U.S. patent application number 17/637847 was filed with the patent office on 2022-09-08 for removing build material particles.
The applicant listed for this patent is HEWLETT-PACKARD DEVELOPMENT COMPANY, L.P.. Invention is credited to David CHANCLON FERNANDEZ, Jorge DIOSDADO BORREGO, Pablo Antonio MURCIEGO RODRIGUEZ.
Application Number | 20220281171 17/637847 |
Document ID | / |
Family ID | 1000006404135 |
Filed Date | 2022-09-08 |
United States Patent
Application |
20220281171 |
Kind Code |
A1 |
DIOSDADO BORREGO; Jorge ; et
al. |
September 8, 2022 |
REMOVING BUILD MATERIAL PARTICLES
Abstract
An example of an apparatus to decake a 3D printed part is
disclosed. The apparatus comprises a housing including at least a
conduit connectable to a gas source and at least a channel
connectable to a vacuum source. The conduit, when in use, is to
direct a gas flow to remove un-solidified build material particles
from a surface of a 3D printed part. The channel, when in use, is
to direct an airflow that generally surrounds the gas flow to
extract the removed un-solidified build material particles.
Inventors: |
DIOSDADO BORREGO; Jorge;
(Sant Cugat del Valles, ES) ; CHANCLON FERNANDEZ;
David; (Sant Cugat del Valles, ES) ; MURCIEGO
RODRIGUEZ; Pablo Antonio; (Sant Cugat del Valles,
ES) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HEWLETT-PACKARD DEVELOPMENT COMPANY, L.P. |
Spring |
TX |
US |
|
|
Family ID: |
1000006404135 |
Appl. No.: |
17/637847 |
Filed: |
September 25, 2019 |
PCT Filed: |
September 25, 2019 |
PCT NO: |
PCT/US2019/052909 |
371 Date: |
February 24, 2022 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22F 10/68 20210101;
B08B 5/043 20130101; B29C 64/35 20170801; B08B 5/023 20130101; B33Y
40/20 20200101; B08B 15/04 20130101 |
International
Class: |
B29C 64/35 20060101
B29C064/35; B22F 10/68 20060101 B22F010/68; B33Y 40/20 20060101
B33Y040/20; B08B 5/02 20060101 B08B005/02; B08B 5/04 20060101
B08B005/04; B08B 15/04 20060101 B08B015/04 |
Claims
1. A 3D cleaning station comprising: a transport module to
transport at least one 3D printed part with un-solidified build
material through the 3D cleaning station; a housing including at
least a conduit connectable to a gas source and at least a channel
connectable to a vacuum source; the conduit, when in use, to direct
a gas flow to remove un-solidified build material particles from a
surface of the 3D printed part; and the channel, when in use, to
direct an airflow that generally surrounds the gas flow to extract
the removed un-solidified build material particles.
2. The 3D cleaning station of claim 1, further comprising a
plurality of the housings located at different positions relative
to the transport module to remove and extract un-solidified build
material particles from the 3D printed part as the 3D printed part
moves through the 3D cleaning station.
3. The 3D cleaning station of claim 1, further comprising a
positioning mechanism to move the housing with respect to the 3D
cleaning station.
4. The 3D cleaning station of claim 1, further comprising the gas
source and the vacuum source respectively connected to the conduit
and the channel.
5. The 3D cleaning station of claim 1, wherein the conduit forms an
airknife that spans substantially the full width of the transport
module.
6. The 3D cleaning station of claim 1, wherein the gas in the
conduit flows at a higher speed than the airflow in the
channel.
7. The 3D cleaning station of claim 1, wherein the conduit and the
channel are located around a central axis.
8. The 3D cleaning station of claim 1, wherein at least one of a
conduit end and a channel end comprises a nozzle opening.
9. The 3D cleaning station of claim 8, further comprising an array
of conduits and channels to span substantially a full width of the
transport module.
10. The 3D cleaning station of claim 1, wherein the housing further
comprises a skirt defining an aperture that spans, at least in
part, a surface of the 3D printed part.
11. An apparatus to decake a 3D printed part comprising: a housing
including at least a conduit connectable to a gas source and at
least a channel connectable to a vacuum source; the conduit, when
in use, to direct a gas flow to remove un-solidified build material
particles from a surface of a 3D printed part; and the channel,
when in use, to direct an airflow that generally surrounds the gas
flow to extract the removed un-solidified build material
particles.
