WO2017023283A1

WO2017023283A1 - Induction fusing

Info

Publication number: WO2017023283A1
Application number: PCT/US2015/043293
Authority: WO
Inventors: Wei Huang; Kristopher J ERICKSON; Yan Zhao; Jun Zeng
Original assignee: Hewlett-Packard Development Company, L.P.
Priority date: 2015-07-31
Filing date: 2015-07-31
Publication date: 2017-02-09

Abstract

Examples described herein include a three-dimensional printer a threedimensional printing device comprising a base material applicator to build a plurality of successive layers of fusible material according data layers define in a three-dimensional model of a three dimensional object, a fusing agent applicator to form an unfused formation corresponding to the threedimensional object by applying a plurality of patterns of fusing agent to corresponding regions of at least some of the plurality of successive layers of the base material according to the three-dimensional model, and an induction heater to fuse the unfused formation to form the three-dimensional object.

Description

INDUCTION FUSING

BACKGROUND

[0001] Three-dimensional printing, also referred to as "3D printing", refers to any processes by which a physical three-dimensional object can be generated based on a corresponding three-dimensional data model. A machine, such as a 3D printer, can reference the three-dimensional data model to form the physical three-dimensional object. Many such 3D printers incrementally build the three-dimensional object. For example, some 3D printers build three-dimensional objects a layer at a time until the three- dimensional object is complete.

BRIEF DESCRIPTION OF THE DRAWINGS

[0002] FIG. 1 illustrates an example process for three-dimensional printing using simultaneous induction fusing.

[0003] FIG. 2 illustrates a schematic of an example three-dimensional printer.

[0004] FIG. 3 is a flowchart of an example method of three-dimensional printing using simultaneous induction fusing.

DETAILED DESCRIPTION

[0005] Implementations of the present disclosure include systems, methods, and devices for three-dimensional printing that use inductive heating to simultaneously fuse multiple layers of fusible material to form a three- dimensional object according to a corresponding three-dimensional model. In such implementations, each a layer of base material can be treated with a corresponding pattern of inductively reactive fusing agent. As the successive layers of base material are built up, each layer can be treated with a pattern of fusing agent corresponding to the structure of the three-dimensional object in that particular layer.

[0006] Once the stack of treated layers are complete, the stack can be exposed to an inductive heating field (e.g., an alternating or static magnetic field) that induces the inductively reactive fusing agent patterns in ail layers to increase in temperature simultaneously. By controlling the frequency of the alternating magnetic field, the strength of the magnetic field, and the duration of exposure to the magnetic field, the inductively reactive fusing agent can be heated to the point that localized regions of the base material within and between layers fuse together. Accordingly, the bonds between the fused layers of base material can be as strong as the bonds of the fused base material within a particular layer

[0007] FIG. 1 depicts an example process 100 of generating a three- dimensional object that uses layers of base materials treated with fusing agent that can then be fused simultaneously using induction heating, in various implementations, the process can start at reference 11 at which a substrate or platform 101 is provided. The substrate 101 can include any type of material suitable for accepting unfused or fused base material. For example, the substrate 101 can include materials such as, metal, ceramic, plastic, and the like. The substrate 101 can be implemented as a reusable or disposable platform that other elements or components of a three-dimensional printing device (e.g.. a substrate handler) can manipulate to facilitate the various steps in the process 100. For example, the substrate 101 can be moved into position to be proximate to the base material applicator 130. Thus, at reference 12, the base material applicator 130 can apply a layer of base material 103. To apply the layer of base material 103, the base material applicator 130 can move relative to the surface of the substrate 101. For instance, the base material applicator 130 can move along the direction of the arrow 131 to build up the base material layer 103.

