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US 2026/0273858 A1Published application
Systems and methods for powder handling in additive fabrication devices
AssigneeFormlabs, Inc.
InventorsLuke Boppart, Chun Ho Chan
Life of this patent
Estimating the term…
Abstract
An additive fabrication system recirculates fresh and recycled powder using a hopper, an overflow chute, and an auger channel arranged so recycled powder reaches the auger channel more directly than fresh powder. A flipper and a recoater roller spread and smooth the powder. Print preparation software arranges parts using physics-based placement and natural re-flow after user adjustments, and can generate print instructions after a stable arrangement is reached.
Claims26
An additive fabrication device comprising:
- a build chamber comprising an adjustable build platform;
- a hopper positioned below the adjustable build platform and comprising a slanted bottom surface with one or more hopper openings;
- an overflow chute configured to receive recycled powder from the build chamber;
- an auger channel fluidly connected to the overflow chute and comprising a screw auger configured to transport powder from the overflow chute toward the build chamber;
- and
- a powder spreading mechanism comprising a flipper and a recoater roller, the additive fabrication device being configured such that the recycled powder follows a more direct path from the overflow chute to the auger channel than fresh powder introduced through the one or more hopper openings.
3 more elements
A method for recirculating powder in an additive fabrication device, the method comprising:
- storing fresh powder in a hopper positioned below a build platform;
- receiving recycled powder from a build chamber in an overflow chute;
- directing the fresh powder from one or more hopper openings into the overflow chute to mix with the recycled powder;
- directing the recycled powder from the overflow chute toward an auger channel along a more direct path than the fresh powder;
- transporting mixed powder upward through the auger channel with a screw auger;
- and
- depositing the mixed powder onto the build platform with a flipper and smoothing the mixed powder into a layer with a recoater roller.
4 more elements
A computer-implemented method for arranging parts in print preparation software for additive fabrication, the method comprising:
- receiving one or more three-dimensional model files representing parts to be fabricated;
- applying one or more packing constraints to the parts within a virtual build volume;
- performing an initial automatic placement of the parts using a physics-based simulation;
- and
- in response to a user adjustment to a position or orientation of a first part, continuing the physics-based simulation to automatically reposition one or more remaining parts without restarting the entire packing process and, after the one or more remaining parts reach a stable arrangement, generating print instructions.
2 more elements
An additive fabrication system comprising:
- a build chamber;
- a powder storage compartment positioned adjacent to the build chamber;
- a refill door positioned above the powder storage compartment and movable to an open position in which the refill door defines a powder transfer path into the powder storage compartment;
- a powder sifting box configured to removably couple to the build chamber through a locating and latching interface and comprising a first partition configured to receive a powder cake from the build chamber, a second partition configured to store sifted powder, and a mesh positioned between the first partition and the second partition;
- and
- a part extraction workstation comprising a docking interface configured to receive the powder sifting box and an air-handling system configured to maintain negative pressure while a user extracts a printed part from the powder cake and reclaims powder from the powder sifting box.
3 more elements
An additive fabrication system comprising:
- a plurality of build chamber units having different build volumes or powder-bed surface dimensions;
- a plurality of laser processing units, each laser processing unit comprising a laser source and a beam-delivery system;
- a mechanical coupling interface configured to removably couple a selected laser processing unit to a selected build chamber unit in optical alignment;
- an electrical interface and a control interface configured to communicatively couple the selected laser processing unit to the selected build chamber unit;
- and
- a control system configured to identify the selected laser processing unit and the selected build chamber unit and automatically set at least one operational parameter based on the identified laser processing unit and build chamber unit.
3 more elements
An additive fabrication system comprising:
- a process chamber;
- an optical assembly positioned to direct a processing beam toward the process chamber;
- an optical cassette associated with the optical assembly and comprising a carrier plate, a plurality of optical windows supported by the carrier plate, and one or more heaters thermally coupled to the carrier plate;
- an outer shroud and an inner shroud defining an airflow space around at least a portion of the optical assembly;
- a fan configured to drive air through the airflow space;
- a finned air heater positioned within the airflow space;
- a temperature sensor configured to monitor a temperature of the optical cassette, a temperature of airflow in the airflow space, or both;
- and
- a control system configured to control the one or more heaters, the fan, the finned air heater, or a combination thereof to maintain a selected thermal condition for the optical assembly and the process chamber.
6 more elements
Dependencies are inferred from the claim text.