12. The apparatus of claim 11, wherein the conduit and the channel
are located around a central axis.
13. The apparatus of claim 11, wherein the gas flow in the conduit
is to have an average speed from about 0.01 m/s to about 1 m/s.
14. The apparatus of claim 1, wherein the distance in which the
housing is positioned relative to the 3D printed part is
adjustable.
15. A non-transitory machine-readable medium storing instructions
executable by a processor, the non-transitory machine-readable
medium comprising: instructions to control a transport module to
move through a 3D cleaning station; instructions to control a gas
source to generate a gas flow towards the transport module to
remove un-solidified build material particles from a 3D printed
part placed thereon; and instructions to control a vacuum source to
direct an airflow that generally surrounds the gas flow to extract
the removed un-solidified build material particles.
Description
BACKGROUND
[0001] Some additive manufacturing or three-dimensional printing
systems selectively solidify portions of successive layers of a
powdered build material to generate 3D objects. After the
generation of the 3D objects a decaking operation may be performed.
A decaking operation comprises the separation of the 3D objects
from the un-solidified build material that has not been used in the
generation of the 3D objects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] The present application may be more fully appreciated in
connection with the following detailed description of non-limiting
examples taken in conjunction with the accompanying drawings, in
which like reference characters refer to like parts throughout and
in which:
[0003] FIG. 1A is a schematic diagram showing an example of a front
view of an apparatus to decake a 3D printed part.
[0004] FIG. 1B is a schematic diagram showing an example of a
bottom view of an apparatus to decake a 3D printed part.
[0005] FIG. 10 is a schematic diagram showing another example of a
bottom view of an apparatus to decake a 3D printed part.
[0006] FIG. 2 is a schematic diagram showing an example of a 3D
cleaning station.
[0007] FIG. 3A is a schematic diagram showing another example of a
3D cleaning station.
[0008] FIG. 3B is a schematic diagram showing an example of a
bottom view of a 3D cleaning station.
[0009] FIG. 3C is a schematic diagram showing another example of a
bottom view of a 3D cleaning station.
[0010] FIG. 4 is a schematic diagram showing another example of a
3D cleaning station.
[0011] FIG. 5A is a schematic diagram showing another example of a
3D cleaning station.
[0012] FIG. 5B is a schematic diagram showing a bottom view of an
example of a 3D cleaning station.
[0013] FIG. 6 is a schematic diagram showing another example of a
3D cleaning station.
[0014] FIG. 7 is a block diagram illustrating an example of a
processor-based system to control a 3D cleaning station.
DETAILED DESCRIPTION
[0015] The following description is directed to various examples of
additive manufacturing, or three-dimensional printing, apparatus
and processes to generate high quality 3D objects. Throughout the
present disclosure, the terms "a" and "an" are intended to denote
at least one of a particular element. In addition, as used herein,
the term "includes" means includes but not limited to, the term
"including" means including but not limited to. The term "based on"
means based at least in part on.
[0016] For simplicity, it is to be understood that in the present
disclosure, elements with the same reference numerals in different
figures may be structurally the same and may perform the same
functionality.
[0017] Some examples of additive manufacturing use build material
to generate 3D objects by selectively solidifying a plurality of
layers of build material. Suitable powder-based build materials for
use in examples herein may include, where appropriate, at least one
of polymers, metal powder, ceramic powder such as for example,
polyamides (e.g., PA11, PA12), Thermoplastic Polyurethane (TPU),
and stainless-steel. Some additive manufacturing systems use build
material in, for example, a powdered or granular form.
[0018] Different powders may have different characteristics, such
as different average particle sizes, different minimum and maximum
particle sizes, different coefficients of friction, different angle
of repose, and the like. In some examples non-powdered build
materials may be used such as gels, pastes, and slurries.
