U.S. patent application number 14/520669 was filed with the patent office on 2016-04-21 for three-dimensional printer having an expandable envelope.
The applicant listed for this patent is Lenovo Enterprise Solutions (Singapore) Pte. Ltd.. Invention is credited to Alvin G. Davis, William M. Megarity, April E. Ruggles, Paul A. Wormsbecher.
Application Number | 20160107378 14/520669 |
Document ID | / |
Family ID | 55699896 |
Filed Date | 2016-04-21 |
United States Patent
Application |
20160107378 |
Kind Code |
A1 |
Davis; Alvin G. ; et
al. |
April 21, 2016 |
THREE-DIMENSIONAL PRINTER HAVING AN EXPANDABLE ENVELOPE
Abstract
One embodiment of the present invention provides a method of
three-dimensional printing. The method includes a three-dimensional
printer printing a first layer of an object onto a surface that is
not part of the three-dimensional printer, wherein the first layer
is printed while a printing platform of the three dimensional
printer is in a first position. The printer is autonomously
repositioned in a second position elevated above the first position
by being supported either on the three-dimensional object itself or
on a scaffold printed separate from the object. The printer prints
a second layer of the three-dimensional object onto the first layer
of the three-dimensional object while the printing platform is in
the second position. The printer may have a plurality of legs for
controllably repositioning the printing platform.
Inventors: |
Davis; Alvin G.; (Durham,
NC) ; Megarity; William M.; (Raleigh, NC) ;
Ruggles; April E.; (Durham, NC) ; Wormsbecher; Paul
A.; (Apex, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lenovo Enterprise Solutions (Singapore) Pte. Ltd. |
Singapore |
|
SG |
|
|
Family ID: |
55699896 |
Appl. No.: |
14/520669 |
Filed: |
October 22, 2014 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
14518405 |
Oct 20, 2014 |
|
|
|
14520669 |
|
|
|
|
Current U.S.
Class: |
264/129 |
Current CPC
Class: |
B33Y 10/00 20141201;
B33Y 50/02 20141201; B29C 64/245 20170801; B29C 64/393 20170801;
B29C 64/236 20170801; B29C 64/118 20170801; B25J 9/026 20130101;
B29C 64/232 20170801; B29L 2009/00 20130101; B29C 64/112 20170801;
B33Y 30/00 20141201; B62D 57/032 20130101; G05B 15/02 20130101;
B25J 9/0096 20130101; B29C 64/106 20170801 |
International
Class: |
B29C 67/00 20060101
B29C067/00 |
Claims
1. A method, comprising: a three-dimensional printer printing a
first layer of a three-dimensional object onto a surface that is
not part of the three-dimensional printer, wherein the first layer
is printed while a printing platform of the three dimensional
printer is in a first position; the three-dimensional printer
printing a first layer of a scaffold separate from the first layer
of the three-dimensional object; autonomously repositioning the
three-dimensional printer to be supported on the scaffold in a
second position elevated above the first position; and printing a
second layer of the three-dimensional object onto the first layer
of the three-dimensional object while the printing platform is in
the second position.
2. The method of claim 1, wherein the scaffold is printed around
the perimeter of the three-dimensional object.
3. The method of claim 1, wherein the three-dimensional printer
includes a plurality of legs secured to the printing platform.
4. The method of claim 3, wherein the plurality of legs include a
first subset of at least three legs and a second subset of at least
three legs.
5. The method of claim 4, wherein the scaffold includes a separate
scaffold structure associated with each of the plurality of
legs
6. The method of claim 4, wherein the scaffold includes a first
subset of scaffold structures associated with the first subset of
legs and a second subset of scaffold structures associated with the
second subset of legs.
7. The method of claim 6, wherein autonomously repositioning the
three-dimensional printer to be supported on the scaffold in a
second position elevated above the first position, includes:
supporting the printing platform on the second subset of legs;
articulating the first subset of the legs to engage the first
subset of scaffold structures and support the printing platform in
the first position while the first layer of the second subset of
scaffold structures is printed; articulating the second subset of
the legs to engage the second subset of scaffold structures and
support the printing platform in the first position; and
articulating the first subset of the legs to lift the printing
platform from the first position to the second position.
8. The method of claim 6, wherein autonomously repositioning the
three-dimensional printer to be supported on the scaffold in a
second position elevated above the first position, includes:
supporting the printing platform on the second subset of legs; and
articulating the first subset of the legs to engage the first
subset of scaffold structures and lift the printing platform to the
second position before the first layer of the second subset of
scaffold structures is printed.
9. The method of claim 1, further comprising: while the printing
platform is in the second position, the three-dimensional printer
printing a second layer of the three-dimensional object over the
first layer of the three-dimensional object and a second layer of
the scaffold over the first layer of the scaffold.
10. The method of claim 7, further comprising: moving the first
subset of the legs out of alignment with the first subset of
scaffold structures to allow printing a second layer of the first
subset of scaffold structures on the first layer of the first
subset of scaffold structures; and moving the second subset of the
legs out of alignment with the second subset of scaffold structures
to allow printing a second layer of the second subset of scaffold
structures on the first layer of the second subset of scaffold
structures.
11. The method of claim 3, wherein each leg includes a scaffold
print head for printing a scaffold structure to support the
leg.
12. The method of claim 11, wherein the scaffold print head prints
the scaffold structure outside the range of the object print
head.
