Method and apparatus for prototyping a three-dimensional object

An apparatus for fabricating a three-dimensional object by depositing a sufficient amount of a binder liquid needed to solidify build material at a particular location in the apparatus, comprising:

• a build chamber that can be filled with the build material;
• a gantry mounted for displacement across the build chamber;
• at least one printhead mounted on the gantry for depositing a binder liquid on the build material;
• a first set of software instructions for determining a total amount of binder liquid solidify the build material at the particular location;
• a second set of software instructions for determining a contribution of a colored binder liquid at the particular location of the build material to produce a desired color at the particular location;
• and
• a third set of software instructions for determining the contribution of a colorless binder liquid to be added to the colored binder liquid at the particular location of the build material;
• and
• a fourth set of software instructions for controlling the printhead to deposit the total amount of the colored binder liquid and colorless binder liquid, the total amount of colored binder liquid and colorless binder liquid approximating the amount of total binder liquid sufficient to bind the build material at the particular location of build material.

A method of fabricating a three-dimensional object by depositing a predetermined amount of a binder liquid on build material at a particular location of the object, comprising:

• determining a contribution of a colored binder liquid at a particular location of the build material needed to produce the desired color at the particular location;
• determining a contribution of a colorless binder liquid at the particular location of the build material;
• determining the total amount of colored binder liquid and colorless binder liquid sufficient to solidify the build material at the particular location, the total amount of colored binder liquid and colorless binder liquid not exceeding the predetermined amount of binder liquid at the particular location of build material;
• and
• depositing the total amount of colored binder liquid and colorless binder liquid at the particular location.

An apparatus for fabricating a three-dimensional object comprising:

• a feed reservoir having stored therein a supply of build material for forming the object;
• a build chamber for receiving layers of the build material from the feed reservoir;
• and
• a vacuum pump coupled to the feed reservoir to create an airflow through the feed reservoir.

A method of fabricating a three-dimensional object comprising:

• providing a feed reservoir having stored therein a supply of build material for forming the object;
• providing a build chamber for receiving incremental layers of the build material from the feed reservoir;
• providing an overflow cavity for receiving an excess quantity of build material transferred from the feed reservoir but not received by the build chamber;
• and
• creating an airflow through the feed reservoir or the build chamber.

An apparatus for fabricating a three-dimensional object comprising:

• a feed reservoir having stored therein a supply of build material for forming the object;
• a build chamber for receiving layers of the build material from the feed reservoir;
• and
• a vacuum pump coupled to the feed reservoir and to the build chamber to create an airflow through the feed reservoir or the build chamber in response to a switch.

A method of printing a three-dimensional object, comprising:

• depositing a first colored binder liquid on a bed of build material to form a first colored band along a first edge;
• depositing a second colored binder liquid on the bed of build material to form a second colored band along a second edge;
• and
• depositing colorless binder liquid on the bed of material between the first band and the second band.

A method for three-dimensional printing comprising the steps of:

• with at least one printhead, depositing binder liquid onto a bed of build material to form sections of a three-dimensional object;
• with at least one printhead, depositing a substance including colorant of a first color onto the bed of build material in a band extending from a first surface of the three-dimensional object into the object, wherein the band is tapered at an edge where the first surface meets an adjacent surface;
• and
• with at least one printhead, depositing a substance including colorant of a second color onto the bed of build material in a band extending from the adjacent surface into the object, wherein the band is tapered at the edge where the adjacent surface meets the first surface to leave a non-colored section between the bands.

An apparatus for fabricating a three-dimensional object comprising:

• a structural frame;
• a build chamber supported by the frame, the build chamber being suited to be filled with a build material;
• a gantry mounted for displacement across the build chamber,
• at least one printhead mounted on the gantry;
• and
• at least one cleaning element movable relative to the frame for cleaning the at least one printhead.

A method for fabricating a three-dimensional object comprising:

• providing a structural frame;
• supporting a build chamber with the frame, the build chamber suited to be filled with a build material;
• providing a gantry for displacement across the build chamber;
• mounting at least one printhead mounted on the gantry;
• and
• mounting a moveable cleaning element relative to the frame for cleaning the at least one printhead.

