DESC:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)

AND

THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10; rule 13)

THREE-DIMENSIONAL (3D) PRINTER

Sahajanand Technologies Private Limited, a company organized and existing under the laws of India, of A1, Sahajanand Estate, Vakhariawadi, Near Dabholi Char Rasta, Ved Road, Surat- 395004, Gujarat, India

The following specification particularly describes the invention and the manner in which it is to be performed
TECHNICAL FIELD
[0001] The present invention generally relates to a three-dimensional (3D) printer, and more particularly, to a Selective Laser Sintering (SLS) technology 3D printer.
BACKGROUND
[0002] This section is intended to provide information relating to the field of the invention and thus, any approach or functionality described below should not be assumed to be qualified as prior art merely by its inclusion in this section.
[0003] A three-dimensional (3D) printer is used to make three-dimensional (3D) objects. The 3D printer uses a wide range of materials such as molten plastic or powders. The 3D printer comprises a heat source, a print bucket, at least one feed plunger, a re-coater assembly, a laser assembly, a plurality of controllers and a plurality of motors to be used in combination with each other to print the 3D object. There are three types of 3D printers available, namely stereolithography 3D (SLA), Selective Laser Sintering (SLS), and Fused Deposition Modelling (FDM) 3D printers.
[0004] The procedure of making 3D printed objects in the SLS 3D printer using powder involves heat energy to tune the powder’s particle density, and warp free layers of the powder and then sinter the layers of powder in a desired shape layer by layer throughout the object’s height. While applying the layer of powder, the heat energy should be stable throughout the sintering process. Similarly, rate of heat energy input as well as rate of heat energy output should also be tuned gradually to produce a quality object. For such operations to perform, combination of heat sources and thermal insulation should be calibrated proportionally.
[0005] The challenge with the aforementioned procedure of producing heat energy using heat sources is that a high amount of electrical power is required to be supplied to the 3D printer to power the heat source. On the other hand, excess heat is also needed to be removed to maintain a thermal equilibrium. To maintain the thermal equilibrium, a thermal insulation needs to have active provisions to take out the excess heat. The high electrical consumption leads to huge electricity bills, resulting in a lower profit margin, and ineffective heat transfer leads to increased cooling time and sometimes partially distorted 3D objects.
[0006] Accordingly in light of the aforementioned drawbacks and several other limitations inherent in the existing art, there is a well felt need to provide an improved 3D printer capable of addressing the aforementioned problems.
SUMMARY
[0007] This section is intended to introduce certain aspects of the disclosed system and method in a simplified form and is not intended to identify the key advantages or features of the present disclosure.
[0008] The present disclosure relates to a three-dimensional (3D) printer for printing three-dimensional (3D) objects, the 3D printer comprising a unary heat source, and at least one print bucket configured to adjustably house and support a print base plate therein. The unary heat source is capable of providing controlled heat to a printing material deployed onto the print base plate, for efficiently printing of 3D objects in the at least one print bucket.
[0009] According to an aspect of the present disclosure, the print bucket is capable of being detachably removed from the 3D printer, to be loaded into an auxiliary machine for removing excess printing material from within the print bucket.
[0010] According to another aspect of the present disclosure, the print bucket, along with an auxiliary machine, is integrated into the 3D printer, to facilitate removal of excess printing material from within the print bucket.
[0011] According to yet another aspect of the present disclosure, the three-dimensional (3D) printer comprising at least one feeder plunger deployed on either side of the at least one print bucket, each of the at least one feeder plunger being adapted to spray or feed the printing material onto the print base plate, to facilitate printing operation within the print bucket.
[0012] According to yet another aspect of the present disclosure, the at least one feed plunger is selected from a group consisting of a single feed plunger, a hopper type feed plunger, a bucket type feed plunger, and combinations thereof.
[0013] According to yet another aspect of the present disclosure, the three-dimensional (3D) printer comprising at least one re-coater assembly employed to supply a new layer of printing material atop an existing layer of printing material, to facilitate printing of 3D objects, at least one laser assembly comprising a laser delivery path, one or more laser source, an optical component, and one or more galvo scanner, wherein each of the one or more galvo scanner is employed to direct the laser source of the laser assembly to the print base plate.
