公开(公告)号：US20230405932A1

公开(公告)日：2023-12-21

申请号：US18453794

申请日：2023-08-22

Applicant: Stratasys Powder Production Ltd.

Inventor： Frederik TJELLESEN ,  Anders HARTMANN ,  Alexander RASMUSSEN

IPC: B29C64/307 ,  B29C64/214 ,  B29C64/314 ,  B29C64/321 ,  B29C64/357 ,  B29C64/153 ,  B29C64/245 ,  B29C64/255 ,  B29C64/295 ,  B33Y40/00 ,  B22F10/73 ,  B22F12/50

CPC classification number: B29C64/307 ,  B29C64/214 ,  B29C64/314 ,  B29C64/321 ,  B29C64/357 ,  B29C64/153 ,  B29C64/245 ,  B29C64/255 ,  B29C64/295 ,  B33Y40/00 ,  B22F10/73 ,  B22F12/50 ,  B33Y30/00

Abstract: A method for recirculating powder in an apparatus for manufacturing a three-dimensional object from the powder. The powder recirculation method includes: providing powder in a powder repository, the powder being one of fresh powder, excess powder or a blend thereof; transferring the powder from the repository to a work surface; distributing the powder across a build surface and resulting in a portion of the powder defining excess powder; returning the excess powder back to the repository; monitoring the amount of powder in the repository relative to a predetermined amount of powder; and delivering fresh powder from a powder tank to the repository when the amount of powder in the repository is less than the predetermined amount and not delivering fresh powder when excess powder is being returned to repository and the amount of powder in the repository is greater than the predetermined amount of powder.

公开(公告)号：US20230249400A1

公开(公告)日：2023-08-10

申请号：US18301478

申请日：2023-04-17

Applicant: Stratasys Powder Production Ltd.

Inventor： Frederik Tjellesen ,  Anders Hartmann ,  Neil Hopkinson

IPC: B29C64/165 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/314 ,  B29C64/209 ,  B29C64/236 ,  B29C64/277 ,  B29C64/218 ,  B33Y40/10 ,  B22F10/14 ,  B22F10/28 ,  B22F12/13 ,  B22F12/45 ,  B22F12/67 ,  B29C64/282

CPC classification number: B29C64/165 ,  B22F10/14 ,  B22F10/28 ,  B22F12/13 ,  B22F12/45 ,  B22F12/67 ,  B29C64/209 ,  B29C64/218 ,  B29C64/236 ,  B29C64/277 ,  B29C64/282 ,  B29C64/314 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/10 ,  B22F10/68

Abstract: A method of manufacturing a three-dimensional object from a powder to form each layer of the object. The method includes the steps of driving a powder distribution sled in a first direction to distribute a layer of powder; driving a print sled in the first direction; driving the print sled and the powder distribution sled in a second direction; preheating the layer of powder by activating multiple radiation sources during various ones of the driving steps; during some of the driving steps, depositing a pattern of fluid onto the layer of powder; and sintering the powder on which fluid was deposited only in the second direction, by activating the at least one radiation source assembly during various ones of the driving steps in that direction. Repeating the above steps to distribute the next layer of powder.

公开(公告)号：US20230191694A1

公开(公告)日：2023-06-22

申请号：US17920677

申请日：2021-04-22

Applicant: Stratasys Powder Production Ltd.

Inventor： Gianluca Dorini

IPC: B29C64/165 ,  B29C64/153 ,  B29C64/393 ,  B29C64/264 ,  B22F10/28 ,  B22F12/46 ,  B22F12/90 ,  B22F10/31 ,  G01J5/80

CPC classification number: B29C64/165 ,  B29C64/153 ,  B29C64/393 ,  B29C64/264 ,  B22F10/28 ,  B22F12/46 ,  B22F12/90 ,  B22F10/31 ,  G01J5/80 ,  B33Y10/00

Abstract: A method for determining a set point for measurements from a temperature sensor of an apparatus for the layer-by-layer formation of a three-dimensional object from particulate material, and associated controllers. The method includes distributing a calibration layer of particulate material over a build bed surface; selectively applying absorption-modifying fluid to a reference area or a surrounding area thereof, on the build bed surface; (c) lowering the build bed surface to a calibration depth, (d) applying heat to the reference area using a moveable heat source while measuring the temperature increase of a sub-reference area over a duration of time and/or taking optical readings of an optical property of the sub-reference area over the duration of time; (e) determining the onset of fusion of the particulate material; and (f) applying the onset of fusion as the set point for subsequent temperature measurements.

公开(公告)号：US20220383460A1

公开(公告)日：2022-12-01

申请号：US17741984

申请日：2022-05-11

Applicant: Stratasys Powder Production Ltd.