[0019] Some 3D printing systems comprise a 3D printer that
selectively solidifies portions of a plurality of build material
layers in a build chamber. The plurality of build material layers
in the build chamber are referred hereinafter as a build bed. The
build bed may comprise, after completion of a 3D printing process,
solidified portions corresponding to the 3D objects and
non-solidified portions corresponding to the build material that is
not used for the generation of the 3D objects. In an example, the
solidified portions are portions of the build bed that have been
melted, coalesced, and cooled. In another example, the solidified
portions are portions of the build bed that have been combined with
a binder (e.g., thermal curable binder, UV curable binder) in a
binder matrix. In some examples, to achieve the above-mentioned
solidification, portions in which a binder has been ejected are
subject to a curing stage, such as a thermal curing stage, that may
be performed either in the printer or outside the printer.
[0020] The 3D objects from the build bed may be separated from the
un-solidified build material. The separation of the 3D objects from
the un-solidified build material is also known as decaking. In some
examples, the decaking is performed in the 3D printer. In other
examples, the decaking is performed in a 3D cleaning station. In
some of the examples herein, a 3D cleaning station may further
include build material processing operations, such as loading a
build material store with build material. In other examples herein,
the 3D cleaning station may not include the build material
processing operations.
[0021] Referring now to the drawings, FIG. 1A is a schematic
diagram showing an example of a vertical cross-section of an
apparatus 100 to decake a 3D printed part 140. The illustrated
example may correspond to the cut plane of the section A-A' of the
example bottom view from FIG. 1B.
[0022] The apparatus 100 comprises a housing 110 including a
cleaning channel 120 (also referred herein as conduit 120) and a
return channel 130 (also referred herein as channel 130). The
cleaning channel 120 may be any structure suitable for transporting
a gas fluid such as air. The return channel 130 may be any
structure suitable for transporting a mix of a gas fluid and build
material particles. In some examples, the cleaning channel 120
and/or the return channel 130 may comprise a conduit, a pipe, a
hose, or a duct.
[0023] The cleaning channel 120 is connectable to an external gas
source 150 and the return channel 130 is connectable to a vacuum
source 160. The gas source 150 is any device suitable for
generating a gas flow 125 which is directed through the cleaning
channel 120 towards a 3D printed part 140. The vacuum source 160
may be any device suitable for generating an airflow 135 through
the return channel 130. Examples of the gas source 150 and/or
vacuum source 160 may comprise pumps, fans, and the like.
[0024] The 3D printed part 140 (indicated as cross-linear hatching)
is not part of the apparatus 100. The 3D printed part 140 is formed
by solidified build material particles. Some un-solidified build
material particles 145 may stick to a surface of the 3D printed
part 140 during its generation.
[0025] The cleaning channel 120, when in use, is to direct the gas
flow 125 towards the 3D printed part 140. The gas flow 125 is to
remove, at least in part, un-solidified build material particles
145 from a surface of the 3D printed part 140. The particles from
the un-solidified build material particles 145 which are removed by
the gas flow 125 are referred hereinafter as particles 147. In some
examples, the particles 147 may become airborne and form a particle
cloud between the apparatus 100 and the 3D printed part 140.
[0026] The gas flow 125 may be formed from a gaseous fluid with
high levels of purity (i.e., low amount of impurities flowing
therein). In an example, the gas flow 125 has a purity level of
above 98%. In another example, the gas flow 125 has a purity level
of above 95%. In another example, the gas flow 125 has a purity
level of above 90%. In another example, the gas flow 125 has a
purity level of above 80%. In another example, the gas flow 125 has
a purity level of above 70%.
[0027] When the gas flow 125 is directed towards a 3D printed part
140 through the cleaning channel 120, any impurities in the gas
flow 125 may damage the 3D printed part 140 by, for example,
causing erosion thereon. Therefore, a gas flow 125 with high levels
of purity reduces damage caused to the 3D printed part 140 during
the decaking operation.
[0028] The return channel 130, when in use, is to direct the
airflow 135 to extract any removed un-solidified build material
particles 147 through the return channel 130.
[0029] The airflow 135 extracts the particles 147, previously
removed by the gas flow 125, to the return channel 130. In some
examples, the airflow 135 may further extract un-solidified build
material particles 145 not removed by the gas flow 125. The
particles 147 in the return channel 130 are directed to the
opposite end of the return channel 130 where they may be stored for
recycling or may be discarded. The airflow 135 surrounding the gas
flow 125 ensures that most of the particles 147 are extracted by
the airflow 135 through the return channel 130, thereby preventing
the removed particles from eroding the surface of the 3D printed
part 140 and from reaching other areas from the working area.