[0008] The layer of base material 103 can include various materials and be built up to various thicknesses. For example, the base material layer 103 can include materials, such as metals, plastics, polymers, ceramics, glasses, and the like. Any of such materials can be laid down as a powder, slurry, or gel. In various implementations, thickness of the base material layer 103 can be selected based on material properties of the base material, the

corresponding fusing agents, and/or the features defined in the three- dimensional data model corresponding to the particular layer of the desired resulting three-dimensional object.

[0009] To define which regions of the base material layer 103 will be fused, fusing agent applicator 140 can apply a pattern of fusing agent to define treated and untreated regions of the base material in a particular layer at reference 13. The fusing agent applicator 140 can move relative to the substrate 101 and the surface of the most recent base material layer 103 (e.g., along direction of the arrow 141 ). The fusing agent applicator 140 can selectively applying a pattern of fusing agent according to layer-level data of the three-dimensional data model corresponding to the desired three- dimensional object. The three-dimensional data model can include data usable by a corresponding three-dimensional printer that defines how a three- dimensional object can be built, in some implementations, the layer level data of the three-dimensional data model can be organized as an ordered set of stacked data layers. Each data layer can correspond to a layer of the resulting physical three-dimensional object.

[0010] The fusing agent applicator 140 can include any type of applicator, such as, inkjets (e.g., thermal inkjet, piezoelectric inkjet), sprayers, and the like, suitable for spraying, printing, injecting, or otherwise applying the corresponding fusing agent. In some implementations, the fusing agent applicator 143 can include a page-wide-array of inkjets that can selectively apply a pattern of the fusing agent to a corresponding layer of base material 103 based on the corresponding layer-data of the three-dimensional data model, in other implementations, the fusing agent applicator 140 can include a print head that scans across various dimensions relative to the substrate 101 or the surface of the topmost layer of base material 103.

[0011] Layers of base material 103 treated with patterns of fusing agent can create corresponding regions 105 of treated based layer material 103. In some implementations, the fusing agent can be applied to the surface of the corresponding base material layer 103. in some implementations, the fusing agent can be formulated to remain at the surface to avoid bleeding into previous or subsequent layers. In other implementations, the fusing agent can be formulated to diffuse into the base material, in other implementations, applying the fusing agent can include injecting the fusing agent into a particular depth of the base layer material 103.

[0012] As described herein , the patterns of the fusing agent can be applied to corresponding layers of base materials based on the corresponding layer-level data in the corresponding three-dimensional data object by repeating (e.g., N times) the processes described at reference numerals 12 and 13. As such, multiple layers of base material 103 with corresponding fusing agent treated regions 105 can be built up into an unfused formation corresponding to the desired three-dimensional object, as shown at reference 14. The unfused formation of the three-dimensional object shown at reference 14 can include any number of layers of base material 103 having treated regions 105 created according to patterns described in the layer data in the three-dimensional data model. In the example shown in FIG. 1, there can be as many as N, where N is an integer, layers of base material 103 with fusing agent treated regions 105.

[0013] Once the unfused formation of the desired three-dimensional object is constructed, implementations of the present disclosure can include applying an induction field to seamlessly fuse the layers of treated regions 105 of the base material to themselves and one another to create the fused form of the three-dimensional object 110, as shown at reference 15.

[0014] In one implementation, the unfused formation can be disposed in an induction heater 150 that generates a corresponding induction field 151. For example, the induction heater 150 can include a coil of conductor having multiple loops in which the unfused formation of the three-dimensional object can be positioned. The coil of conductor can thus be driven with an electrical current. The electrical current can be controlled to have various frequencies and/or magnitudes to generate a corresponding alternating magnetic field having various frequencies or magnitudes. The magnetic field can then be applied to the unfused formation. Accordingly, applying the induction field 151 can include applying any alternating or static magnetic field to the unfused formation suitable for causing the fusing agent treated regions 105 to increase in temperature to a threshold fusing or melting point of the particular base material and/or base material and fusing agent combination. [0015] At reference 16, the fused form of the three-dimensional object 110 can be removed from the induction heater 150 and/or the substrate 101. In later steps, not shown in FIG. 1 , the unfused portions of the base material layers 103 can be removed (e.g., blown, washed, or shaken way) to expose the fused form of the three-dimensional object 110.