13. The method of claim 11, wherein the scaffold print heads
included with the first subset of legs print scaffold structures
simultaneously, and wherein the scaffold print heads included with
the second subset of legs print scaffold structures
simultaneously.
14. The method of claim 11, wherein printing a first layer of the
three-dimensional object while the printer is supported on the
first subset of scaffolds, includes printing multiple layers of the
three-dimensional object while the printer is supported on the
first subset of scaffolds at a particular elevation; and wherein
printing a second layer over the first layer of the
three-dimensional object while the printer is supported on the
second subset of scaffolds, includes printing multiple layers of
the three-dimensional object while the printer is supported on the
second subset of scaffolds at a particular elevation.
15. The method of claim 14, wherein printing the second layer of
the second subset of the scaffold structures, includes printing
multiple layers on the second subset of scaffold structures while
the three-dimensional printer is supported on the first subset of
scaffolds at a particular elevation; and wherein printing the
second layer of the first subset of the scaffold structures,
includes printing multiple layers on the first layer of the first
subset of scaffold structures while the three-dimensional printer
is supported on the second subset of scaffolds at the particular
elevation.
16. The method of claim 1, further comprising: optically scanning
the three-dimensional object after the three-dimensional printer is
supported in the second position; and adjusting printing
instructions for printing the second layer of the three-dimensional
object after the three-dimensional printer is supported in the
second position to account for changes in alignment of the printer
relative to the three-dimensional object.
17. A method, comprising: a three-dimensional printer printing a
first layer of a three-dimensional object onto a surface that is
not part of the three-dimensional printer, wherein the first layer
is printed while a printing platform of the three dimensional
printer is in a first position; autonomously repositioning the
printing platform of the three-dimensional printer to be supported
on the three-dimensional object in a second position elevated above
the first position; and printing a second layer of the
three-dimensional object on the first layer of the
three-dimensional object while the printing platform of the
three-dimensional printer is in the second position.
18. The method of claim 17, further comprising: modifying print
instructions for the three-dimensional object to reinforce the
strength of regions of the three-dimensional object that will
support the three-dimensional printer.
19. The method of claim 17, wherein autonomously repositioning the
printing platform of the three-dimensional printer to be supported
on the three-dimensional object in a second position elevated above
the first position, includes: a second subset of at least three
legs supporting the printing platform on the surface that is not
part of the three-dimensional printer; and articulating a first
subset of the legs to engage the first layer of the three
dimensional object and support the printing platform while the
second layer of the three-dimensional object is printed.
20. The method of claim 19, further comprising: articulating the
second subset of the legs to engage the second layer of the
three-dimensional object and support the printing platform;
articulating the first subset of the legs out of alignment with a
region of the three-dimensional object where the first subset of
the legs engaged the three-dimensional object; and printing in the
region to complete the second layer of the three-dimensional
object.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/518,405 filed on Oct. 20, 2014, which
application is incorporated by reference herein.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to methods and apparatus for
three dimensional printing.
[0004] 2. Background of the Related Art
[0005] Three-dimensional (3D) printing is a process of making a
three-dimensional object from a digital model using an additive
process, where successive layers of material are laid down over
previous layers. The material may be a thermoplastic polymer
filament that is heated and extruded through a narrow nozzle. In
one type of three dimensional printer, the nozzle, the table
supporting the material, or both is moved to control where the
material is deposited. Other types of three dimensional printers
may use alternative mechanisms to control the position of a nozzle
for dispensing the material.
[0006] 3D printing has become a large industry with a growing
number of printer manufacturers and web sites that provide
construction plans in the form of a data file for downloading to a
computer. Unfortunately, 3D printing is much more complex than 2D
printing and requires much more time to produce an object. Objects
that are printed at a fine level of detail or have significant size
can take many hours to complete.
[0007] Various three-dimensional printing processes include
Stereolithography (SLA), Selective Laser Sintering (SLS), Fused
Deposition Modeling (FDM), Robocasting, Laser Engineered Net
Shaping (LENS), Direct Metal Laser Sintering (DMLS), and Electron
Beam Melting (EBM). The size of the three-dimensional printer
determines the maximum size of an object that may be printed. If a
larger object is desired, multiple parts of the object within the
size limitations of the printer may be printed and then manually
assembled together.
BRIEF SUMMARY
[0008] One embodiment of the present invention provides a method of
three-dimensional printing. The method comprises a
three-dimensional printer printing a first layer of a
three-dimensional object onto a surface that is not part of the
three-dimensional printer, wherein the first layer is printed while
a printing platform of the three dimensional printer is in a first
position. The method further comprises the three-dimensional
printer printing a first layer of a scaffold separate from the
first layer of the three-dimensional object. The three-dimensional
printer is autonomously repositioned to be supported on the
scaffold in a second position elevated above the first position,
and a second layer of the three-dimensional object is printed onto
the first layer of the three-dimensional object while the printing
platform is in the second position.
[0009] Another embodiment of the present invention provides a
method comprising a three-dimensional printer printing a first
layer of a three-dimensional object onto a surface that is not part
of the three-dimensional printer, wherein the first layer is
printed while a printing platform of the three dimensional printer
is in a first position, autonomously repositioning the printing
platform of the three-dimensional printer to be supported on the
three-dimensional object in a second position elevated above the
first position, and printing a second layer of the
three-dimensional object on the first layer of the
three-dimensional object while the printing platform of the
three-dimensional printer is in the second position.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a three-dimensional
printer.
