Example described herein include a three-dimensional printer a threedimensional printing device that includes a fusible material applicator to apply a layer of fusible material, a inhibiting material applicator to apply a patterned layer of inhibiting material to establish exposed regions of the layer of fusible material and blocked regions of the layer of fusible material based on information corresponding to a three-dimensional model, and a photonic energy emitter to apply photonic energy to fuse the exposed regions of the layer of fusible material.

BACKGROUND

Three-dimensional printing, otherwise known as “3D printing”, involves processes by which a machine transforms machine readable instructions into a three-dimensional physical object. The machine readable instructions often include an electronic or digital model that describes the dimensions and configuration of the physical object. The materials and the corresponding characteristics of the physical object can vary based on the particular process used in the three-dimensional printing process.

DETAILED DESCRIPTION

Example implementations of the present disclosure include systems, apparatuses, and methods for three-dimensional, or “3D”, printing using photonic fusing of powdered, slurry, or liquid fusible material. In such implementations, the layers of fusible material are built up on top of one another. The structure of each layer is defined by printing or otherwise applying a pattern using an inhibiting material, such as a non-fusing absorptive material, a non-fusing reflective material, or a material that chemically or physically inhibits the fusible material from fusing.

Each combination layer of fusible material and inhibiting material can be exposed to photonic energy. As used herein, the terms “photonic energy” and “photonic fusing” refer to energy or processes that involve non-coherent light emissions with a spectral range of approximately 0.2 microns to 1.5 micron. In various implementations, the photonic energy can be applied to all or portions of a topmost layer simultaneously in controlled bursts or flashes. In response to the photonic energy, regions of the topmost layer of fusible material not obscured or inhibited by the inhibiting material can be purified, fused, melted, vaporized, or ablated. In some examples, the fusing of the fusible material in response to the photonic energy occur on an inner-layer and inter-layer basis. In such implementations, regions of the fusible material obscured/inhibited by the inhibiting material can remain in an unfused state. Specific details of the three-dimensional printing processes and apparatuses are described in more detail herein in reference to various examples and the accompanying figures.

FIG. 1illustrates an example process10for generating a three-dimensional object using photonic fusing, according to various implementations of the present disclosure. As shown, the process10can begin at reference11by providing a substrate105. In some implementations, substrate105can be composed of and/or include materials similar to the fusible materials used in other parts of the process. For example, the substrate105can include a metal, plastic, wood, glass, ceramic, or other material substrate formed in a separate process.

The substrate105can include a disposable and/or a reusable platform that a corresponding three-dimensional printing device can manipulate while handling the other processes of the three-dimensional printing. For example, the substrate105can be moved by the three-dimensional printer in multiple dimensions according to the needs of the processes described herein. For example, the substrate105can be moved relative to other elements of the three-dimensional printer to facilitate, improve, or optimize the results of the various three-dimensional printing processes.

At reference12, the example process10can include laying down a layer of fusible material110using a fusible material applicator130. In some examples, the fusible material applicator130can include a print head type applicator that moves relative to the substrate105in directions such as131. In some implementations, the fusible material applicator130can include a substrate wide arrangement such that the layer110can be laid down in a single pass over the substrate105having a particular dimension. For example, the fusible material applicator130can include a “page-wide-array” of jets or openings that release the layer of fusible material110on the substrate105as it moves in the directions indicated by arrow131.

To achieve layers of fusible material110of variable thickness, the fusible material applicator130can make multiple passes over the substrate100tend to build up the layer to a specific thickness. In other examples, the rate at which the fusible material applicator130lays down of the fusible material layer110can be adjusted to achieve a particular thickness. Accordingly, implementations of the present invention can apply a lay of fusible material that is as thin as one particle of fusible material.

Once a layer of fusible material110is laid down, an inhibiting material applicator140can lay down a patterned layer of inhibiting material120at reference13. In one example, the pattern of the patterned layer of inhibiting material120can include a negative of the desired layer to be fused in that particular layer of the three-dimensional object. As such, the patterned layer of inhibiting material120can establish a number of exposed regions125of the fusible material layer110and corresponding blocked regions of the fusible material110under the areas covered by or in contact with the inhibiting material120. The patterned layer of inhibiting material120can be based on a corresponding model of the desired three-dimensional object.

The inhibiting material applicator140can include any type of printing apparatus capable of applying the pattern of inhibiting material120on the fusible material layer110. For example, the inhibiting material applicator140can include an inkjet (e.g., thermal inkjet, a piezoelectric inkjet, etc.) or a sprayer that can selectively apply a liquid or a semi liquid (e.g., a gel) layer of inhibiting material120onto the layer of fusible material110.

The inhibiting material applicator140can move relative to the substrate105and/or the fusible material layer110along direction141. In various examples, the direction141can include a two-dimensional or three-dimensional degree of freedom by which to apply the inhibiting material120. In some implementations, the inhibiting material applicator140can include a page-wide-array print head or a scanning print head that moves across one dimension of the fusible material layer110while scanning across another dimension. In any such implementations, the distance between the inhibiting material applicator140and the fusible material layer110can be varied to accommodate and/or optimize the quality of the application of inhibiting material120. For example, as the layers of fusible material110and inhibiting material120are built up, example implementations of the present disclosure can include moving the inhibiting material applicator140further away from the substrate105to provide clearance.