[0016] FIG. 2 depicts a schematic of a three-dimensional printer 200. As shown, three-dimensional printer 200 can include a processor 210 to execute machine readable code stored in the memory 230 to perform operations and control other components of the three-dimensional printer 200 according various examples described herein, in various examples, processor 210 may be a microprocessor, a micro-controller, an application specific integrated circuit (ASIC), or the like. According to an example implementation, the processor 210 is a hardware component, such as a circuit. The memory 230 can include a volatile or non-volatile memory, such as dynamic random access memory (DRAM), electrically erasable programmable read-only memory (EEPROM), magnetoresistive random access memory (MRAM), memristor, flash memory, floppy disk, a compact disc read only memory (CD- ROM), a digital video disc read only memory (DVD-ROM), or other optical or magnetic media, and the like, on which executable code may be stored.

[0017] In various implementations, the processor 210 can execute three- dimensional printing code 231. Three-dimensional printing code 231 can include instructions for generating control signals that cause the base material applicator 130, the fusing agent applicator 140, and/or the induction heater 150 to implement the corresponding operations or functionality of three-dimensional printing processes according to various implementations of the present disclosure. For example, the instructions included in the three-dimensional printing code 231 can cause the processor 210 to control the components of the three-dimensional printer 200 to perform the example process 100 depicted in FIG. 1 and/or the method described in reference to FIG. 3. In some implementations, the three-dimensional printing code 231 can include a three- dimensional data model usable by the three-dimensional printer 200 to create a corresponding physical three-dimensional object. [0018] in some example implementations, the three-dimensional printer 200 can include a communication interface 220. The communication interface 220 can be used by the processor 210 for sending and receiving signals to and from an external computing device, such as a desktop, laptop, or server computer, in various implementations, the communication interface 220 can include a networking communication interface, a universal serial bus (USB) interface, a parallel communication interface, a serial communication interface, or any other communication interface suitable for communicating with other electronic or computing devices. For example, the three-dimensional printer 200 can receive printing instructions and/or electronic files through the communication interface 220. The instructions or electronic flies can include computer readable code comprising instructions or three-dimensional data models that the processor 210 can use to generate a three-dimensional object using the other subcomponents of the three-dimensional printer 200 according to implementations of the present disclosure.

[0019] FIG. 3 is a flowchart of an example method 300 for generating a three-dimensional object based on a corresponding three-dimensional data model using induction fusing. As shown, method 300 can begin by

establishing a layer of base material at box 310. in one implementation of the present disclosure, the layer of base material can be established by roiling out, applying, spraying, or otherwise applying a layer of powder, slurry, gel, or other suitable form of fusible base material. For example, the base material applicator 130 can sift a powdered base material layer 103 onto the substrate or a previously applied layer. The fusible base material can include various combinations of metal, ceramics, polymers, plastics, and other materials that can melt or fuse upon reaching a threshold temperature. The specific fusible base material and/or its thickness can be based on information contained in a corresponding data layer of a three-dimensional data model of a desired three-dimensional object.

[0020] At box 320, the base material layer can be treated by applying a pattern of fusing agent according to information in the corresponding data layer of the three-dimensional data model. The pattern of the fusing agent applied at box 320 can correspond to the desired physical elements of the three-dimensional object at that particular corresponding layer.

[0021] If there are more data layers in the three-dimensional data model for which more physical layers of base material treated with or without fusing agent are to be created, as determined at 330, then tile operations and processes described in reference to boxes 310 and 320 can be repeated to create successive layers of base materials. The stack of base material layers treated with corresponding patterns of fusing build up to create an unfused formation corresponding to the desired three-dimensional physical object.