[0014] According to yet another aspect of the present disclosure, the three-dimensional (3D) printer comprises at least one thermal insulation layer provided on an outer periphery of the print bucket, the at least one thermal insulation layer being made up of one of ceramics, fiberglass, wool, silica aerogel, poly amide foams, and polyurethane (PU) foams.
[0015] According to yet another aspect of the present disclosure, at least one safety interlock for ensuring safety during operation of the 3D printer, the at least one safety interlock including a door interlock, an emergency stop provision, and an active interlock.
[0016] According to yet another aspect of the present disclosure, the three-dimensional (3D) printer comprising at least one temperature sensor deployed in a thermal equilibrium region, to continuously detect real-time temperature within the thermal equilibrium region, at least one fan being adapted to provide cool atmospheric air to the thermal equilibrium region, upon activation thereof, and a heater controller configured to receive and monitor the real-time temperature, to controllably activate/deactivate at least one of the unary heat source and the at least one fan, to maintain a thermal equilibrium within the thermal equilibrium region, to thereby enable efficient printing of 3D objects within the print bucket.
[0017] According to yet another aspect of the present disclosure, the at least one temperature sensor is one of a contact-type temperature sensor and a non-contact type temperature sensor.
[0018] According to yet another aspect of the present disclosure, the unary heat source is one of a coil heater, a ceramic heater, a convection heater, an inductive heater, a quartz radiation heating tube with reflective plates, and combinations thereof.
[0019] According to yet another aspect of the present disclosure, the printing material is a material selected from the group consisting of nylon (PA12, PA11, PA6, PA6/66), TPE powder, PP powder, bio compatible powder, composite powders, glass-filled polymers, carbon-filled polymers, and combinations thereof.
[0020] According to yet another aspect of the present disclosure, the three-dimensional (3D) printer comprising at least a front wall and a pair of sidewalls, each being adapted to provide thermal insulation to each of the print bucket, the print base plate, the at least one feed plunger, and the re-coater assembly of the 3D printer. Each of the front wall and the pair of sidewalls comprise, a first layer of thermal insulation, and a second layer of thermal insulation, wherein the first layer of thermal insulation faces inwards, while the second layer of thermal insulation faces towards the ambient.
[0021] According to yet another aspect of the present disclosure, each of the first and second layers of thermal insulation is selected from the group consisting of ceramics, fiberglass, wool, silica aerogel, polyamide foams, and polyurethane (PU) foams.
[0022] According to yet another aspect of the present disclosure, the 3D printer is a selective laser sintering (SLS) technology 3D printer.
BRIEF DESCRIPTION OF DRAWINGS
[0023] In order to explain the technical solution in the embodiments of the present application more clearly, the drawings used in the description of the embodiments will be briefly introduced below. It is obvious that the drawings in the following description are only some embodiments of the application. For those skilled in the art, without any creative work, other drawings can be obtained based on these drawings.
[0024] Figure 1 illustrates a front perspective exploded view of a three-dimensional (3D) printer, in accordance with the concepts of the present disclosure.
[0025] Figure 2 illustrates a rear perspective exploded view of the 3D printer, in accordance with the concepts of the present disclosure.
[0026] Figure 3 illustrates another front perspective exploded view of the 3D printer depicting at least one thermal insulation, in accordance with the concepts of the present disclosure.
[0027] Figure 4 illustrates a front view of the 3D printer, in accordance with the concepts of the present disclosure.
[0028] Figure 5 illustrates a schematic representation depicting sectional cut-out planes of the 3D printer, in accordance with the concepts of the present disclosure.
[0029] Figure 6 illustrates a top view of Figure 5, depicting a sectional view along an A-A plane, in accordance with the concepts of the present disclosure.
[0030] Figure 7 illustrates a top view of Figure 5, depicting a sectional view along a B-B plane, in accordance with the concepts of the present disclosure.
[0031] Figure 8 illustrates a side view of Figure 5, depicting a sectional view along a C-C plane, in accordance with the concepts of the present disclosure.
[0032] Figure 9 illustrates a front perspective view of the 3D printer, in accordance with the concepts of the present disclosure.
[0033] Figure 10 illustrates a rear perspective view of the 3D printer, in accordance with the concepts of the present disclosure.
[0034] Figure 11 illustrates a thermal equilibrium region of the 3D printer, in accordance with the concepts of the present disclosure.
[0035] Figure 12 illustrates a schematic diagram of a system architecture of the 3D printer, in accordance with the concepts of the present disclosure.