Inventor： Gianluca Dorini

IPC: G06T5/00 ,  G01J5/00 ,  G01J5/80

Abstract: A method for correcting thermal image distortion in a thermal camera in an apparatus for the layer-by-layer manufacture of three-dimensional objects, the thermal camera comprising a plurality of sensor pixels arranged along a first direction; the method comprising the steps of: (a) causing a temperature reference to be at a first steady state temperature; (b) moving the temperature reference at the first steady state temperature through a plurality of positions along the first direction through the field of view of the thermal camera; (c) recording a plurality of thermal images with the thermal camera while moving the temperature reference during step (b), each thermal image corresponding to one of the plurality of positions and comprising the detected temperature of the temperature reference as detected by at least one pixel of the plurality of sensor pixels; (d) identifying the at least one pixel that detected the temperature of the temperature reference within a respective thermal image at the corresponding one of the plurality of positions; (e) constructing a thermal map from the identified pixels representing the detected temperature of the temperature reference at the plurality of positions; (f) generating a correction matrix for the identified pixels based on comparison between the thermal map and the first steady state temperature; and (g) applying the correction matrix to subsequent measurements of the thermal camera. A controller and an apparatus for the layer-by-layer manufacture of three-dimensional objects comprising the controller to carry out the method are also provided.

公开(公告)号：US20220184887A1

公开(公告)日：2022-06-16

申请号：US17685041

申请日：2022-03-02

Applicant: Stratasys Powder Production Ltd.

Inventor： Frederik TJELLESEN ,  Anders HARTMANN

IPC: B29C64/153 ,  B29C64/314 ,  B29C64/245 ,  B29C64/255 ,  B29C64/241 ,  B01F27/053 ,  B01F27/112 ,  B01F27/1121 ,  B01F27/1125

Abstract: A stirring device for a powder tank of an apparatus for manufacturing a three-dimensional object. The stirring device is configured to rotate within the powder tank about an axis of rotation, and comprises a base plate and a strut. The strut extends from the base plate and is arranged to extend into the powder tank forming an obtuse angle with the outer edge of the base plate

公开(公告)号：US12115729B2

公开(公告)日：2024-10-15

申请号：US17610153

申请日：2020-12-11

Applicant: Stratasys Powder Production Ltd.

Inventor： Gianluca Dorini ,  Anders Hartmann ,  Marcel Garrido Barrabes ,  Steffen Kongensbjerg Larsen

IPC: B29C64/286 ,  B29C64/153 ,  B29C64/236 ,  B29C64/245 ,  B29C64/282 ,  B33Y30/00

CPC classification number: B29C64/286 ,  B29C64/153 ,  B29C64/236 ,  B29C64/245 ,  B29C64/282 ,  B33Y30/00

Abstract: An infrared lamp assembly for an apparatus for the formation of three-dimensional objects by consolidation of particulate material, the assembly comprising: an elongate infrared lamp extending along a lamp axis, an elongate shield extending parallel to and along one side of the axis of the lamp, and a support structure holding at least one of the ends of the lamp and of the shield, wherein the elongate shield at least partially bounds the space to one side of the lamp, and wherein the assembly provides a lower opening below the lamp and an upper opening above the lamp, such that, in use, radiation generated by the lamp is able to radiate through the openings and away from the lamp in directions not bounded by the shield.

公开(公告)号：US12086966B2

公开(公告)日：2024-09-10

申请号：US17741984

申请日：2022-05-11

Applicant: Stratasys Powder Production Ltd.

Inventor： Gianluca Dorini

IPC: G06T5/80 ,  G01J5/00 ,  G01J5/80

CPC classification number: G06T5/80 ,  G01J5/0066 ,  G01J5/80 ,  G01J2005/0077 ,  G06T2207/10048

Abstract: A method for correcting thermal image distortion in a thermal camera in an apparatus for the layer-by-layer manufacture of three-dimensional objects, the thermal camera comprising a plurality of sensor pixels arranged along a first direction; the method comprising the steps of: (a) causing a temperature reference to be at a first steady state temperature; (b) moving the temperature reference at the first steady state temperature through a plurality of positions along the first direction through the field of view of the thermal camera; (c) recording a plurality of thermal images with the thermal camera while moving the temperature reference during step (b), each thermal image corresponding to one of the plurality of positions and comprising the detected temperature of the temperature reference as detected by at least one pixel of the plurality of sensor pixels; (d) identifying the at least one pixel that detected the temperature of the temperature reference within a respective thermal image at the corresponding one of the plurality of positions; (e) constructing a thermal map from the identified pixels representing the detected temperature of the temperature reference at the plurality of positions; (f) generating a correction matrix for the identified pixels based on comparison between the thermal map and the first steady state temperature; and (g) applying the correction matrix to subsequent measurements of the thermal camera. A controller and an apparatus for the layer-by-layer manufacture of three-dimensional objects comprising the controller to carry out the method are also provided.

公开(公告)号：US20240001612A1

公开(公告)日：2024-01-04

申请号：US18367346

申请日：2023-09-12

Applicant: Stratasys Powder Production Ltd.