[0030] FIG. 1B illustrates a bottom view example of the housing 110
from the apparatus 100. As shown, the cleaning channel 120 and a
return channel 130 are axially concentric. In an example, the
output nozzle of the cleaning channel 120 may be located at the
center of the bottom of the apparatus. The airflow 135 generally
surrounds the gas flow 125 around the axis of the gas flow 125. In
the illustrated example, the airflow 135 fully surrounds the gas
flow 125 around the axis of the gas flow 125.
[0031] In a different example, illustrated in FIG. 10, a plurality
of return channels 130A-F may be provided around the cleaning
channel 120. In the example, six return channels 130A-F are shown,
however in other examples other numbers of return channels may be
used. In this example, return channels 130A-F are radially aligned
around the axis of the cleaning channel 120. The cleaning channel
120 may be located at the center of the apparatus.
[0032] When the apparatus 100 is in use, the gas flow 125 and the
airflow(s) 135 may be generated to generally surround the gas flow
125. In some examples, the airflow 135 partially surrounds the gas
flow 125 with regards to the vertical axis (e.g., there may be gaps
in between two consecutive return channels 130A-F).
[0033] In other examples, the relative position between the
cleaning channel 120 and the return channel 130 may be different
than the relative position depicted in the examples above. In an
example, the return channel 130 may surround, at least partially,
the cleaning channel 120. In other examples, the return channel 130
may not surround the cleaning channel 120, but the airflow 135
directed from the return channel 130 surrounds, at least in part,
the gas flow 125 directed from the cleaning channel 120.
[0034] In an example, the gas flow 125 is controllable
independently from the airflow 135 (by e.g., different controllers,
different inlet valves). In other examples, however, the airflow
135 is controlled based on the gas flow 125. The speed of the gas
flow 135 and the airflow 135 may depend on the size and geometry of
the section in which the gas flow 135 or the airflow 135 flows
through. For example, the gas flow 125 at the cleaning channel 120
may flow at a lower speed than the gas flow 125 at a nozzle at the
end of the cleaning channel 120, given that the nozzle has a
smaller section than the cleaning channel 120. The gas flow 125
speed and the airflow 135 speed may be controlled to be any
suitable combination of speeds that allow each of the flows to
perform the respective functionality described herein.
[0035] In some examples, the gas flow 125 in the cleaning channel
120 flows at a higher speed than the airflow 135 in the return
channel 130. In another example, the airflow 135 in the return
channel 130 flows at a higher speed than the gas flow 125 in the
cleaning channel 120. In yet other examples, the gas flow 125 in
the cleaning channel 120 flows at about the same speed than the
airflow 135 in the return channel 130.
[0036] In an example, the gas flow generator 150 is controlled to
generate a gas flow 125 in the cleaning channel 120 to have an
average speed from about 0.01 m/s to about 1 m/s, for example 0.7
m/s. In another example, the gas flow generator 150 is controlled
to generate a gas flow 125 in the cleaning channel 120 to have an
average speed from about 0.1 m/s to about 0.5 m/s, for example 0.25
m/s. In yet another example, the gas flow generator 150 is
controlled to generate a gas flow 125 in the cleaning channel 120
to have an average speed from about 0.2 m/s to about 0.4 m/s, for
example 0.38 m/s.
[0037] FIG. 2 is a schematic diagram showing an example of a
cross-section of a portion of a 3D cleaning station 200 comprising
the apparatus 100 shown in FIG. 1.
[0038] The 3D cleaning station 200 comprises a transport module 270
to transport at least one 3D printed part 140 with attached
un-solidified build material 145 through the 3D cleaning station
200. For clarity reasons, the illustrated example comprises
un-solidified build material particles 145 on the top portion of
the 3D printed part 140, however it is to be understood that the 3D
printed part 140 may be covered in un-solidified build material
particles 145. The 3D printed part 140 may be moved along the 3D
cleaning station 200 as indicated by the arrow 275 by the transport
module 270. The transport module 270 may be implemented in a number
of different ways, for example, as a conveyor belt, a moveable
tray, or any other suitable mechanism that enables the
transportation of the 3D printed part 140 through the 3D cleaning
station 200.