[0036] Figure 13A illustrates a flow diagram of method of functioning of the 3D printer, in accordance with the concepts of the present disclosure.
[0037] Figure 13B illustrates a flow diagram in continuation of the method of Figure 13A, in accordance with the concepts of the present disclosure.
[0038] Figure 13C illustrates a flow diagram in continuation of the method of Figure 13B, in accordance with the concepts of the present disclosure.
DETAILED DESCRIPTION
[0039] In the following description, for the purpose of explanation, various specific details are set forth in order to provide a thorough understanding of the embodiments of the present invention. It will be apparent, however, that the embodiments of the present invention may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address any of the problems discussed above or might address only one of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein. Exemplified embodiments of the present invention are described below, as illustrated in various drawings in which reference numerals refer to the same parts throughout the different drawings.
[0040] The specification may refer to “an”, “one”, “different” or “some” embodiment(s) in several locations. This does not necessarily imply that each such reference is to the same embodiment(s), or that the feature only applies to a single embodiment. Single features of different embodiments may also be combined to provide other embodiments.
[0041] As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes”, “comprises”, “including” and/or “comprising” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being “attached” or “connected” or “coupled” or “mounted” to another element, it can be directly attached or connected or coupled to the other element or intervening elements may be present. As used herein, the term “and/or” includes any and all combinations and arrangements of one or more of the associated listed items.
[0042] The figures depict a simplified structure only showing some elements and functional entities, all being logical units whose implementation may differ from what is shown.
[0043] A three-dimensional (3D) printer [100] is a printing device which is used to make three-dimensional (3D) objects. The 3D printer [100] uses a wide range of materials such as molten plastic or powders to make the 3D objects. 3D printing is a popular technique for creating complex three-dimensional objects from digital designs by selectively fusing printing material using a high-power laser. The 3D printer [100] comprises a heat source, a print bucket, at least one feed plunger [108], at least one re-coater assembly [114], at least one laser assembly [116], a controller and a plurality of motors to be used in combination with each other to print the 3D object. There are three types of 3D printers [100] available, namely stereolithography (SLA) 3D printer, Selective Laser Sintering (SLS) 3D printer, and Fused Deposition Modelling (FDM) 3D printer. The 3D printer [100], particularly the SLS 3D printer [100], produces 3D objects using an additive manufacturing process. The additive manufacturing process starts with a printing material, typically a polymer, which is applied in a thin layer across the print bucket by the at least one re-coater assembly [114], thus, the at least one re-coater assembly [114] is employed to supply a new layer of printing material atop an existing layer of printing material, to facilitate printing of 3D objects. The heat source starts heating the said thin layer with a predefined temperature and the at least one laser assembly [116] then scans the cross-section of the 3D objects to be printed, selectively sintering, or fusing the printing material together based on the digital design. The printing material, particularly the polymer is selected from a group of nylon such as PA12, PA11, PA6, PA6/PA66, TPE powder, PP powder, bio compatible powder, composite powders, glass filled polymers, carbon filled polymers and any combination thereof. Once application of the thin layer of printing material is completed, the print bucket is lowered, and a new thin layer of the printing material is applied on top. The heat source starts heating the said new thin layer with desired selected temperature and the at least one laser assembly [116] scans the next cross-section, fusing it to the previously applied thin layer. This process is repeated layer by layer until the entire 3D objects is created. The at least one re-coater assembly [114] is selected from a group consisting of a roller re-coater, blade type re-coater, a screw type re-coater, a brush type re-coater, a pin-type re-coater, a multi-layer re-coater and combinations thereof. The excess printing material acts as support for the 3D objects during the manufacturing process. Accordingly, the terms ‘SLS technology 3D printer’ and ‘3D printer’ shall be interchangeably referred to hereinafter.
[0044] Referring to figures 1 to 8, the SLS 3D printer [100] comprises a unary heat source [102], at least one print bucket [104], at least one feeder plunger [108], a print base plate [106], the at least one re-coater assembly [114], the at least one laser assembly [116], , at least one thermal insulation layer [112], at least one safety interlock [118], at least one temperature sensor [122], at least one fan [120], and a heater controller [128]. The at least one laser assembly [116] comprises a laser delivery path, one or more laser source, an optical component, and one or more galvo scanner [130], wherein each of the one or more galvo scanner [130] is employed to direct the laser source of the laser assembly [116] to the print base plate [106].