[0011] FIG. 2 is a schematic diagram of a subsystem for controlling
two-dimensional movement of a print head.
[0012] FIGS. 3A and 3B are perspective views of one leg of the
three-dimensional printer in a retracted position and an extended
position, respectively.
[0013] FIG. 4 is a diagram of a computer according to one
embodiment of the present invention.
[0014] FIGS. 5A-5C illustrate the three-dimensional printer in a
progression of initial steps building and using scaffold
structures.
[0015] FIGS. 6A-6B illustrate another embodiment of a
three-dimensional printer in a progression of initial steps
building and using scaffold structures.
[0016] FIGS. 7A-7C are diagrams illustrating possible progression
of printing steps.
[0017] FIG. 8 is a flowchart of a method according to one
embodiment of the present invention.
[0018] FIG. 9 is a flowchart of a method according to another
embodiment of the present invention.
DETAILED DESCRIPTION
[0019] One embodiment of the present invention provides a method of
three-dimensional printing. The method comprises a
three-dimensional printer printing a first layer of a
three-dimensional object onto a surface that is not part of the
three-dimensional printer, wherein the first layer is printed while
a printing platform of the three dimensional printer is in a first
position. The method further comprises the three-dimensional
printer printing a first layer of a scaffold separate from the
first layer of the three-dimensional object. The three-dimensional
printer is autonomously repositioned to be supported on the
scaffold in a second position elevated above the first position,
and a second layer of the three-dimensional object is printed onto
the first layer of the three-dimensional object while the printing
platform is in the second position. Preferably, the
three-dimensional printer will also print a second layer of the
scaffold over the first layer of the scaffold while the printing
platform is in the second position.
[0020] The surface that is not part of the three-dimensional
printer may be a table top, floor or other suitable surface. In
fact, the surface may be another object previously printed or
another object to which the three dimensional object is to be
added. Since the surface is not part of the three-dimensional
printer, the object printed may or may not be separable from the
surface.
[0021] The printing platform of the three-dimensional printer is
typically a rigid frame or bracket that supports a mechanism for
controllably positioning a print head. One non-limiting example of
a positioning mechanism may utilize sets of guide rails and an
x-axis motor, a y-axis motor, and a z-axis motor for controllably
positioning the print head in three-dimensional (XYZ) space. An
alternative example of a positioning mechanism may utilize an
orbital bearing and motors to control the angle from vertical, the
rotational angle, and the elevation. Regardless of the mechanism,
three-dimensional printers deliver a working material through a
print head or nozzle and move along a controlled path to deposit
the working material in layers. While only a single layer may be
printed or deposited at any point in time, one or more layers may
be printed or deposited before repositioning the printing platform.
For example, this may occur using a z-axis mechanism and motor that
control the vertical position of the print head relative to the
printing platform, whereas the repositioning of the printing
platform is affected by separate mechanisms and motors, such as
with a plurality of legs secured to the printing platform as
described further below.
[0022] The scaffold printed in accordance with the present
invention is not part of the three-dimensional object being
printed. Accordingly, the scaffold may be printed around the
perimeter of the three-dimensional object and does not interfere
with the object being printed. The purpose of the scaffold or
individual scaffold structures is to support the legs of the
three-dimensional printer. Accordingly, the three-dimensional
printer can print the scaffold structures needed for the printer to
reposition itself, primarily in the vertical (z-axis) direction
above the surface onto which the object is being printed or
fabricated. Beneficially, the printer can print an object that is
taller than otherwise possible with a printer of similar size.
[0023] Embodiments of the present invention provide a
three-dimensional printer including a plurality of legs secured to
the printing platform. The plurality of legs preferably includes a
first subset of at least three legs and a second subset of at least
three legs. Since each subset of legs includes at least three legs,
the printing platform can be supported by one subset of legs while
the other subset of legs is repositioning. The legs in each subset
are preferably widely or uniformly spaced apart around the
perimeter of the printing platform. For example, a subset of three
legs may be spaced apart around the perimeter of a printing
platform at angles of separation measuring about 120 degrees from a
vertical axis through the center of the printing platform.
[0024] While a scaffold could completely encircle the object being
printed, this would waste lots of material and time. Accordingly,
the scaffold preferably includes a separate scaffold structure
associated with each of the plurality of legs. For example, a
three-dimensional printer having six legs may print six separate
scaffold structures. Both the object being printed and the separate
scaffold structures are printed in layers. Where the plurality of
legs includes first and second subsets of legs, the scaffold may
include a first subset of scaffold structures associated with the
first subset of legs and a second subset of scaffold structures
associated with the second subset of legs. Accordingly, the
movement of the legs in a subset is coordinated with the printing
of an associated subset of scaffold structures. Specifically, a
first subset of legs supports the printing platform while the
second subset of legs is moved out of alignment with the scaffold
structures to allow printing on the scaffold structures associated
with the second subset of legs. Similarly, the second subset of
legs supports the printing platform while the first subset of legs
is moved out of alignment with the scaffold structures to allow
printing on the scaffold structures associated with the first
subset of legs.