[0039] The 3D cleaning station 200 includes the housing 110
including the cleaning channel 120 removably connected to the gas
source 150 and a return channel 130 removably connected to the
vacuum source 160. When in use, the cleaning channel 120 is to
direct the gas flow 125 to remove, at least in part, un-solidified
build material particles 145 from a surface of the 3D printed part
140 (e.g., particles 147). The return channel 130 is to direct the
airflow 135, that generally surrounds the gas flow 125, to extract
the particles 147.
[0040] In some examples, the 3D cleaning station 200 may comprise
at least one of the gas source 150 and the vacuum source 160. In
other examples, however, the gas source 150 and the vacuum source
160 are external to the cleaning station 200 but are respectively
connectable to the cleaning channel 120 and the return channel
130.
[0041] In some examples, the 3D cleaning station 200 may comprise a
plurality of the housings 110 located at different positions
relative to the advancement location (i.e., axis X) of the
transport module. The plurality of housings 110 are to remove and
extract un-solidified build material particles 145 from the 3D
printed part 140 as the 3D printed part 140 moves through the 3D
cleaning station 200.
[0042] Additionally, the distance in which the distal end of the
housing 110 is positioned relative to, for example, a 3D printed
part 140 may be adjustable. Adjusting the height between the distal
end of the housing 110 and the 3D printed part 140 may enable the
housing 110 to be located at a preset distance from the 3D printed
part 140.
[0043] A number of different mechanisms may be used to adapt the
distance of the housing 110 with regards of the vertical axis. In
an example, the distance in which the housing 110 is positioned may
be adjusted by a manual mechanism operated by a user. A manual
mechanism may include at least one of a ramp, a pin, a lever, a
piston, or any suitable mechanism to adjust manually the distance
between the distal end of the housing 110 and the 3D printed part
140. In another example, the distance in which the distal end of
the housing 110 is positioned may be adjusted by an automatic
driving mechanism including, for example, a motor. In some of the
examples herein, the distal end of the housing 110 is to be
adjusted to be at a distance from the 3D printed part from about 5
mm to about 100 mm. In other examples, the distal end of the
housing 110 is to be adjusted to be at a distance from the surface
of a portion of the 3D printed part being cleaned from about 5 mm
to about 50 mm. In yet other examples, the distal end of the
housing 110 is to be adjusted to be at a distance from the 3D
printed part from about 10 mm to about 40 mm.
[0044] Additionally, the 3D cleaning station 200 may comprise a
positioning mechanism (not shown) to move the housing 110 with
respect to the 3D cleaning station 200. In an example, the
positioning mechanism may move the housing 110 with regard to the
vertical axis (i.e., Z axis). Additionally, or alternatively, the
positioning mechanism may move the housing 110 with regard to the
transportation movement axis (i.e., X axis). Additionally, or
alternatively, the positioning mechanism may move the housing 100
with respect to the width (e.g., Y axis, not shown) from the
transport module. In some additional examples, the positioning
mechanism may be automatically adjusted to be located at a preset
distance from the uppermost surface of the 3D printed part 140 as
the 3D printed part 140 moves through the 3D cleaning station 200
by means of, for example, a height sensor connectable to the
positioning mechanism.
[0045] FIG. 3A is a schematic diagram showing another example of a
cross-section of a section of a 3D cleaning station 300. In some
examples, the 3D cleaning station 300 may include the apparatus 100
from FIG. 1A. In other examples, the 3D cleaning station 300 may
include elements from the 3D cleaning station 200 from FIG. 2.
[0046] The housing 110 comprises a cleaning channel 120 (visible in
FIG. 3B) and a plurality of return channels, for example a first
return channel 130M and a second return channel 130N. The return
channels 130M and 130N may be the same as or similar to the return
channel 130 from FIG. 1A. The cleaning channel 120 from the 3D
cleaning station 300 forms an airknife that spans substantially the
full width of the transport module 270 (i.e., axis Y). In an
example, the airknife has a length of from about 250 mm to about
400 mm. In another example, the airknife has a length of from about
100 mm to about 500 mm. In yet another example, the airknife has a
length of from about 275 mm to about 350 mm.
