The Ex One Company

Anthony S Dugan

Michael John McCoy

Joseph J Bolt

Thomas Lizzi

Daniel T Brunermer

Travis Maxwell Inks

Rick D Lucas

Lawrence Joseph Voss

Adam W Stroud

Andrew P Klein

Paul P Knor

Alec Hydock

Jake Flick

Michael R Orner

Michael John Mccoy

Michael J Mccoy

Lawrence J Voss

The present invention relates to apparatuses for distributing build powder in powder-layer three-dimensional printers () and for the collection of particulates of the build powder that have become suspended in the gaseous atmosphere in the vicinity of the build platform of the three-dimensional printer. These apparatuses include recoaters () that are particularly useful in providing uniform distribution of fine build powder across the width of the build platform or powder bed. The present invention also includes powder-layer three-dimensional printers () which comprise such apparatuses for distributing build powder and/or apparatuses for collecting such suspended particulates. The improved fine powder recoater () uses an ultrasonic transducer () to move powder through a sheet screen (). The sheet screen () may be presented to the powder fed onto it in a narrow dispensing slot to limit the flow rate of powder from the dispenser and to provide control over the amount of powder dispensed. The width of the slot may extend to cover the entire build box fill zone. The ultrasonic transducer () is preferably adapted to periodically sweep through a range of frequencies during operation. The ultrasonic vibration system may be augmented with a low frequency vibration system. The dust collection system () draws air from the perimeter of the build box () down through the deck plate () of the printer () and out of the printer's housing () to an external dust collector ().

Powder distribution system for three-dimensional printer

The present invention relates to powder-layer three-dimensional printers () having a discrete supply hopper () and a recoater (). The discrete supply hopper () is configured to transfer a build powder to the recoater () in a manner that enhances the uniformity of build powder layers that are dispensed from the recoater (). In some embodiments, at least one of the discrete supply hopper and the powder hopper of the recoater is adapted to selectively contact the other, seal against the other, and/or have one partially inserted inside the other so as to diminish or prevent powder pluming during the transfer of build powder from the discrete supply hopper to the recoater.

Powder layer smoothing devices () adapted for use with powder-layer three-dimensional printers () are described. The smoothing devices () include a counter rotating roller () having a complex powder engaging face () that may include a series or plurality of flutes () or may include knurling () extending along at least a portion of the counter rotating roller () along its rotational axis (). The smoothing device () may also include a vertically adjustable finishing roller () to follow the counter rotating roller () across the build box () of the powder-layer three-dimensional printer ().

Powder-layer three-dimensional printer with smoothing device

A powder layer smoothing devices adapted for use with powder-layer three-dimensional printers are described. The smoothing devices include a counter rotating roller having a complex powder engaging face that may include a series or plurality of flutes or may include knurling extending along at least a portion of the roller along the rotational axis. The smoothing device may also include a vertically adjustable finishing roller to follow the counter rotating roller across the build box of the powder-layer three-dimensional printer.

Recoaters are described which are adapted for use in powder-layer three-dimensional printers. The recoaters comprise a mesh discharge device that is adapted to be selectively activated by the application of an agitation, e.g. a vibration. Such mesh discharge devices include a planar mesh, i.e. a screen or sieve, which is adapted to support a quantity of powder when the quantity of powder and the mesh are static and to dispense at least a portion of the quantity of powder when at least one of the quantity of powder and the mesh is agitated. Preferably, the mesh is disposed substantially horizontally, but may be disposed at an angle to the horizontal. Also described are powder-layer three-dimensional printers comprising such recoaters. In some embodiments, the powder-layer three-dimensional printers are adapted to space the mesh no more than about two to ten powder layer thicknesses from the top surface of the powder bed or substrate upon which a powder layer is to be deposited.

Selectively activated mesh discharge powder recoater for three-dimensional printing

A three-dimensional printing apparatus is disclosed has one or more troughs for receiving excess deposited particulate. Such troughs may be positioned to receive the excess deposited particulate into a particulate receiving chamber of the trough. An evacuation chamber is located at the bottom of each trough. A partition separates the evacuation chamber from the receiving chamber of the trough. The partition is selectively perforated to permit a desired amount of the particulate to flow into the evacuation chamber from the receiving chamber. The evacuation chamber is connected to a vacuum source to periodically or continuously draw ambient gas from a gas inlet to the evacuation chamber and/or from the receiving chamber through the perforations of the partition and then through the evacuation chamber toward the vacuum source to entrain an amount of the particulate and carry the entrained particulate out of the evacuation chamber.

Three-dimensional printing excess deposited particulate handling

Powder-layer three-dimensional printer recoaters, which are adapted for use with fine powders, are disclosed. The recoaters comprise a controllably vibrated traveling powder dispenser having a hopper section adapted to contain the build powder, an opening through which the powder can be controllably discharged laterally into a chamber which is located beside the opening and which has a mesh covering at least a portion of its bottom. The recoaters also comprise a vibrator that is operably connected to the traveling powder dispenser and is adapted to selectively cause the powder to flow from the hopper through the opening and be discharged through the mesh. In some embodiments, the recoaters also comprise a smoothing device which is adapted to smoothen the powder dispensed through the mesh. In some embodiments the smoothing device is adapted to compact the density of the dispensed powder level a selectable amount. Also disclosed are powder-layer three-dimensional printers having such recoaters.

Fine powder recoater for three-dimensional printer

Recoaters for powder-layer three-dimensional printers which are capable of producing enhanced powder layer uniformity and powder-layer three-dimensional printers having such recoaters are described. The recoater comprises a bridge, two supports, one at either end of the bridge, a powder reservoir, and a substantially rectangular plate which extends between the two supports and contains an opening through which the powder reservoir either extends into or through or through which build powder can be fed into the powder reservoir. The plate has a length to minimum width ratio of no more than about 7.0 and a length to maximum width ratio of no more than about 5.0, the plate being adapted to brace the bridge into a perpendicular relationship with the first and second supports when the recoater is being controllably moved and the powder reservoir is dispensing powder to form a powder layer.

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McKeesport, PA, United States of America

Anthony S Dugan