[0045] The at least one feeder plunger [108] is deployed on either side of the at least one print bucket [104], such that each of the at least one feeder plunger [108] is adapted to spray or feed the printing material onto the print base plate [106], to facilitate printing operation within the print bucket [104]. The unary heat source [102] is capable of providing controlled heat to the printing material deployed onto the print base plate [106], for efficiently printing of 3D objects in the at least one print bucket [104], and the at one print bucket [104] is configured to adjustably house and support the print base plate [106] therein. The at least one feeder plunger [108] and print bucket [104] are outfitted with a first and second layer of thermal insulation. The at least one feeder plunger [108] and print bucket [104] are equipped with the unary heat source [102], which are used to heat the printing material before and/or during the sintering process. In one embodiment, the print bucket [104] may also be equipped with another heating source above the at least one feeder plunger [108] to heat the printing material.
[0046] The re-coater assembly [114] is employed to supply a new layer of printing material atop an existing layer of printing material, to facilitate printing of 3D objects. This process is repeated layer by layer until the entire 3D objects is created. In an embodiment, the print base plate [106] is configured to provide a flat and smooth surface for the bottom (first) layer of the 3D object to be sprayed or fed. The print base plate [106] is sprayed or fed with printing material of some depth that makes a temporary bond with the first layer of the 3D object. This is achieved by running few pre-sintering layers wherein laser is not fired but printing material layers are created. According to an exemplary embodiment, a layer of PA12 i.e., the printing material selected for this embodiment, of about 0.15mm, is loosely coated on the print base plate [106]. However, those skilled in the art may very well appreciate that the thickness of such a layer of printing material may vary as per the requirements of the user and/or 3D object to be printed. This layer is heated by the unary heat source [102] to reach a threshold temperature. The rate of reaching threshold temperature is linear or non-linear increment and is maintained by the at least one thermal insulation layer [112].
[0047] In an embodiment, a thermal equilibrium region [124] of the print bucket [104] is configured as 295°C ± 2%. Hence, the time for reaching threshold temperature 186°C ± 2% is about 20 mins ± 10%. For such an embodiment, as the thermal equilibrium region [124] is still 58.6% far of the threshold, the unary heat source [102] are programmed with Boolean ON & OFF logic to maintain the threshold temperature. Henceforth sintering is also achieved with the threshold temperature range. Those skilled in the art may appreciate that the above mentioned embodiment is merely illustrative and does not intend to limit the scope of the present invention. Based on the specific type of printing material employed, the threshold temperature range may also vary, and accordingly, the relative difference between the temperature of the thermal equilibrium region [124] and the threshold temperature may also correspondingly vary.
[0048] The unary heat source [102] is one of a coil heater, a ceramic heater, a convection heater, an inductive heater, a quartz radiation heating tube with reflective plates, and combinations thereof. The at least one feed plunger [108] is selected from a group consisting of a single feed plunger, a hopper type feed plunger, a bucket type feed plunger, and combinations thereof. The at least one feed plunger [108] is equipped with homing sensors [126] to detect a position of the at least one feed plunger [108] and accordingly change motion of the at least one feed plunger [108] corresponding to an input received from the 3D printer [100]. In an embodiment, unary heat source [102] is the quartz radiation heating tube is an array of quartz radiation heaters with reflective plates. In an embodiment, the quartz radiation heating tube converts electrical energy into radiant heat. In the quartz radiation heating tube, thermal energy is transferred directly to the printing material at a lower temperature.