[0047] In the examples herein, the term airknife should be regarded
to include any suitable device to provide a uniform sheet of
laminar gas flow. Some examples of airknifes are regarded to be a
pressurized air plenum containing a plurality of holes or
continuous slots through which the gas flow 125 is ejected in a
laminar flow pattern.
[0048] Additionally, to increase the decaking speed, the 3D
cleaning station 300 may further comprise a plurality of the
housings 110 located at different positions relative to the length
(axis X) of the transport module 270 to remove and extract
un-solidified build material particles 145 from the 3D printed part
140 as the 3D printed part 140 moves along the 3D cleaning
station.
[0049] FIG. 3B illustrates a bottom view example of the housing 110
from FIG. 3A. The illustrated example may correspond to the cut
plane of the section B-B' of the example vertical cross-section
view from FIG. 3A. In the bottom-view example of FIG. 3B the
housing 110, at the middle portion, comprises a strip formed from
an elongated cleaning channel aperture 120. The housing 110 further
comprises a first elongated return channel aperture 130M located at
a first side of the elongated cleaning channel aperture 120, and a
second elongated return channel aperture 130N located at a second
side of the elongated channel aperture 120. In the illustrated
examples, the return channel apertures 130M and 130N generally
surround the cleaning channel 120.
[0050] FIG. 3C illustrates a bottom view example of an alternative
rearrangement of the cleaning channel 120 and plurality of return
channels of the housing 110 from FIG. 3A. In the bottom-view
example of FIG. 3C, at the middle portion, the housing 110
comprises a strip formed from a plurality of cleaning channel
nozzles 120A-F. The housing 110 further comprises a first
additional strip of a first plurality of return channel nozzles
130A-F located at a first side of the cleaning channel nozzles
120A-F, and a second additional strip of a second plurality of
return channel nozzles 130G-L located at a second side of the
cleaning channel nozzles 120A-F.
[0051] FIG. 4 is a diagram showing a cross-section of another
example of a cleaning apparatus 400.
[0052] The 3D cleaning station 400 comprises the housing 110
including the cleaning channel 120 that is at least partially
surrounded by the return channel 130. The cleaning channel 120 and
the return channel 130 are located around a central axis 490. In an
example, the distal end of the cleaning channel 120 is a nozzle
structure which corresponds with the central axis 490. The distal
end from the return channel 130 is, at least partially, coaxially
concentric to the distal end of the cleaning channel 120. Thereby,
the return channel 130 generally surrounds the cleaning channel
120. The cleaning channel 120 surrounding the return channel 130
ensures that most part of the particles 147 are driven by the
airflow 135 through the return channel 130, thereby preventing the
removed particles from eroding the surface of the 3D printed part
140. Additionally, since most part of the particles 147 are driven
by the airflow 135, it may prevent the particles 147 from reaching
other areas from the working area of the apparatus 110, thereby
providing a cleaner working environment.
[0053] Additionally, to increase the decaking speed, the 3D
cleaning station 400 may further comprise a plurality of the
housings 110 located at different positions relative to the
transport module 270 to remove and extract un-solidified build
material particles 145 from the 3D printed part 140 as the 3D
printed part 140 moves along the 3D cleaning station.
[0054] FIG. 5A is a schematic diagram showing another example of a
3D cleaning station 500. Respectively, FIG. 5B illustrates a
bottom-view of a housing 510 from the 3D cleaning station 500.
[0055] The housing 510 from the 3D cleaning station 500 further
comprises a skirt 330. In the examples herein, a skirt is a part
from the housing 510 that increases from a constant width for most
of the housing 510, and then expands the width of the housing 510
as it approaches to the distal end of the housing 510. In an
example, the skirt 330 is located at the lower position of the
housing 510. The distal end of the housing 510 including the skirt
330 may correspond to the return channel 130 extension from the
bottom-view illustrated in FIG. 5B. The skirt 330 defines an
aperture around the cleaning channel 120. In an example, the
aperture of the skirt 330 is from about 200 mm to about 400 mm. In
another example, the aperture of the skirt 330 is from about 100 mm
to about 200 mm. In another example, the aperture of the skirt 330
is from about 50 mm to about 100 mm. In yet another example, the
aperture of the skirt 300 is less than about 50 mm.