At reference14, the inhibiting material layer120of the fusible material layer110can be exposed to photonic energy151emitted by photonic emitter150. In some implementations, the photonic energy is provided by non-coherent light source. For example, the non-coherent light source can include a xenon (Xe) source. Such Xe sources can emit non-coherent photonic energy (e.g., electromagnetic radiation) in the range of 150 nm to 1100 nm with radiation peaks in visible and near IR below 1 micron (e.g., 475 nm, 827 nm, 885 nm, 919 nm, and 980 nm).

The photonic energy can be delivered across some or all of the surface of the topmost layers of inhibiting material120and fusible material110simultaneously in short pulses. In some implementations the pulse of photonic energy is less than 1 millisecond. Such short pulses can be used to ensure that only a single top layer of the fusible material is heated to a point of melting without dissipating energy by heating underlying layers or by significant radiation into the air. Accordingly, implementations that use short pulses of photonic energy151allow for melting particles while using relatively low power density.

The portions of the topmost layer of fusible material layer110beneath the regions125are exposed through the pattern of the inhibiting material layer120can react to the photonic energy151by heating to the temperature at which the fusible material110fuses. In some implementations, regions of the fusible material layer110under the pattern of the inhibiting layer120are protected from the photonic energy151, and therefore do not to fuse.

Implementations of the present disclosure can include inhibiting materials120that use various mechanisms to inhibit the fusing of the fusible material110. In one example implementation, the inhibiting material120can include a material that reflects or absorbs electromagnetic radiation within the spectral range of the photonic emitter150.

In one example, the inhibiting material120can include a white ink that includes reflective additives, such as titanium oxide (TiO2). Example white inks can reflect electromagnetic radiation in UV, visible, and near-IR regions while being transport to wavelengths above 1 micron. In other implementations, the inhibiting material120can include a multilayer structure that provides an interference filter that selectively reflects the electromagnetic radiation of the photonic emitter150. For example, the reflective material can comprise layers of different materials applied by the inhibiting material applicator that in combination form an interference dielectric mirror with a rejection band that corresponds to the spectral range of the photonic emitter150. In such implementations, photonic energy151incident on the surface of the reflective material is reflected away from the underlying fusible material110, thus shielding the underlying fusible material110.

In another example, the inhibiting material120can include material that quickly absorbs the photonic energy151but does not fuse or is otherwise thermal insulator or nonconductor. For example, the inhibiting material layer120can include a layer of material that absorbs the electromagnetic radiation from the photon emitter150(e.g., Xe radiation), melts and/or evaporates during the light pulse, thus shielding the underlying fusible material layer110from fusing. Example absorptive materials that evaporative in response applied photonic energy include, but are not limited to, polymers, latexes, and the like.

In yet another example, the inhibiting material120may include a chemical or physical properties that influence on the underlying fusible material that prevents it from fusing in response to the photonic energy151.

As illustrated at reference15, the regions115of the fusible material110left exposed through the gaps125in the patterned inhibiting material layer120can be fused by the photonic energy151to form solid elements in the fusible material layer110. To form the next layer of the three-dimensional object, the fusible material applicator130can lay down another layer of fusible material, here designated as fusible material layer110-2. As shown, fusible material layer110-2can be laid down on top of the first layer of fusible material110-1and the patterned layer of inhibiting material120. As shown, the subsequent layer of fusible material110-2can fill in the gaps, previously designated as125, while maintaining a substantially flat upper surface.

With the subsequent layer of fusible material110-2applied to the previously applied layers of fusible material110-1and inhibiting material120, the inhibiting material applicator140can apply another patterned layer of inhibiting material120according to the corresponding model of the three-dimensional object. As with the previous patterned layer of inhibiting material120, the topmost patterned layer of inhibiting material120can leave gaps125to establish exposed layers of the fusible material layer110-2. At this point, the processes depicted at reference numerals14,15, and16can be repeated to successively build up a three-dimensional object of fusible material115.

The wavelength, intensity, and/or duration of the photonic energy151can vary based on the material properties of the inhibiting material layer120and/or the fusible material layer110. For example, photonic energy151emitted by the photonic emitter150can include high-intensity photonic energy the can be delivered in short pulses. In some implementations, the pulses can be delivered as a series of short pulses. In such implementations, the duration and intensity of the photonic energy151can aid in removal of unwanted impurities from the fusible material110, faster fusion of the fusible material110, limiting thermal bleeding, and promoting the fusion between layers of fusible material110.

In various implementations, the material and thickness between layers of fusible material110can be varied to form alloys or semi alloys in the resulting three-dimensional object.FIG. 2depicts an example of alloy formation, according to various implementations of the present disclosure. As shown in the cross sectional view at reference20, multiple layers of fusible material110-1and110-2have been built up to generate fused material regions115. A subsequent layer of fusible material111has been laid on top of the fused material regions115, and another patterned layer of inhibiting material120has been laid on top of the fusible material layer111to establish exposed regions125. In such implementations, the fusible material110and fusible material111can be different. For example, the fusible material can include one metal, while the fusible material layer111can include a different metal. When the fusible material layer111is exposed to the photonic energy151, some portion can be fused with and/or combined with the underlying previously fused layer of fusible material110to create a localized alloy.

