variation is always included in any given measure.
In cases where other disclosures are incorporated by reference and there is a conflict with the present disclosure, the present disclosure takes precedence to the extent of the conflict, or to provide a broader disclosure or definition of terms. If two disclosures conflict, the later-dated disclosure will take precedence.
The use of examples or exemplary language (such as "for example") is intended to illustrate aspects of the invention and should not be seen as limiting the scope unless otherwise claimed. No language in the specification should be interpreted as implying that any non-claimed element is essential to the practice of the invention.
While many alterations and modifications of the present invention will likely become apparent to those skilled in the art after reading this description, the specific aspects shown and described by way of illustration are not intended to be limiting in any way.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the scope of the disclosure. Accordingly, other implementations are within the scope of the following claims. ,CLAIMS:1. A system (100) comprising:
a three-dimensional (3D) printer (102) having a print bed (110);
a material restricting mechanism (112) that is disposed on the print bed (110), the material restricting mechanism (112) comprising a material restrictor (200,300) configured to be moved such that the material restrictor (200,300) creates an active region (202) on the print bed (110), wherein the active region is filled with the printing material based on a quantity of the printing material required to print an object.
2. The system (100) as claimed in claim 1, wherein, to create the active region (202) on the print bed (110), the material restrictor (200,300) is configured to be moved in one of, X-axis, Y-axis, or a combination thereof.
3. The system (100) as claimed in claim 1, wherein the material restrictor (200) is a rigid wiper configured to be moved to create the active region (202) on the print bed (110).
4. The system (100) as claimed in claim 1, wherein the material restrictor (300) comprising a plurality of interlinked parts (302a-302n) such that each part of the plurality of interlinked parts (302a-302n) is controlled independently to form the active region (202) of a pre-selected shape.
5. The system (100) as claimed in claim 1, wherein the material restricting mechanism (112) comprising one or more handles (206) coupled to the material restrictor (200,300) to move the material restrictor (112) and create the active region (202).
6. The system (100) as claimed in claim 1, further comprising:
one or more sensors (114) configured to sense signals representing one of, a geometry of the print bed (110), an amount of a printing material in a storage (104), a type of a printing material in the storage (104), an amount of a printing material in the 3D printer (102), a printing material required to print an object, a current position of the material restricting mechanism (112) on the print bed (110), or a combination thereof.
one or more actuators (116) coupled to the material restricting mechanism (112); and
processing circuitry (118) coupled to the one or more sensors (114) and the one or more actuators (116), wherein the processing circuitry (118) is configured to control each actuator of the one or more actuators (116) to actuate the material restricting mechanism (112) to create the active region (202) based on the sensed signals.
7. The system (100) as claimed in claim 4, wherein the processing circuitry (118) is configured to control each actuator of the one or more actuators (116) to actuate the material restricting mechanism (112) to create the active region (202) based on one or more input parameters provided by a user.
8. The system (100) as claimed in claim 4, further comprising a roller (208) configured to level the printing material when the active region (202) is filled with the printing material.
9. The system (100) as claimed in claim 1, further comprising a laser (210) configured to scan and melt the printing material layer by layer to form the object.
10. The system (100) as claimed in claim 4, wherein the processing circuitry (118) is configured to generate an alert signal when an amount of a printing material in the storage (104) is less than a predefined threshold value to replenish the corresponding printing material in the storage (104), wherein the alert signal is displayed by way of a user interface.
11. A method (400) for three-dimensional (3D) printing, the method (400) comprising:
providing a 3D printer (102) having a print bed (110);
disposing a material restricting mechanism (112) on the print bed (110), the material restricting mechanism (112) comprising a material restrictor (200,300);
moving the material restrictor (200,300) to create an active region (202) on the print bed (110); and
filling the active region (202) with printing material based on a quantity of the printing material required to print an object.
12. The method (400) as claimed in claim 9, wherein creating the active region (202) on the print bed (110) comprises moving the material restrictor (200,300) in one of, X-axis, Y-axis, or a combination thereof.
13. The method (400) as claimed in claim 9, wherein the material restrictor (200) is a rigid wiper, and wherein creating the active region (202) comprises moving the rigid wiper on the print bed (110).
14. The method (400) as claimed in claim 9, wherein the material restrictor (300) comprises a plurality of interlinked parts (302a-302n), and wherein creating the active region (202) comprises independently controlling each part of the plurality of interlinked parts (302a-302n) to form the active region (202) of a pre-selected shape.
15. The method (400) as claimed in claim 9, wherein moving the material restrictor (200,300) comprises actuating one or more handles (206) coupled to the material restrictor (200,300).
16. The method (400) as claimed in claim 9, further comprising:
sensing, by one or more sensors (114), signals representing one of, a geometry of the print bed (110), an amount of a printing material in a storage (104), a type of a printing material in the storage (104), an amount of a printing material in the 3D printer (102), a printing material required to print an object, a current position of the material restricting mechanism (112) on the print bed (110), or a combination thereof; and
controlling, by processing circuitry (118), one or more actuators (116) coupled to the material restricting mechanism (112) to actuate the material restricting mechanism (112) to create the active region (202) based on the sensed signals.
17. The method (400) as claimed in claim 14, further comprising controlling, by the processing circuitry (118), the one or more actuators (116) to actuate the material restricting mechanism (112) to create the active region (202) based on one or more input parameters provided by a user.
18. The method (400) as claimed in claim 14, further comprising leveling the printing material with a roller (208) when the active region (202) is filled with the printing material.
19. The method (400) as claimed in claim 9, further comprising scanning and melting the printing material layer by layer with a laser (210) to form the object.
20. The method (400) as claimed in claim 14, further comprising:
generating, by the processing circuitry (118), an alert signal when an amount of a printing material in the storage (104) is less than a predefined threshold value to replenish the corresponding printing material in the storage (104); and
displaying the alert signal by way of a user interface.