[0056] The skirt 330 provides a wider surface in which the gas flow
125 and/or airflow 135 operate. In some examples, however, a wider
skirt 330 may involve a higher vacuum power from the vacuum source
160 (not shown) to counterpart the loss of airflow 135 speed caused
by the wider aperture of the skirt 330. The skirt 330 may ensure
that most of the particles 147 are transported by the airflow 135
into the apparatus 510, thereby enhancing the efficiency with which
the return channel 130 prevents the removed particles from eroding
the surface of the 3D printed part 140. Additionally, since most
part of the particles 147 are driven by the airflow 135, it may
prevent the particles 147 from reaching other areas from the
working area of the apparatus 510, thereby providing a cleaner
working environment.
[0057] In some examples, the skirt 330 may be removable and
interchangeable with a different skirt 330 with a different
aperture. Additionally, some examples of the skirt 330 may be
generated through 3D printing means in order to accurately span, at
least in part, to the surface of subsequent 3D objects to be
printed. Alternatively, some examples of skirt 330 may be generated
through other technologies, such as injection molding.
[0058] FIG. 6 is a diagram showing another a cross-section of a 3D
cleaning station 600 according to one example.
[0059] The 3D cleaning station 600 comprises a series of housings
610A-610D. Each housing 610A-D constitutes an individual cleaning
element. The series of cleaning elements 610A-D collectively span
up to substantially the full width (axis Y) of the transport module
270. Each cleaning element comprises a cleaning channel 120 and a
return channel 130 with respective functionalities as described
above, to enable the 3D cleaning station 600 to perform decaking
operations.
[0060] Additionally, to increase the decaking speed, the 3D
cleaning station 600 may comprise a plurality of series of cleaning
elements (e.g., cleaning elements 610A-610D) located at different
positions relative to the length of the transport module (i.e., X
axis) to remove and extract un-solidified build material particles
145 from the 3D printed part 140, as the 3D printed part 140 moves
along the 3D cleaning station.
[0061] FIG. 7 is a block diagram illustrating a processor-based
system 700 that includes a machine-readable medium 720 encoded with
instructions to control a 3D cleaning station (e.g., 3D cleaning
station 200 from FIG. 2). In some implementations, the system 700
is a processor-based system and may include a processor 710 coupled
to a machine-readable medium 720. The processor 710 may include a
micro-controller.
[0062] The machine-readable medium 720 may be any medium suitable
for storing executable instructions, such as a random-access memory
(RAM), electrically erasable programmable read-only memory
(EEPROM), flash memory, hard disk drives, optical disks, and the
like. In some example implementations, the machine-readable medium
720 may be a tangible, non-transitory medium, where the term
"non-transitory" does not encompass transitory propagating signals.
The machine-readable medium 720 may be disposed within the
processor-based system 700, as shown in FIG. 7, in which case the
executable instructions may be deemed "installed" on the system
700. Alternatively, the machine-readable medium 720 may be a
portable (e.g., external) storage medium, for example, that allows
system 700 to remotely execute the instructions or download the
instructions from the storage medium. In this case, the executable
instructions may be part of an "installation package". As described
further herein below, the machine-readable medium may be encoded
with a set of executable instructions 721-723.
[0063] Instructions 721, when executed by the processor 710, may
cause the processor 710 to control a transport module (e.g.,
transport module 270) to move through a 3D cleaning station (e.g.,
3D cleaning station 200 from FIG. 2). In an example, the transport
module may move in a continuous manner. In other example, the
transport module may move periodically.
[0064] Instructions 722, when executed by the processor 710, may
cause the processor 710 to control a gas source (e.g., gas source
150) to generate a gas flow (e.g., gas flow 125) which is directed
through the conduit (e.g., channel 120) towards the transport
module to remove un-solidified build material particles (e.g.,
un-solidified build material particles 145) from a 3D printed part
(e.g., 3D printed part 140) placed thereon.
[0065] Instructions 723, when executed by the processor 710, may
cause the processor 710 to control a vacuum source (e.g., vacuum
source 160) to direct an airflow (e.g., airflow 135) through the
channel (e.g., channel 130) that generally surrounds the gas flow
to extract the removed un-solidified build material particles
(e.g., particles 147).
