The Ex One Company

Desktop Metal, Inc.

Joseph J Bolt

Anthony S Dugan

Michael John McCoy

Travis Maxwell Inks

Rick D Lucas

Adam W Stroud

Alec Hydock

Jake Flick

Daniel T Brunermer

Thomas Lizzi

Lawrence Joseph Voss

Andrew P Klein

Paul P Knor

Michael John Mccoy

Lawrence J Voss

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 distribution system for three-dimensional printer

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 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.

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

Growing community of inventors

Irwin, PA, United States of America

Joseph J Bolt