Inventor： Gianluca DORINI ,  Anders HARTMANN ,  Marcel GARRIDO BARRABES ,  Steffen KONGENSBJERG LARSEN

IPC: B29C64/286 ,  B33Y30/00 ,  B29C64/282 ,  B29C64/153 ,  B29C64/245 ,  B29C64/236

CPC classification number: B29C64/286 ,  B33Y30/00 ,  B29C64/282 ,  B29C64/153 ,  B29C64/245 ,  B29C64/236

Abstract: An apparatus for formation of three-dimensional objects and having an infrared radiation deflector. The radiation deflector includes opposing first and second elongate side walls; at least one end support connecting the side walls; an upper opening and a lower opening arranged to pass lamp radiation to an exterior of the radiation deflector; and a mounting point provided at the/each end support for mounting an infrared lamp. The side walls include first and second elongate mirrors extending parallel to a lamp axis and along a lower internal portion of the respective side walls. The lamp axis extends along and between the first and second mirrors, each of which has a concave surface with respect to the lamp axis. The first mirror is an upward deflecting mirror and is arranged for redirecting at least a portion of direct lamp radiation through the upper opening.

公开(公告)号：US20230182389A1

公开(公告)日：2023-06-15

申请号：US18080240

申请日：2022-12-13

Applicant: Stratasys Powder Production Ltd.

Inventor： Torben LANGE ,  Anders HARTMANN ,  Christopher PLEASS

IPC: B29C64/295 ,  B29C64/153 ,  B29C64/188 ,  B29C64/393 ,  B33Y10/00 ,  B33Y50/02 ,  B33Y40/10

CPC classification number: B29C64/295 ,  B29C64/153 ,  B29C64/188 ,  B29C64/393 ,  B33Y10/00 ,  B33Y50/02 ,  B33Y40/10

Abstract: Provided is a method for the layer-by-layer manufacture of an object from particulate material, the method comprising the steps of: (a) distributing a layer of particulate material over a build bed, the layer forming a build bed surface and having a layer thickness; (b) preheating the layer to a preheat temperature; (c) heating a cross section of the object of the layer to at least a sintering temperature to cause the particulate material of the cross section to sinter or melt; (d) lowering the build bed by an increment; and (e) distributing a further layer of particulate material of substantially an intended layer thickness, the further layer forming the build bed surface; wherein an object layer cycle comprises the steps (b) to (d); and (f) optionally, repeating the object layer cycle until the object is complete; wherein the increment is different to the intended layer thickness. Further provided is a controller for carrying out the method and an apparatus comprising the controller.

公开(公告)号：US11660809B2

公开(公告)日：2023-05-30

申请号：US17311242

申请日：2019-12-05

Applicant: Stratasys Powder Production Ltd.

Inventor： Frederik Tjellesen ,  Anders Hartmann ,  Neil Hopkinson

IPC: B29C64/165 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/209 ,  B29C64/236 ,  B29C64/218 ,  B33Y40/10 ,  B22F10/14 ,  B22F10/28 ,  B22F12/13 ,  B22F12/45 ,  B29C64/282 ,  B29C64/314 ,  B29C64/277 ,  B22F12/67 ,  B22F10/68 ,  B22F10/73 ,  B22F12/41 ,  B22F12/90

CPC classification number: B29C64/165 ,  B22F10/14 ,  B22F10/28 ,  B22F12/13 ,  B22F12/45 ,  B22F12/67 ,  B29C64/209 ,  B29C64/218 ,  B29C64/236 ,  B29C64/277 ,  B29C64/282 ,  B29C64/314 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/10 ,  B22F10/68 ,  B22F10/73 ,  B22F12/41 ,  B22F12/90

Abstract: Apparatus (1) for manufacturing a three-dimensional object from a powder, the apparatus (1) comprising: a build bed (201) having a build area (190), wherein successive layers of said three-dimensional object are formed in the build bed (201); a powder distribution sled (300) operable to distribute a layer of powder within the build area (190), the powder distribution sled (300) being driveable in a first direction along a first axis, across the build area (190), and driveable in a second direction, opposite to the first direction, along the first axis; and a print sled (350) operable to deposit a pattern of fluid onto the layer of powder within the build area (190) to define the cross section of said object in said layer, the print sled (350) being driveable in the first direction along a second axis across the build area, and driveable in the second direction along the second axis; wherein the first axis is parallel to, or coaxial with, the second axis; wherein the print sled (350) comprises one or more droplet deposition heads (370) for depositing the fluid, a first radiation source assembly (L1), and a second radiation source assembly (L2); wherein the powder distribution sled (300) comprises a powder distribution device (320) for distributing the powder, a third radiation source assembly (L3) and a fourth radiation source assembly (L4); and wherein each of the first, second, third and fourth radiation source assemblies is operable to both preheat and sinter powder within the build area (190). A method of manufacturing a three-dimensional object from a powder using such apparatus is also provided.