[0066] As used herein, the terms "about" and "substantially" are
used to provide flexibility to a numerical range endpoint by
providing that a given value may be, for example, an additional 20%
more or an additional 20% less than the endpoints of the range. The
degree of flexibility of this term can be dictated by the
particular variable and would be within the knowledge of those
skilled in the art to determine based on experience and the
associated description herein.
[0067] The drawings in the examples of the present disclosure are
some examples. It should be noted that some units and functions of
the procedure may be combined into one unit or further divided into
multiple sub-units. What has been described and illustrated herein
is an example of the disclosure along with some of its variations.
The terms, descriptions and figures used herein are set forth by
way of illustration. Many variations are possible within the scope
of the disclosure, which is intended to be defined by the following
claims and their equivalents.
[0068] There have been described example implementations with the
following sets of features:
[0069] Feature set 1: A 3D cleaning station comprising: [0070] a
transport module to transport at least one 3D printed part with
un-solidified build material through the 3D cleaning station;
[0071] a housing including at least a conduit connectable to a gas
source and at least a channel connectable to a vacuum source;
[0072] the conduit, when in use, to direct a gas flow to remove
un-solidified build material particles from a surface of the 3D
printed part; and [0073] the channel, when in use, to direct an
airflow that generally surrounds the gas flow to extract the
removed un-solidified build material particles.
[0074] Feature set 2: A 3D cleaning station with feature set 1,
further comprising a plurality of the housings located at different
positions relative to the transport module to remove and extract
un-solidified build material particles from the 3D printed part as
the 3D printed part moves through the 3D cleaning station.
[0075] Feature set 3: A 3D cleaning station with any preceding
feature set 1 or 2, further comprising a positioning mechanism to
move the housing with respect to the 3D cleaning station.
[0076] Feature set 4: A 3D cleaning station with any preceding
feature set 1 to 3, further comprising the gas source and the
vacuum source respectively connected to the conduit and the
channel.
[0077] Feature set 5: A 3D cleaning station with any preceding
feature set 1 to 4, wherein the conduit forms an airknife that
spans substantially the full width of the transport module.
[0078] Feature set 6: A 3D cleaning station with any preceding
feature set 1 to 5, wherein the gas in the conduit flows at a
higher speed than the airflow in the channel.
[0079] Feature set 7: A 3D cleaning station with any preceding
feature set 1 to 6, wherein the conduit and the channel are located
around a central axis.
[0080] Feature set 8: A 3D cleaning station with any preceding
feature set 1 to 7, wherein at least one of a conduit end and a
channel end comprises a nozzle opening.
[0081] Feature set 9: A 3D cleaning station with any preceding
feature set 1 to 8, further comprising an array of conduits and
channels to span substantially a full width of the transport
module.
[0082] Feature set 10: A 3D cleaning station with any preceding
feature set 1 to 9, wherein the housing further comprises a skirt
defining an aperture that spans, at least in part, a surface of the
3D printed part.
[0083] Feature set 11: An apparatus comprising: [0084] a housing
including at least a conduit connectable to a gas source and at
least a channel connectable to a vacuum source; [0085] the conduit,
when in use, to direct a gas flow to remove un-solidified build
material particles from a surface of a 3D printed part; and [0086]
the channel, when in use, to direct an airflow that generally
surrounds the gas flow to extract the removed un-solidified build
material particles.
[0087] Feature set 12: An apparatus with preceding feature set 11,
wherein the conduit and the channel are located around a central
axis.
[0088] Feature set 13: An apparatus with any preceding feature set
11 to 12, wherein the gas flow in the conduit is to have an average
speed from about 0.01 m/s to about 1 m/s.
[0089] Feature set 14: An apparatus with any preceding feature set
11 to 13, wherein the distance in which the housing is positioned
relative to the 3D printed part is adjustable.
[0090] Feature set 15: A non-transitory machine-readable medium
storing instructions executable by a processor, the non-transitory
machine-readable medium comprising: [0091] instructions to control
a transport module to move through a 3D cleaning station; [0092]
instructions to control a gas source to generate a gas flow towards
the transport module to remove un-solidified build material
particles from a 3D printed part placed thereon; and [0093]
instructions to control a vacuum source to direct an airflow that
generally surrounds the gas flow to extract the removed
un-solidified build material particles.
* * * * *