[0025] In one option, the step of autonomously repositioning the
three-dimensional printer to be supported on the scaffold in a
second position elevated above the first position, may include
supporting the printing platform on the second subset of legs,
articulating the first subset of the legs to engage the first
subset of scaffold structures and support the printing platform in
the first position while the first layer of the second subset of
scaffold structures is printed, articulating the second subset of
the legs to engage the second subset of scaffold structures and
support the printing platform in the first position, and
articulating the first subset of the legs to lift the printing
platform from the first position to the second position. This
optional sequence is beneficial in that the printing platform does
not require its own z-axis control.
[0026] In another option, the step of autonomously repositioning
the three-dimensional printer to be supported on the scaffold in a
second position elevated above the first position, may include
supporting the printing platform on the second subset of legs, and
articulating the first subset of the legs to engage the first
subset of scaffold structures and lift the printing platform to the
second position before the first layer of the second subset of
scaffold structures is printed. This optional sequence is
beneficial in that the printing may proceed faster, but in order to
continue the sequence to reposition the printer at higher levels it
is necessary for the printing platform to have its own z-axis
control in order to print first and second layers of the second
subset of scaffold structures without repositioning the printing
platform.
[0027] In another embodiment, each leg includes a scaffold print
head for printing a scaffold structure to support the leg.
Optionally, the end of the scaffold print head may also serve as a
foot to support the leg on a scaffold structure. One benefit of
this embodiment is that a layer of the scaffold structure may be
printed at the same time that a layer of the three-dimensional
object is printed. Another benefit of this embodiment is that the
scaffold print heads may print the scaffold structures outside the
range of the object print head. A further potential benefit is that
it is possible for the scaffold print heads included with the first
subset of legs to print scaffold structures simultaneously, and for
the scaffold print heads included with the second subset of legs to
print scaffold structures simultaneously. In one option, the step
of printing a first layer of the three-dimensional object while the
printer is supported on the first subset of scaffolds may include
printing multiple layers of the three-dimensional object while the
printer is supported on the first subset of scaffolds at a
particular elevation, and the step of printing a second layer over
the first layer of the three-dimensional object while the printer
is supported on the second subset of scaffolds, includes printing
multiple layers of the three-dimensional object while the printer
is supported on the second subset of scaffolds at a particular
elevation. In another option, the step of printing the second layer
of the second subset of the scaffold structures may includes
printing multiple layers on the second subset of scaffold
structures while the three-dimensional printer is supported on the
first subset of scaffolds at a particular elevation, and the step
of printing the second layer of the first subset of the scaffold
structures, includes printing multiple layers on the first layer of
the first subset of scaffold structures while the three-dimensional
printer is supported on the second subset of scaffolds at the
particular elevation.
[0028] The methods of the present invention may further comprise
optically scanning the three-dimensional object after the
three-dimensional printer is supported in the second position, and
adjusting printing instructions for printing the second layer of
the three-dimensional object after the three-dimensional printer is
supported in the second position to account for changes in
alignment of the printer relative to the three-dimensional object.
For example, if the repositioning of the printing platform from a
first position to a second position happens to shift the printing
platform laterally in the x-direction by 3 millimeters, then the
subsequent printing instructions that control the object print head
attached to the printing platform should be adjusted by 3
millimeters in the opposite direction.
[0029] Yet another embodiment of the present invention provides a
method comprising a three-dimensional printer printing a first
layer of a three-dimensional object onto a surface that is not part
of the three-dimensional printer, wherein the first layer is
printed while a printing platform of the three dimensional printer
is in a first position, autonomously repositioning the printing
platform of the three-dimensional printer to be supported on the
three-dimensional object in a second position elevated above the
first position, and printing a second layer of the
three-dimensional object on the first layer of the
three-dimensional object while the printing platform of the
three-dimensional printer is in the second position. This
embodiment may incorporate features from the previous embodiments,
but does not use separate scaffold structures. Rather, the printing
platform is repositioned to be supported on that portion of the
three-dimensional object that has already been printed.
Accordingly, this embodiment does not consume print material, time
and energy in constructing scaffold structures, but each subset of
legs must be sequentially moved out of alignment with the
three-dimensional object so that each layer of the
three-dimensional object may be completely printed. In one option,
the print instructions for the three-dimensional object may be
modified in order to reinforce the strength of regions of the
three-dimensional object that will support the weight of the
three-dimensional printer.
[0030] In the foregoing method, the step of autonomously
repositioning the printing platform of the three-dimensional
printer to be supported on the three-dimensional object in a second
position elevated above the first position, may include a second
subset of at least three legs supporting the printing platform on
the surface that is not part of the three-dimensional printer,
articulating a first subset of the legs to engage the first layer
of the three dimensional object and support the printing platform
while the second layer of the three-dimensional object is printed.
The method may then further comprise articulating the second subset
of the legs to engage the second layer of the three-dimensional
object and support the printing platform, articulating the first
subset of the legs out of alignment with a region of the
three-dimensional object where the first subset of the legs engaged
the three-dimensional object, and printing in the region to
complete the second layer of the three-dimensional object.
[0031] While three-dimensional printers have been designed to print
various materials, one preferred type of material includes
thermoplastic polymers. Various thermoplastic polymers may be used,
including acrylonitrile butadiene styrene (ABS), polycarbonate
(PC), polylactic acid (PLA), high density polyethylene (HDPE),
PC/ABS, and polyphenylsulfone (PPSU).