[0049] Referring to figures 3, 6, 7, 8 and 11, in an embodiment, the unary heat source [102] converts electrical energy into radiant heat. A surrounding air in the print bucket [104] is not heated and is uninvolved in the heat transfer, making the unary heat source [102] energy efficient, convenient, and healthy. The surrounding air can be a noble gas or a combination of inert gases. In an embodiment, power is supplied by electricity. In the present invention, the thermal energy produced by the unary heat source [102] is supplied to a thermal equilibrium region [124]. The at least one thermal insulation layer [112] helps in preventing the release of heat outside of the thermal equilibrium region [124] and hence, maintains the thermal equilibrium [124] in the thermal equilibrium region [124]. The at least one thermal insulation layer [112] is provided on an outer periphery of the print bucket [104], the at least one thermal insulation layer [112] being made up of one of ceramics, fiberglass, wool, silica aerogel, poly amide foams, and polyurethane (PU) foams. The 3D printer [100] comprises at least a front wall and a pair of sidewalls, each being adapted to provide thermal insulation to each of the print bucket [104], the print base plate [106], the at least one feed plunger [108], and the re-coater assembly [114] of the 3D printer [100], wherein each of the front wall and the pair of sidewalls comprise a first layer of thermal insulation, and a second layer of thermal insulation. The first layer of thermal insulation faces inwards, while the second layer of thermal insulation faces towards the ambient. Thus, aiding in maintaining the thermal equilibrium in the thermal equilibrium region [124], and reducing 3D object deformation due to heat gradient. At the same time, heat is discharged into the thermal equilibrium region [124], which is separated by an Aluminium sheet [110]. The thermal equilibrium region [124] does not have the at least one thermal insulation layer [112] and this is how excess heat is dissipated via the Aluminium sheet [110] and thermal equilibrium of the system is obtained. Those skilled in the art may appreciate that “Aluminium sheet [110]” may be replaced with any other metal, plastic non-metal, composite material, and combinations thereof, to perform the same function as that of the Aluminium sheet [110]. The first and second layers of thermal insulation is selected from the group consisting of ceramics, fiberglass, wool, silica aerogel, polyamide foams, and polyurethane (PU) foams, and combinations thereof. The first layer can be made up of Teflon (PTFE) sheet having thermal resistivity of about 3.33 (Kelvin/watt) and the second layer comprising the ceramic, such as ceramic wool having thermal resistivity of about 13.33 (Kelvin/watt). Each of the first and second later materials can interchangeably be selected from the group of materials described above. Similarly, the second layer can be made up of Teflon (PTFE) but can also be selected from the group of materials described above.
[0050] Referring to figures 6 to 11, to achieve the quality of formed 3D object, gradual cooling of the print bucket [104] post sintering is provided. The at least one temperature sensor [122] is deployed in the thermal equilibrium region [124], to continuously detect real-time temperature within the thermal equilibrium region [124]. While the at least one fan [120] is adapted to provide cool atmospheric air to the thermal equilibrium region [124], upon activation thereof, preferably after completion of the printing of the 3D object. The heater controller configured to receive and monitor the real-time temperature, to controllably activate/deactivate at least one of the unary heat source [102] and the at least one fan [120], to maintain a thermal equilibrium within the thermal equilibrium region [124], to thereby enable efficient printing of 3D objects within the print bucket [104].The heat can be gradually released by natural cooling, convection cooling, active air cooling, water cooling, cooling by vacuum, Peltier cooling, and the like. The at least one temperature sensor [122] is one of a contact-type temperature sensor such as thermocouples and a non-contact type temperature sensor such as thermal imaging camera, fiber optic temperature sensor.
[0051] The print bucket [104] is capable of being detachably removed from the 3D printer [100], to be loaded into an auxiliary machine for removing excess printing material from within the print bucket [104]. In an embodiment, the print bucket [104], along with the auxiliary machine, is integrated into the 3D printer [100], to facilitate removal of excess printing material from within the print bucket [104]. To ensure safety during operation of the 3D printer [100], the at least one safety interlock [118] includes a door interlock, an emergency stop provision, and an active interlock, to ensure that a user due to negligence does not face any harm. The safety interlocks [118] prevent the user from removing the print bucket [104], when the 3D printer [100] is printing the 3D object.
[0052] Figure 12 illustrates a schematic diagram of a system architecture of the 3D printer [100] in accordance with one embodiment of the present invention. The 3D printer [100] employs a computer software to control various components of the 3D printer [100]. The computer software is configured to control the one or more laser (at least one laser assembly [116]), galvo (one or more galvo scanners [130]), and interlocks (at least one safely interlock [118]), by a scanner control. The computer software is also configured to establish a two-way communication with at least one temperature sensor [122] to monitor the heat inside the thermal equilibrium region [124]. In an embodiment the at least one temperature sensor [122] may be replaced by a pyrometer temperature sensor, which is in turn connected to the heater controller [128] via a two-way communication. The computer software is also configured to control the quartz radiation heating tube (a unary heat source [102]) with reflective plates , through the heater controller [128]. In an embodiment, a COM port is provided to connect the computer software with the heater controller [128]. Furthermore, the computer software is configured to control the motion of various components of the 3D printer [100], such as the homing sensor [126], motors, print bed (print bucket [104]), left & right feeder (at least one feed plunger [108]) and re-coater (at least one re-coater assembly [114]) through the motion controller. In an embodiment, a COM port is provided to connect the computer software with the motion controller.