[0022] Once the last physical layer of base material treated with fusing agent is created in the unfused formation, the entire or portions of the unfused formation can be exposed to an induction heating field, at box 340. As such, the entire unfused formation can be exposed to a common temporally, directionaliy, or energetically static or dynamic induction field, in other examples, select regions or volumes of the unfused formation can be exposed to different inductions fields. For example, regions or volumes of the unfused formation can be exposed to varied temporally, directionaliy, or energetically static or dynamic induction field induction fields. In this way, fusing of the unfused formation can be controlled.

[0023] In other examples, the unfused formation can be exposed to an induction field as it is being built. For example, groups of any number of layers in the total number of layers of fusing agent treated base material layers can be exposed to an induction field. As such, previous layers of fusing agent treated base material can be exposed to an induction field before subsequent layers are applied. Such implementations can provide control over heating, fusing, and/or cooling during the induction fusing process. The induction heating field can include a magnetic field that induces the fusing agent and/or the base material treated with the fusing agent to increase in temperature. Once the fusing agent and/or the base material treated with the fusing agent reaches a threshold temperature, the materials of the unfused formation of the three-dimensional object can fuse to form a seamless fused three-dimensional object corresponding to the three-dimensional data model. [0024] The fusing agent used in various implementations of the present disclosure can include various inductively reactive materials, in one particular implementation, the inductively reactive material can include an ink that includes conductive particles that increase in temperature when subjected to an induction field. In another example implementation, the inductively reactive material can include an ink that includes nanoparticles that increase in temperature when subjected to an induction field. Accordingly, when the treated regions 105 of a base material layer 103 are subjected to an induction field, the fusing agents in the treated regions 105 can increase to a temperature at which the base material layer to melt and/or fuse.

[0025] In some implementations, the amount and/or concentration of the fusing agent can be selectively controlled. For example, implementations of the fusing agent application 140 can control the amount and/or concentration of fusing agent applied to various regions of the layer of fusible material. Thus, the amount and/or concentration of the fusing agent can vary across the surface and depth of a particular layer of fusible material. The level of variation of in the amount or concentration of the fusing agent applied by the fusing agent applicator 140 can be based on corresponding data in the three- dimensional data model.

[0026] In other implementations, the fusible material applicator can selectively apply supplemental base materials to the base material layer to augment the composition of the base material and the resulting fused material. As such, the fusible material applicator can vary position, concentration, and amount of fusing agent or supplemental base materials to achieve multiple material structures within the resulting three-dimensional object.

[0027] In yet another example implementations, the fusing agent can be mixed and/or applied along with a non-inducttve!y reactive agent (e.g., agents to absorb or infrared or ultra violet electromagnetic energy) and/or a binding agent (e.g., glue or epoxy), such that the induction fusing agent contributes to or leads a multi-stage fusing process. For example, the fusing agent applicator can include a mixer to combine the different types of fusing agents, For example, the mixer can mix an inductively reactive component of the fusing agent with an ultraviolet fusing agent and then selectively apply the mixture to the base material, in other Implementations, the fusing agent application can include multiple print heads that jet or spray different types fusing agents, such as, inductively reactive fusing agents, absorptive fusing agents, binding agents, and the like. The different print heads can selectively apply the corresponding fusing agents in varied amounts or concentrations to the base material to form regions in the base material with a mixture of fusing agents. The fusing agents can then be subjected to the corresponding fusing energy (e.g., induction field for the inductively reactive fusing agent) or treatment (e.g., wash of the second part of an epoxy or a fixer for binding epoxy fusing agent). In some implementations, the fusing process can include applying multiple fusing energies or treatments to all or some of the unfused formation.

[0028] These and other variations, modifications, additions, and improvements may fall within the scope of the appended daims(s). As used in the description herein and throughout the claims that follow, "a", "an", and "the" includes plural references unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of "in" includes "in" and "on" unless the context clearly dictates otherwise. Ail of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the elements of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or elements are mutually exclusive.