[0032] A still further embodiment of the present invention provides
a computer program product comprising a computer readable storage
medium having program instructions embodied therewith, where the
program instructions are executable by a processor to cause the
processor to perform a method. The method comprises: a
three-dimensional printer printing a first layer of a
three-dimensional object onto a surface that is not part of the
three-dimensional printer, wherein the first layer is printed while
a printing platform of the three dimensional printer is in a first
position; the three-dimensional printer printing a first layer of a
scaffold separate from the first layer of the three-dimensional
object; autonomously repositioning the three-dimensional printer to
be supported on the scaffold in a second position elevated above
the first position; and the three-dimensional printer printing a
second layer of the three-dimensional object onto the first layer
of the three-dimensional object while the printing platform is in
the second position.
[0033] An additional embodiment of the present invention provides a
computer program product comprising a computer readable storage
medium having program instructions embodied therewith, where the
program instructions are executable by a processor to cause the
processor to perform a method. The method comprises: a
three-dimensional printer printing a first layer of a
three-dimensional object onto a surface that is not part of the
three-dimensional printer, wherein the first layer is printed while
a printing platform of the three dimensional printer is in a first
position; autonomously repositioning the printing platform of the
three-dimensional printer to be supported on the three-dimensional
object in a second position elevated above the first position; and
the three-dimensional printer printing a second layer of the
three-dimensional object on the first layer of the
three-dimensional object while the printing platform of the
three-dimensional printer is in the second position.
[0034] The foregoing computer program products may further include
program instructions for implementing or initiating any one or more
aspects of the methods described herein. Accordingly, a separate
description of the methods will not be duplicated in the context of
a computer program product.
[0035] FIG. 1 is a diagram of a three-dimensional printer 10. This
three-dimensional printer 10 uses a material source 12 that
supplies a material, such as a plastic, into a tube 22. The tube 22
is secured to a carriage 24 that may include a heater to heat and
soften the plastic as it is pushed through the tube 22. The heated
and softened plastic is then pushed through a print head 26 onto a
surface 30, such as a table or floor, which is not a part of the
printer. The position of the tip of the print head 26 determines
where a thin layer of the plastic material will be placed.
[0036] The printer 10 includes a printing platform 40 in the form
of a rigid rectangular frame having sides 42 that establish an area
in which the carriage 24 and print head 26 can travel. Two of the
sides 42 include guide rails 44 that constrain a pair of shuttles
46 to move along the guide rails 44 only in the y-direction. The
shuttles 46 secure the ends of other guide rails 48 that constrain
the carriage 24 to move along the other guide rails 48 only in the
x-direction.
[0037] The printer 10 further includes a plurality of legs 50
secured around a perimeter of the printing platform 40. Each leg 50
is able to articulate and move as described in reference to FIGS.
3A and 3B, below. However, the legs 50 support and position the
print platform 40 above the surface 30. A computer or other
controller 20 is provided for controlling the position of the print
head 26, such as controlling the xy position of the print head 26
relative to the printing platform 40 and controlling the z position
of the printing platform 40 relative to the surface 30. A source of
electrical power 21 is needed to operate various motors that
control the movement of the print head 26 and the movement of the
legs 50.
[0038] FIG. 2 is a schematic diagram of subsystems for controlling
two-dimensional movement of the carriage 24. The carriage 24 may be
moved back and forth along an X-axis by an X-axis motor 41 that
rotates a drive gear or pulley 43 to move a string or belt 45 to
which the carriage 24 is attached. The direction and extent of
rotation of the drive gear 43 determines the direction and distance
that the carriage is moved. Similarly, the shuttles 46 may be moved
back and forth along the Y-axis by a Y-axis motor 47 that rotates a
drive gear or pulley 49 to move a string or belt 51 to which one of
the shuttles is attached. The direction and extent of rotation of
the drive gear 49 determines the direction and distance that the
shuttles move. The computer 20 provides instructions to the printer
10 to operate the X-axis motor 41 and the Y-axis motor 47 in a
manner that positions the print head where it can progressively
fabricate the intended object. As each layer has been completed in
the X-Y plane, the print head may be moved up or down along a
Z-axis by a Z-axis motor that is secured to the carriage 24.
However, the entire printing platform 40 may be moved in the
Z-direction by the plurality of legs 50 as described below.
[0039] FIGS. 3A and 3B are perspective views of one leg 50 of the
three-dimensional printer in a retracted position and an extended
position, respectively. The computer 20 provides control signals to
motors in or adjacent the pivot joints. A first joint or swivel 52
allows the leg to rotate about a vertical axis 53, a second joint
54 allows a distal segment 55 to move about a lateral axis 59, and
a third joint 56 allows a further segment 58 to move about another
lateral axis 57. The position of each of these joints 52, 54, 56 is
independently controlled by the computer 20.
[0040] FIG. 4 is a diagram of an exemplary computer 20 that may be
used in accordance with one embodiment of the present invention.
The computer 20 includes a processor unit 104 that is coupled to a
system bus 106. Processor unit 104 may utilize one or more
processors, each of which has one or more processor cores. A video
adapter 108, which drives/supports a display 152, is also coupled
to system bus 106. The system bus 106 is coupled via a bus bridge
112 to an input/output (I/O) bus 114. An I/O interface 116 is
coupled to I/O bus 114. I/O interface 116 affords communication
with various I/O devices, including a keyboard 153, a mouse 154, a
camera or scanner 155 and a 3D printer 10. The I/O devices may
optionally include storage devices, such as CD-ROM drives and
multi-media interfaces, other printers, and external USB port(s).