An apparatus for fabricating a three-dimensional object comprising:

• a build chamber that can be filled with a build material;
• a gantry mounted for displacement across the build chamber along a slow axis;
• and
• at least four printheads mounted on the gantry for displacement along a fast axis, the printheads being offset relative to each other.

An apparatus for fabricating a three-dimensional object comprising:

• a build chamber that can be filled with a bed of build material;
• a plurality of printheads mounted for displacement across the build chamber,
• at least one binder source external to the printheads;
• and
• a plurality of conduits coupling each binder source with at least one printhead.

A method for fabricating a three-dimensional object comprising:

• providing a build chamber that can be filled with a bed of build material;
• mounting a plurality of printheads for displacement across the build chamber;
• providing at least one binder source external to the printheads;
• and
• coupling each binder source with at least one printhead through a plurality of conduits.

An apparatus for fabricating a three-dimensional object comprising:

• a container for containing a binder liquid mixed with a colorant to create a colored binder liquid;
• a conduit for delivering the colored binder liquid to a printhead, the printhead depositing the colored binder liquid onto a bed of build material;
• and
• a circulation loop for circulating the colored binder liquid in the conduit.

A method for three-dimensional printing comprising the steps of:

• mixing a binder liquid with a colorant to create a colored binder liquid;
• delivering the colored binder liquid to a printhead with a conduit;
• depositing the colored binder liquid with the printhead onto a bed of build material;
• and
• circulating the colored binder liquid through a first circulation loop in the conduit.

An apparatus for fabricating a three-dimensional object comprising:

• a frame;
• a build chamber mounted to the frame and suited for being filled with a build material;
• a chute defining an overflow cavity, the chute being positioned to receive overflow build material from the build chamber;
• a removable collection chamber coupled with the chute to receive build material that passes through the chute.

A method for reclaiming build material in a three-dimensional printer comprising the steps of:

• filling a feed chamber with build material;
• transporting the build material from the feed chamber to a build chamber;
• printing binder liquid onto the build material in the build chamber,
• removing excess build material to a collection chamber;
• and
• returning the excess build material from the collection chamber to the feed chamber.

An apparatus for fabricating a three-dimensional object comprising:

• a feed reservoir having stored therein a supply of build material for forming the object;
• a build chamber for receiving layers of the build material from the feed reservoir;
• a vacuum pump coupled to the feed reservoir to create an airflow through the feed reservoir, and the vacuum pump is further coupled to the build chamber, and
• a switch that selects airflow through the feed reservoir or the build chamber.

An apparatus for fabricating a three-dimensional object comprising:

• a structural frame;
• a build chamber supported by the frame, the build chamber being suited to be filled with a build material;
• a gantry mounted for displacement across the build chamber;
• at least one printhead mounted on the gantry;
• at least one cleaning element movable relative to the frame for cleaning the at least one printhead;
• and
• a nozzle that sprays the cleaning element with a liquid to clean the at least one cleaning element, wherein the liquid includes water mixed with polyethylene glycol.

A method for fabricating a three-dimensional object comprising:

• providing a structural frame;
• supporting a build chamber with the frame, the build chamber suited to be filled with a build material;
• providing a gantry for displacement across the build chamber;
• mounting at least one printhead mounted on the gantry;
• mounting a cleaning element for cleaning the at least one printhead;
• and
• spraying the cleaning element with a liquid to clean the cleaning element with the cleaning element below the deck, wherein the liquid includes water mixed with polyethylene glycol.

A method for fabricating a three-dimensional object comprising:

• providing a build chamber that can be filled with a bed of build material;
• mounting a plurality of printheads for displacement across the build chamber;
• providing at least one binder source external to the printheads;
• and
• coupling each binder source with at least one printhead through a plurality of conduits wherein the binder sources supply the binder liquid to each of the printheads by conduits, the conduits including circulation loops that allow the binder liquid to be circulated within the conduit.