Claims

Claims What is claimed is:

1. A three-dimensional printer comprising:

a base material applicator to build a plurality of successive layers of fusible material according to data layers define in a three-dimensional model of a three dimensional object;

a fusing agent applicator to form an unfused formation

corresponding to the three-dimensional object by applying a plurality of patterns of fusing agent to corresponding regions of at least some of the plurality of successive layers of the base material according to tine three- dimensional model; and

an induction heater to fuse at least a portion of the unfused formation to form the three-dimensional object.

2. The three-dimensional printer of claim 1 wherein the fusing agent

comprises a liquid, semi-liquid, or solid conductive material.

3. The three-dimensional printer of claim 1 wherein the fusing agent

comprises multiple types of fusing agents, and the fusing agent applicator comprises multiple inkjets or sprayers to selectively apply a corresponding type of fusing agent from the multiple types of fusing agents.

4. The three-dimensional printer of claim 1 wherein the induction heater comprises a conductor loop to generate an alternating magnetic field.

5. The three-dimensional printer of daim 4 wherein to fuse the formation the induction heater applies the alternating magnetic field to induce heat in the plurality of corresponding patterns of fusing agent to melt the corresponding regions of at least some of the plurality of successive layers of the base material.

6. A three-dimensional printer comprising:

a processor;

a base material applicator coupled to the processor;

a fusing agent applicator coupled to the processor;

an induction heater coupled to the processor; and

a non-transitory computer readable medium coupled to the processor and comprising instructions that when executed by the processor cause the processor to:

control the base material applicator and the fusing agent applicator to generate an unfused formation of a three-dimensional object based on a three-dimensional data model of the three- dimensional object, wherein the unfused formation of the three- dimensional object comprises a plurality of layers of base material treated with corresponding patterns of fusing agent; and

control the induction heater to fuse the unfused formation of die three-dimensional object.

7. The three-dimensional printer of claim 6 wherein the unfused formation of the three-dimensional object comprises a plurality of layers of base material treated with corresponding patterns of fusing agent.

8. The three-dimensional printer of claim 7 wherein the instructions that cause the processor to control the induction heater to fuse the unfused formation of the three-dimensional object further cause processor to control the induction heater to fuse the plurality of layers of base material treated with corresponding patterns of fusing agent simultaneously.

9. The three-dimensional printer of claim 6, wherein the instructions that cause the processor to control the base material applicator and the fusing agent applicator to generate an unfused formation of a three-dimensional object further cause the processor to:

for each data layer in an ordered plurality of data layers defined in the three-dimensional data model of the three-dimensional object: control the base material applicator to establish a layer of fusible material corresponding to the data layer in the ordered plurality of data layers; and

control the fusing agent applicator to apply a pattern of fusing agent to the layer of fusible material based the data layer in the ordered plurality of data layers .

10. A method of printing a three-dimensional object comprising:

forming an unfused version of the three-dimensional; and

applying an induction field to the unfused version of the three- dimensional object.

11. The method of claim 10, wherein applying the induction field comprises generating a magnetic field in the vicinity of the unfused version of the three- dimensional object.

12. The method of claim 10, wherein forming the unfused version of the three- dimensional layers comprises forming multiple layers of fusible material treated with corresponding applications of fusing agent

13. The method of claim 10, wherein forming the unfused version of the three- dimensional object comprises:

for each layer in an ordered plurality of layers defined in a three- dimensional model of the three-dimensional object:

establishing a layer of fusible material corresponding to the layer in the ordered plurality of layers; and

applying a pattern of fusing agent to the layer of fusible material based on model data in the three-dimensional model corresponding to the layer in the ordered plurality of layers.

14. The method of claim 13, wherein the fusing agent comprises a conductive material that causes the fusible material to fuse in response to the induction field.

15. The method of claim 10, wherein forming the unfused version of the three* dimensional layers comprises forming multiple layers of fusible material treated with corresponding applications of fusing agent