While the format of the ports connected to I/O interface 116 may be
any known to those skilled in the art of computer architecture, in
a preferred embodiment some or all of these ports are universal
serial bus (USB) ports. As depicted, the computer 20 is able to
communicate over a network 38 using a network interface 130. The
network 38 may be an external network, such as the global
communication network, and perhaps also an internal network such as
an Ethernet LAN or a virtual private network (VPN).
[0041] A hard drive interface 132 is also coupled to system bus 106
and interfaces with a hard drive 134. In a preferred embodiment,
the hard drive 134 populates a system memory 136, which is also
coupled to system bus 106. System memory is defined as a lowest
level of volatile memory in the computer 20. This volatile memory
may include additional higher levels of volatile memory (not
shown), including, but not limited to, cache memory, registers and
buffers. Data that populates the system memory 136 includes the
computer's operating system (OS) 138 and application programs
144.
[0042] The operating system 138 includes a shell 140, for providing
transparent user access to resources such as application programs
144. Generally, shell 140 is a program that provides an interpreter
and an interface between the user and the operating system. More
specifically, shell 140 executes commands that are entered into a
command line user interface or from a file. Thus, shell 140, also
called a command processor, is generally the highest level of the
operating system software hierarchy and serves as a command
interpreter. The shell provides a system prompt, interprets
commands entered by keyboard, mouse, or other user input media, and
sends the interpreted command(s) to the appropriate lower levels of
the operating system (e.g., a kernel 142) for processing. Note that
while shell 140 is a text-based, line-oriented user interface, the
present invention will equally well support other user interface
modes, such as graphical, voice, gestural, etc.
[0043] As depicted, the OS 138 also includes a kernel 142, which
includes lower levels of functionality for OS 138, including
providing essential services required by other parts of OS 138 and
application programs 144, including memory management, process and
task management, disk management, and mouse and keyboard
management. The application programs 144 in the system memory of
the computer 20 may include various programs and modules for
implementing the methods described herein, such as the 3D printer
control logic 146 and 3D object data files 148.
[0044] The hardware elements depicted in computer 20 are not
intended to be exhaustive, but rather are representative components
suitable to perform the processes of the present invention. For
instance, computer 20 may include alternate memory storage devices
such as magnetic cassettes, digital versatile disks (DVDs),
Bernoulli cartridges, and the like. These and other variations are
intended to be within the spirit and scope of the present
invention.
[0045] FIGS. 5A-5C illustrate the three-dimensional printer 10 in a
progression of initial steps building and using scaffold
structures. Furthermore, the legs 50 are controlled in subsets,
including a first subset of legs 62 and a second subset of legs 60.
In FIG. 5A, the second subset of legs 60 are supporting the
printing platform 40 in a first position above the surface 30, such
that the print head 26 has printed a first layer of an object 32 as
well as a first layer of a first subset of three scaffold
structures 64. In order to accommodate the printing of the scaffold
structures 64, the first subset of legs 62 have been moved out of
the way of the print head 26. More specifically, the first subset
of legs 62 have moved out of alignment with the position on surface
30 that the scaffold structure 64 are to be printed. While the
printing platform 40 is not receiving support from the first subset
of legs 62, the platform 40 is supported by the second subset of
legs 60 which are spaced apart around the perimeter of the platform
40. Although the scaffold structures 64 and the object 32 may be
referred to as being one layer at this point, if the printing
platform 40 has the capability to move the print head 26 in the
z-direction relative to the printing platform 40 then the printed
material shown may be multiple layers.
[0046] In FIG. 5B, the first subset of legs 62 have been
articulated to move directly over the first subset of scaffold
structures 64 and support the printing platform in the first
position. Accordingly, the second subset of legs 60 are moved out
of the way so that the print head 26 has been able to print a first
layer of a second subset of scaffold structures 66.
[0047] With the first layer completed, FIG. 5C shows the beginning
of a second layer. Here, the second subset of legs 60 have moved to
engage the scaffold structures 66 and lift the printing platform 40
to a second position above the first position. Accordingly, the
second subset of legs 60 are again supporting the printing platform
40, but in a second position above the surface 30, such that the
print head 26 has been able to print a second layer of an object 32
as well as a second layer of the first subset of three scaffold
structures 64. In order to accommodate the print head 26 printing
the second layer of the scaffold structures 64, the first subset of
legs 62 have been moved out of alignment with the scaffold
structures 64. It should be recognized that the sequence described
in reference to FIGS. 5A-5C may be repeated as desired to continue
printing additional layers of the object 32 until the object is
completed. There is no inherent or fixed maximum height of the
object to be printed.
[0048] It should also be recognized that the sequence described in
reference to FIGS. 5A-5C may also be incorporated in embodiments
that do not use separate or dedicated scaffold structures 64, 66,
but rather support the print platform by setting the legs on the
object 32 itself. Accordingly, the object 32 may be considered to
include the scaffold structures 64, 66. The legs 50 may be
articulated to reach inwardly to the object 32 and treat a portion
of the object 32 as a scaffold structure. Unlike a dedicated
scaffold structure, the object may have a different layout from one
layer to another, such that the positioning of each leg may change
from layer to layer.
