Makerbot Industries, LLC

Filipp Gelman

Joseph Sadusk

Aljosa Kemperle

Peter Joseph Schmehl

Andrey V Patrov

The strength of a bond between two adjacent layers of a three-dimensional print is weakened by initiating fabrication of a top layer at a height greater than the processing height for the print. This technique may be used in particular at the interface between a raft or other support and an object being fabricated, after which the printing process may return to a regular process height for additional layers used to fabricate the remainder of the object.

Support fabrication techniques in three-dimensional printing

A technique for planarizing build surfaces in three-dimensional printing includes the use of a three-dimensional printer having an extruder with a sensor mechanically coupled thereto, where the sensor is operable to sense a contact force between the extruder and a separate structure. In particular, the sensor may be used to measure the contact force at a plurality of locations across a build surface of the separate structure, so that a difference between the measured contact force at two or more locations can be identified. In response to the difference between the measured contact force at these locations, a control signal may be created to reduce the difference for planarizing the build surface, e.g., by fabricating a layer on the build surface that mitigates irregularities therein, by gap filling on the build surface, or by adjusting a parameter of the three-dimensional printer.

Planarizing build surfaces in three-dimensional printing

An extruder or other tool head of a three-dimensional printer is instrumented to detect contact force against the extruder, such as by a build platform or an object being fabricated. The tool head may also be instrumented to detect deflection forces and the like acting on the tool that might indicate an operating error. The resulting feedback data can be used in a variety of ways to control operation of the three-dimensional printer during fabrication or diagnostics.

Three-dimensional printer with force detection

Three-dimensional printer fabrication is improved by receiving a digital model of an object specifying two or more different build materials, prioritizing the different build materials with a ranking, identifying exclusive locations where a surface layer of the object has one of the build materials, generating an external structure for the object according to one or more design rules, matching a first build material of the external structure to a second build material of the object at each of the exclusive locations, the matching based on at least one shared property of the materials, generating tool instructions for fabricating the object and the external structure, the tool instructions including one or more selections between the first build material and the second build material based upon the ranking and the matching, and controlling the three-dimensional printer according to the tool instructions to fabricate the object and the external structure.

Three-dimensional printing with multi-material support

Raft techniques in three-dimensional printing

Three-dimensional printer fabrication is improved receiving a digital model of an object, the digital model specifying two or more different build materials; prioritizing the two or more different build materials with a ranking; identifying exclusive locations in the plurality of layers where a surface layer of the object has one of the two or more different build materials; generating an external structure for the object according to one or more design rules; matching a first build material of the external structure to a second build material of the object at each of the exclusive locations; and generating tool instructions for fabricating the object and the external structure using at least the first build material and the second build material.

Multi-material, three-dimensional fabrication is improved by the use of a purge wall adjacent to an object to absorb transitional artifacts of material changes. The structure of the purge wall may be selected to reduce build time, and to reduce certain printing artifacts such as warping and delaminating. For example, alternating layers of offset or mirrored zigzag patterns may be used to reduce and distribute the layer-to-layer adhesion surfaces throughout the purge wall while providing sufficient contact points to maintain the structural integrity of the purge wall.

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Staten Island, NY, United States of America

Filipp Gelman