[0053] Referring to Figures 13A to 13C, there is shown a flow diagram of a method [200] of functioning of the 3D printer [100].
[0054] Figure 13A depicts the pre-sintering layering [200a] of printing material on the print bed (print base plate [106]) inside the heated chamber (print bucket [104]). Initially a 3D model is loaded into the software to slice into 2D layers of defined height. These set of 2D layers define the complete object and draw one layer at a time with laser during interslice process in Figure 13B.
[0055] Before initiating process depicted in Figure 13B, a process named pre-slice/pre-sintering layering (Figure 13A) sequence is to be run by the software to spread a layer of powder (printing material) of certain defined height for defined number of times, on the print bed (print base plate [106]). After certain layers of powder (printing material) is deposited on the print bed(print base plate [106]), is when process described in Figure 13B initiates.
[0056] The process shown in Figure 13B is the interslice sintering process [200b] wherein after each powder (printing material) layer is spread through re-coater (at least one re-coater assembly [114]), software commands laser (at least one laser assembly [116]) to fire to draw the shape defined in the 3D object slice/cross- section of that height in 2D domain created during slicing of the object. Laser (at least one laser assembly [116]) is fired only after target temperature is attained using the unary heat source [102], i.e., quartz radiation heating tube. This process is repeated until all the 2D slices created of the object are printed layer by layer.
[0057] Figure 13C depicts the post sintering layering [200c] of powder (printing material) wherein all beds (print bed & feed bed) (at least one print bucket [104] & at least one feed plunger [108]) are actuated to allow deposition of powder (printing material) over the printed 3D object, to create a certain height of heated powder (printing material) over the printed area. This supports retain the heat for printed 3D object and avoids sudden cooling and in turn warping of the layers printed last. It also supports slow cooling method and dissipation of extra heat to avoid sudden solidifying of the powder (printing material) in the areas near printed part, by conduction method.
[0058] Various advantages of the 3D printer [100], particularly the SLS technology 3D printer [100] of the present invention exist. Firstly, 3D printer [100] consumes substantially less power. Secondly, heat exposed parts of the 3D printer [100], such as the at least one laser assembly [116], the at least one re-coater assembly [114], and the like are increased due to the at least one thermal insulation [112]. Thirdly, thermal management of the 3D printer [100], i.e., heating rate before printing, thermal stability during printing and cooling rate after printing, of the present 3D printer [100] is well designed with its reliability and without any type of extra mechanical as well as electrical mechanisms. Thus, reducing the cost of maintenance and improving the operation of the 3D printer [100]. However, it may be understood that the above listed advantages are merely illustrative and not exhaustive. Those skilled in the art may contemplate additional advantages not described herein above, in light of the concepts of the present disclosure.
[0059] While the preferred embodiments of the present invention have been described here in above, it should be understood that various changes, adaptations, and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims. It will be obvious to a person skilled in the art that the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The embodiments described are to be considered in all respects only as illustrative and not restrictive.

LIST OF COMPONENTS
100 – Three-dimensional (3D) printer
102 – Unary heat source
104 – Print bucket
106 – Print base plate
108 – Feed plunger
110 – Aluminium sheet
112 – Thermal insulation layer
114 – Re-coater assembly
116 – Laser assembly
118 – Safety interlock
120 – Fan
122 – Temperature sensor
124 – Thermal equilibrium region
126 – Homing sensor
128 – Heater controller
130 – Galvo scanner ,CLAIMS:I/We Claim:
1. A three-dimensional (3D) printer [100] for printing three-dimensional (3D) objects, the 3D printer [100] comprising:
a unary heat source [102]; and
at least one print bucket [104] configured to adjustably house and support a print base plate [106] therein,
the unary heat source [102] being capable of providing controlled heat to a printing material deployed onto the print base plate [106], for efficiently printing 3D objects in the at least one print bucket [104].
2. The three-dimensional (3D) printer [100] as claimed in claim 1, wherein the print bucket [104] is capable of being detachably removed from the 3D printer [100], to be loaded into an auxiliary machine for removing excess printing material from within the print bucket [104].