[0049] FIGS. 6A-6B illustrate another embodiment of a
three-dimensional printer 70 in a progression of initial steps
building and using scaffold structures. There may be various
structural similarities between the present printer 70 and the
previous printer 10, such that reference numbers used to describe
the previous printer 10 may be reused to describe similar
structures and components of the present printer 70. In particular,
the printing platform 40 may be identical to that previously
described.
[0050] The primary difference in the present printer 70 is that the
distal leg segments 58 (see FIGS. 3A and 3B) have all been replaced
with a scaffold print tube 72, a heat or extruder 74, and scaffold
print head 76. The material source 12 (FIG. 1) or another material
source may provide material to each of the scaffold print heads 76
as needed to print layers of the scaffold structures 64, 66.
[0051] FIG. 6A shows the printer 70 supported on the print heads 76
of a second subset of legs 80 while the other print heads 76, which
are associated with a first subset of legs 82, print a layer of the
first subset of scaffold structures 64. FIG. 6B shows the printer
70 supported on the print heads 76 of the first subset of legs 82
while the other print heads 76, which are associated with a second
subset of legs 80, print a layer of the second subset of scaffold
structures 66 and a layer of the object 32. The layer of the object
32 is shown as being printed while the printer is supported by
second subset of legs 80, but it should be recognized that the
layer of the object 32 could be also be printed while the printer
is supported by the first subset of legs 82. Still further, where
the object 32 takes longer to print than either of the scaffolds
64, 66, the object 32 may be partially printed while the printer is
supported by second subset of legs 80 and completed while the
printer is supported by the first subset of legs 82 or all of the
legs 80, 82.
[0052] FIGS. 7A-7C are diagrams illustrating a few possible
sequences of printing steps in which the material is printed in
numerical order. FIG. 7A is consistent with FIGS. 5A-5C where the
object 32 and the first subset of scaffold structures 64 are
printed in a first step and the second subset of scaffold
structures 66 are printed in a second step. This sequence may
continue to fabricate the object 32 layer by layer, with the
scaffolds 64, 66 also being fabricated layer by layer.
[0053] FIG. 7B illustrates another optional sequence where the
printing platform is repositioned to the next higher position after
every addition to a scaffold structure. However, this sequence
requires the printing platform to provide the print head with its
own z-axis control in order to print first and second layers of the
second subset of scaffold structures 66 without repositioning the
printing platform. After the initial layer of the first subset of
scaffold structures 64, the scaffold structures 64, 66 are always
printed two layers at a time. Accordingly, the print head 26 may
prints a complete layer or nearly complete layer of the object
every time that the printing platform is repositioned. This
optional sequence is beneficial in that the printing may proceed
faster.
[0054] FIG. 7C illustrates another optional sequence that is made
possible using the printer 70 with scaffold print heads 76 on each
of the legs (See FIGS. 6A-6B). In this sequence, each layer of the
object 32 and scaffold structures 64, 66 are completed before the
printing platform is repositioned higher.
[0055] FIG. 8 is a flowchart of a method 90 according to one
embodiment of the present invention. In step 91, a
three-dimensional printer prints a first layer of a
three-dimensional object onto a surface that is not part of the
three-dimensional printer, wherein the first layer is printed while
a printing platform of the three dimensional printer is in a first
position. In step 92, the three-dimensional printer printing a
first layer of a scaffold separate from the first layer of the
three-dimensional object. In step 93, the three-dimensional printer
is autonomously repositioned to be supported on the scaffold in a
second position elevated above the first position. Step 94 includes
printing a second layer of the three-dimensional object onto the
first layer of the three-dimensional object while the printing
platform is in the second position. Steps of the method may be
repeated as needed to print a completed three-dimensional object,
as may be described by a 3D data file.
[0056] FIG. 9 is a flowchart of a method 95 according to another
embodiment of the present invention. In step 96, a
three-dimensional printer prints a first layer of a
three-dimensional object onto a surface that is not part of the
three-dimensional printer, wherein the first layer is printed while
a printing platform of the three dimensional printer is in a first
position. In step 97, the printing platform of the
three-dimensional printer is autonomously repositioned to be
supported on the three-dimensional object in a second position
elevated above the first position. Step 98 then prints a second
layer of the three-dimensional object on the first layer of the
three-dimensional object while the printing platform of the
three-dimensional printer is in the second position. Steps of the
method may be repeated as needed to print a completed
three-dimensional object, as may be described by a 3D data
file.
[0057] The present invention may be a system, a method, and/or a
computer program product. The computer program product may include
a computer readable storage medium (or media) having computer
readable program instructions thereon for causing a processor to
carry out aspects of the present invention.
[0058] The computer readable storage medium can be a tangible
device that can retain and store instructions for use by an
instruction execution device. The computer readable storage medium
may be, for example, but is not limited to, an electronic storage
device, a magnetic storage device, an optical storage device, an
electromagnetic storage device, a semiconductor storage device, or
any suitable combination of the foregoing. A non-exhaustive list of
more specific examples of the computer readable storage medium
includes the following: a portable computer diskette, a hard disk,
a random access memory (RAM), a read-only memory (ROM), an erasable
programmable read-only memory (EPROM or Flash memory), a static
random access memory (SRAM), a portable compact disc read-only
memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a
floppy disk, a mechanically encoded device such as punch-cards or
raised structures in a groove having instructions recorded thereon,
and any suitable combination of the foregoing. A computer readable
storage medium, as used herein, is not to be construed as being
transitory signals per se, such as radio waves or other freely
propagating electromagnetic waves, electromagnetic waves
propagating through a waveguide or other transmission media (e.g.,
light pulses passing through a fiber-optic cable), or electrical
signals transmitted through a wire.