At reference21, the stack of materials can be exposed to photonic infusion process according to various implementations described herein. In response to the photonic energy151, the exposed regions of the fusible material layer111can be fused to generate fused fusible material regions117and fused fusible material regions116. The fused fusible material regions116can include a mixture of the fusible materials110and111. In this way, various fused fusible material regions can be established to have specific alloy properties based on the use of different fusible materials within the layers of the resulting three-dimensional object.

FIG. 3depicts a schematic of a three-dimensional printer300. As shown, three-dimensional printer300can include a processor310to execute machine readable executable code stored in the memory330to perform operations and control other components of the three-dimensional printer300. In various examples, processor310may be a microprocessor, a micro-controller, an application specific integrated circuit (ASIC), or the like. According to an example implementation, the processor310is a hardware component, such as a circuit. The memory330can include a volatile or non-volatile memory, such as dynamic random access memory (DRAM), electrically erasable programmable read-only memory (EEPROM), magnetoresistive random access memory (MRAM), memristor, flash memory, floppy disk, a compact disc read only memory (CD-ROM), a digital video disc read only memory (DVD-ROM), or other optical or magnetic media, and the like, on which executable code may be stored.

The processor310can execute three-dimensional printing code331. Three-dimensional printing code331can include instructions for generating control signals that cause the inhibiting material applicator140, the photonic energy emitter150, and/or the fusible material applicator130to implement the corresponding operations of three-dimensional printing process according to various implementations of the present disclosure. For example, the instructions included in the three-dimensional printing code331can cause the processor310to control the components of the three-dimensional printer300to perform the example process100depicted inFIG. 1and/or the method described in reference toFIG. 4.

In some example implementations, the three-dimensional printer can include a communication interface320. The communication interface320can be used by the processor310for sending and receiving commands in response signals to and from an external computing device, such as a desktop, laptop, or server computer. In various implementations, the communication interface320can include a networking communication interface, a universal serial bus (USB) interface, a parallel communication interface, a serial communication interface, or any other communication interface suitable for communicating with other electronic or computing devices. For example, the three-dimensional printer300can receive printing instructions and/or electronic files through the communication interface320. The instructions or electronic files can include computer readable code comprising instructions or models that the processor310can use to generate a three-dimensional object using the other components of the three-dimensional printer300according to implementations of the present disclosure.

FIG. 4is a flowchart of an example method400for printing the three-dimensional objects according to various implementations of the present disclosure. As shown, the method400can begin at box410in which a fusible material applicator130can establish a layer of fusible material110. The layer of fusible material110can comprise various types of fusible material, such as, fusible powders, fusible gels, fusible slurries, fusible liquids, and the like. The thickness of the fusible material layer110laid down by the fusible material applicator130can vary based on the characteristics of the fusible material and/or the physical features of a particular layer of a resulting three-dimensional object. In some implementations, the fusible material applicator130can include a system for spraying, spreading, rolling out, or jetting the fusible material. As such, the fusible material applicator130can include various sprayers, spreaders, rollers, jets, and the like in a head unit that can scan across a base surface, substrate, or a previously applied layer of fusible material.

Once a layer of fusible material is established, an inhibiting material pattern can be applied to a surface of the layer of fusible material. In some implementations described herein, the pattern of fusible material may be printed, painted, or otherwise dispensed onto the surface of the fusible material layer to defined a number of exposed and blocked regions of the underlying layer of fusible material. The exposed regions represent areas where the fusible material can be fused to generate a particular physical element of the three-dimensional object. As described herein, the pattern of inhibiting material can be applied by inhibiting material applicator140. In some implementations, the inhibiting material can include a reflective ink, such as a white ink containing TiO2to reflect the incident photonic energy away from the underlying fusible material.

With the pattern of inhibiting material disposed on the underlying layer of fusible material110, a photonic emitter150can be used to apply a particular amount of photonic energy151to the regions of the fusible material110exposed through the pattern. The application the photonic energy151can cause the exposed regions of the fusible material100to fuse into a solid or semi solid state. In example implementations, the photon emitter150can use any type of high-intensity, short-duration bursts a photonic energy that expose the top surface of the stack of fusible material layers110and inhibiting material layers120in its entirety simultaneously or in sections. Such photonic energy can quickly and controllably fuse the layer of fusible material with limited to no thermal bleeding into the unexposed/blocked regions of fusible material under the inhibiting material layer120. Once the regions of a particular fusible material layer110are fused, the processes in boxes410,420, and430can be repeated to build up individual layers of the three-dimensional object until it is complete.

These and other variations, modifications, additions, and improvements may fall within the scope of the appended claims(s). As used in the description herein and throughout the claims that follow, “a”, “an”, and “the” includes plural references unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the elements of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or elements are mutually exclusive.