Layer Transfusion with Rotatable Belt for Additive Manufacturing
AssigneeStratasys, Inc.
InventorsSteven A. Chillscyzn, James W. Comb, William J. Hanson, J. Randolph Sanders, Michael W. Bacus
Life of this patent
Estimating the term…
Abstract
An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.
Claims20
An additive manufacturing system for printing a three-dimensional part, the additive manufacturing system comprising:
- a rotatable multiple-layer belt configured to receive imaged layers of a thermoplastic-based powder from an imaging engine;
- a drive mechanism configured to rotate the multiple-layer belt at a rotational rate to transfer the received imaged layers;
- a build platform configured to receive the imaged layers from the multiple-layer belt in a layer-by-layer manner to print the three-dimensional part on the build platform;
- and
- a gantry configured to move the build platform in a reciprocating rectangular pattern that is synchronized with the rotational rate of the multiple-layer belt.
A method for printing a 3D part with an additive manufacturing system, the method comprising:
- forming imaged layers of a thermoplastic-based powder with an imaging engine;
- transferring the imaged layers to a belt in an ordered sequence at a first location;
- driving the belt a rotational rate to convey the imaged layers on the belt from the first location to a second location, wherein at the second location an imaged layer on the belt is positioned in-between a built platform and a layer transfusion element;
- transferring the imaged layer from the belt onto the build platform by engaging a rear surface of the belt with the layer transfusion element and pressing the layer to previously-printed layers of the three-dimensional part while moving the build platform at a synchronized rate with the belt away from the second location;
- continuing to drive the belt after the imaged layer is transferred so that the belt returns to the imaging engine;
- moving the build platform to complete a reciprocating rectangular pattern that returns the build platform to the second location;
- timing the return of the build platform to the second location such that the build platform is positioned to receive a next imaged layer from the belt when the next imaged layer arrives at the second location;
- and
- continuing the reciprocating rectangular pattern of the build platform and the rotation of the belt until each imaged layer is transferred in sequence.
A method for printing a three-dimensional part with an additive manufacturing system, the method comprising:
- rotating a transfer belt;
- moving a build platform in a reciprocating rectangular pattern, which directs the build platform to engage the rotating transfer belt, to then move in the same direction and at the same rate as the rotating transfer belt, and to then disengage from the rotating transfer belt;
- receiving an imaged layer of a thermoplastic-based powder onto the rotating transfer belt;
- aligning the imaged layer on the rotating transfer belt with the moving build platform when the moving build platform engages the rotating transfer belt;
- transfusing the imaged layer to a previously-transfused layer of the three-dimensional part retained by the moving build platform while the build platform is moving in the same direction and at the same rate as the rotating transfer belt;
- and
- releasing the transfused layer from the rotating transfer belt when the moving build platform disengages from the rotating transfer belt.
Dependencies are inferred from the claim text.