[0059] Computer readable program instructions described herein can
be downloaded to respective computing/processing devices from a
computer readable storage medium or to an external computer or
external storage device via a network, for example, the Internet, a
local area network, a wide area network and/or a wireless network.
The network may comprise copper transmission cables, optical
transmission fibers, wireless transmission, routers, firewalls,
switches, gateway computers and/or edge servers. A network adapter
card or network interface in each computing/processing device
receives computer readable program instructions from the network
and forwards the computer readable program instructions for storage
in a computer readable storage medium within the respective
computing/processing device.
[0060] Computer readable program instructions for carrying out
operations of the present invention may be assembler instructions,
instruction-set-architecture (ISA) instructions, machine
instructions, machine dependent instructions, microcode, firmware
instructions, state-setting data, or either source code or object
code written in any combination of one or more programming
languages, including an object oriented programming language such
as Smalltalk, C++ or the like, and conventional procedural
programming languages, such as the "C" programming language or
similar programming languages. The computer readable program
instructions may execute entirely on the user's computer, partly on
the user's computer, as a stand-alone software package, partly on
the user's computer and partly on a remote computer or entirely on
the remote computer or server. In the latter scenario, the remote
computer may be connected to the user's computer through any type
of network, including a local area network (LAN) or a wide area
network (WAN), or the connection may be made to an external
computer (for example, through the Internet using an Internet
Service Provider). In some embodiments, electronic circuitry
including, for example, programmable logic circuitry,
field-programmable gate arrays (FPGA), or programmable logic arrays
(PLA) may execute the computer readable program instructions by
utilizing state information of the computer readable program
instructions to personalize the electronic circuitry, in order to
perform aspects of the present invention.
[0061] Aspects of the present invention are described herein with
reference to flowchart illustrations and/or block diagrams of
methods, apparatus (systems), and computer program products
according to embodiments of the invention. It will be understood
that each block of the flowchart illustrations and/or block
diagrams, and combinations of blocks in the flowchart illustrations
and/or block diagrams, can be implemented by computer readable
program instructions.
[0062] These computer readable program instructions may be provided
to a processor of a general purpose computer, special purpose
computer, or other programmable data processing apparatus to
produce a machine, such that the instructions, which execute via
the processor of the computer or other programmable data processing
apparatus, create means for implementing the functions/acts
specified in the flowchart and/or block diagram block or blocks.
These computer readable program instructions may also be stored in
a computer readable storage medium that can direct a computer, a
programmable data processing apparatus, and/or other devices to
function in a particular manner, such that the computer readable
storage medium having instructions stored therein comprises an
article of manufacture including instructions which implement
aspects of the function/act specified in the flowchart and/or block
diagram block or blocks.
[0063] The computer readable program instructions may also be
loaded onto a computer, other programmable data processing
apparatus, or other device to cause a series of operational steps
to be performed on the computer, other programmable apparatus or
other device to produce a computer implemented process, such that
the instructions which execute on the computer, other programmable
apparatus, or other device implement the functions/acts specified
in the flowchart and/or block diagram block or blocks.
[0064] The flowchart and block diagrams in the Figures illustrate
the architecture, functionality, and operation of possible
implementations of systems, methods, and computer program products
according to various embodiments of the present invention. In this
regard, each block in the flowchart or block diagrams may represent
a module, segment, or portion of instructions, which comprises one
or more executable instructions for implementing the specified
logical function(s). In some alternative implementations, the
functions noted in the block may occur out of the order noted in
the figures. For example, two blocks shown in succession may, in
fact, be executed substantially concurrently, or the blocks may
sometimes be executed in the reverse order, depending upon the
functionality involved. It will also be noted that each block of
the block diagrams and/or flowchart illustration, and combinations
of blocks in the block diagrams and/or flowchart illustration, can
be implemented by special purpose hardware-based systems that
perform the specified functions or acts or carry out combinations
of special purpose hardware and computer instructions.
[0065] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, components and/or groups, but do not
preclude the presence or addition of one or more other features,
integers, steps, operations, elements, components, and/or groups
thereof. The terms "preferably," "preferred," "prefer,"
"optionally," "may," and similar terms are used to indicate that an
item, condition or step being referred to is an optional (not
required) feature of the invention.
[0066] The corresponding structures, materials, acts, and
equivalents of all means or steps plus function elements in the
claims below are intended to include any structure, material, or
act for performing the function in combination with other claimed
elements as specifically claimed. The description of the present
invention has been presented for purposes of illustration and
description, but it is not intended to be exhaustive or limited to
the invention in the form disclosed. Many modifications and
variations will be apparent to those of ordinary skill in the art
without departing from the scope and spirit of the invention. The
embodiment was chosen and described in order to best explain the
principles of the invention and the practical application, and to
enable others of ordinary skill in the art to understand the
invention for various embodiments with various modifications as are
suited to the particular use contemplated.
* * * * *