3. The three-dimensional (3D) printer [100] as claimed in claim 1, wherein the print bucket [104], along with an auxiliary machine, is integrated into the 3D printer [100], to facilitate removal of excess printing material from within the print bucket [104].
4. The three-dimensional (3D) printer [100] as claimed in claims 1, 2, or 3, comprising at least one feeder plunger [108] deployed on either side of the at least one print bucket [104], each of the at least one feeder plunger [108] being adapted to spray or feed the printing material onto the print base plate [106], to facilitate printing operation within the print bucket [104].
5. The three-dimensional (3D) printer [100] as claimed in 4, wherein the at least one feed plunger [108] is selected from a group consisting of a single feed plunger, a hopper type feed plunger, a bucket type feed plunger, and combinations thereof.
6. The three-dimensional (3D) printer [100] as claimed in claim 1, comprising:
at least one re-coater assembly [114] employed to supply a new layer of printing material atop an existing layer of printing material, to facilitate printing of 3D objects;
at least one laser assembly [116] comprising a laser delivery path, one or more laser source, an optical component, and one or more galvo scanners [130], wherein each of the one or more galvo scanner [130] is employed to direct corresponding each of the one or more laser source of the laser assembly [116] to the print base plate [106].
7. The three-dimensional (3D) printer [100] as claimed in claim 1, comprising at least one thermal insulation layer [112] provided on an outer periphery of the print bucket [104], the at least one thermal insulation layer [112] being made up of one of ceramics, fiberglass, wool, silica aerogel, poly amide foams, and polyurethane (PU) foams.
8. The three-dimensional (3D) printer [100] as claimed in claim 1, comprising at least one safety interlock [118] for ensuring safety during operation of the 3D printer [100], the at least one safety interlock [118] including a door interlock, an emergency stop provision, and an active interlock.
9. The three-dimensional (3D) printer [100] as claimed in claims 1 and 3, comprising:
at least one temperature sensor [122] deployed in a thermal equilibrium region [124], to continuously detect real-time temperature within the thermal equilibrium region [124];
at least one fan [120] being adapted to provide cool atmospheric air to the thermal equilibrium region [124], upon activation thereof; and
a heater controller [128] configured to receive and monitor the real-time temperature, to controllably activate/deactivate at least one of the unary heat source [102] and the at least one fan [120], to maintain a thermal equilibrium within the thermal equilibrium region [124], to thereby enable efficient printing of 3D objects within the print bucket [104].
10. The three-dimensional (3D) printer [100] as claimed in claim 9, wherein the at least one temperature sensor [122] is one of a contact-type temperature sensor and a non-contact type temperature sensor.
11. The three-dimensional (3D) printer [100] as claimed in claim 1, wherein the unary heat source [102] is one of a coil heater, a ceramic heater, a convection heater, an inductive heater, a quartz radiation heating tube with reflective plates, and combinations thereof.
12. The three-dimensional (3D) printer [100] as claimed in claim 1, wherein the printing material is a material selected from the group consisting of nylon (PA12, PA11, PA6, PA6/66), TPE powder, PP powder, bio compatible powder, composite powders, glass-filled polymers, carbon-filled polymers, and combinations thereof.
13. The three-dimensional (3D) printer [100] as claimed in claims 1 or 6, comprising at least a front wall and a pair of sidewalls, each being adapted to provide thermal insulation to each of the print bucket [104], the print base plate [106], the at least one feed plunger [108], and the re-coater assembly [114] of the 3D printer [100], wherein each of the front wall and the pair of sidewalls comprise:
a first layer of thermal insulation; and
a second layer of thermal insulation,
the first layer of thermal insulation facing inwards, while the second layer of thermal insulation facing towards the ambient.
14. The three-dimensional (3D) printer [100] as claimed in claim 13, wherein each of the first and second layers of thermal insulation is selected from the group consisting of ceramics, fiberglass, wool, silica aerogel, polyamide foams, and polyurethane (PU) foams.
15. The three-dimensional (3D) printer [100] as claimed in claim 1, wherein the 3D printer [100] is a selective laser sintering (SLS) technology 3D printer.

dated this 05th day of January 2024

_______________________
ABHISHEK MAGOTRA
IN/PA No. – 1517
of MS LAW PARTNERS
Agent for the Applicant