Patent Description:
Exemplary additive fabrication devices configured to produce three-dimensional objects by sintering a source material, comprising electronic components, are disclosed in the documents <CIT> or <CIT>.

According to the invention, an additive fabrication device configured to produce three-dimensional objects by sintering a source material is provided, the additive fabrication device comprising a chamber, a material deposition mechanism, a fabrication platform arranged within the chamber configured to receive source material from the material deposition mechanism, and an electronic component module coupled to the chamber opposite the fabrication platform. The electronic component module comprises at least one gas intake channel, a primary channel coupled to the at least one gas intake channel and comprising an orifice at a first end, an electronic component arranged at least partially within the primary channel at a second end of the primary channel, the second end opposing the first end of the primary channel, and at least one gas exhaust channel coupled to a side of the primary channel, wherein the at least one gas exhaust channel is oriented away from the electronic component.

The foregoing apparatus embodiments may be implemented with any suitable combination of aspects, features, and acts described above or in further detail below. These and other aspects, embodiments, and features of the present teachings can be more fully understood from the following description in conjunction with the accompanying drawings.

In some applications, electronic components can come into contact with contaminants such as particulates and/or other atmospheric hazards such as vaporized chemicals. Without preventative measures, these contaminants can adhere to the electronic components over time, potentially causing degradation of the electronic components and/or the electronic components' ability to perform their desired function. While one solution may be to periodically replace or clean the electronic components, such periodic maintenance may be expensive, may interfere with calibrated systems, and/or may be otherwise undesirable to a user.

As an illustrative example of an application in which such contamination may occur, some additive fabrication techniques such as Selective Laser Sintering (SLS) form parts by fusing a source material such as a fine powder together into larger solid masses. Typically the powder is preheated and a laser beam is directed at the powder to cause consolidation of the powder. Maintaining the powder at an elevated temperature can, however, cause the powder material and/or system components to outgas contaminants that were previously trapped in the powder. This outgassed material may be drawn toward electronic components of the additive fabrication apparatus and may condense or otherwise deposit contamination on the electronic component. In the case of an optical sensor, for example, contamination may be deposited on an optical window of the optical sensor, which may reduce the optical sensor's ability to accurately perform sensing (e.g., monitoring the temperature of the source material via infrared optical sensing, monitoring the progress of object formation using a camera, etc.).

Some conventional systems may employ gas purge techniques, such as an air knife, to prevent the accumulation of contaminants on an electronic component. An air knife uses a high-intensity, uniform sheet of laminar airflow to remove or prevent contaminants from adhering to a surface by directing the sheet of laminar airflow over the surface. However, in applications where such purging gas flow is coupled to another system, such techniques can result in significant thermal exchange between the cooler gas of the purging mechanism and the coupled system. In some applications, such thermal exchange may be undesirable because the coupled system may need to be maintained within a particular range of temperatures, and operating the gas purge may make it difficult or impossible to maintain such temperatures in view of said thermal exchange.

The inventors have recognized and appreciated that a purging gas may be directed around and away from an electronic component to prevent contamination from adhering to the electronic component. In particular, the inventors have recognized that the gas exhaust mechanism may be shaped, oriented or otherwise configured to harness the Coand<IMG> effect and to direct the gas away from the electronic component and a coupled system, thereby mitigating thermal and/or material exchange between the electronic component and the coupled system (e.g., a portion of an additive fabrication device). As a result of this technique, there may be a reduced risk of contaminant accumulation on the electronic component without increased thermal exchange between the electronic component and the coupled system. Accordingly, the electronic component may need less maintenance and/or cleaning, may have a reduced rate of failure, and/or may need to be replaced less frequently.

According to some embodiments, an apparatus may include at least one gas intake channel coupled to a primary channel, the primary channel including an orifice arranged at a first end. An electronic component (e.g., a sensor) may be arranged at least partially within the primary channel at a second end of the primary channel, with the second end opposing the first end of the primary channel. Gas directed through the intake channel may pass from the second end to the first end, thereby directing the gas past the electronic component, and away from the electronic component. As such, purging an apparatus may include directing a gas through the primary channel and past a sensor arranged at least partially within the primary channel.

According to some embodiments, an apparatus may include one or more structures coupled to the primary channel, such as one or more vessels, chambers, etc. for which thermal exchange between the primary channel and the structure(s) is undesirable. As discussed above, it may be desirable when operating a gas purge to mitigate thermal exchange between the purge and a coupled system. Such a coupled system may include any suitable structure or structures.

In some embodiments, at least one gas exhaust channel may be coupled to a side of the primary channel such that the at least one gas exhaust channel is oriented away from the electronic component. The gas may be directed out of the primary channel away from the sensor through at least one gas exhaust channel coupled to a side of the primary channel. The gas exhaust channel(s) may be shaped and/or oriented to harness the Coand<IMG> effect and to direct the gas away from the electronic component while also directing the gas away from a coupled system (e.g., including one or more vessels, chambers, etc.) coupled to the primary channel. In some cases, a gas pressure produced within the primary channel and/or the gas exhaust channel(s) may act to limit contaminants present within the coupled system from entering the primary channel and thereby potentially negatively impacting the electronic component. Examples of such relative pressure arrangements are discussed further below.

According to some embodiments, an additive fabrication device may include a sensor module coupled a chamber. The additive fabrication device may be configured to produce three-dimensional objects by sintering a source material. The additive fabrication device may further include a material deposition mechanism and a fabrication platform arranged within the chamber. The sensor module may be coupled to the additive fabrication device opposite the fabrication platform, and may include at least one gas intake channel coupled to a primary channel, the primary channel including an orifice arranged at a first end. An electronic component (e.g., a sensor, an optical sensor) may be arranged at least partially within the primary channel at a second end of the primary channel, the second end opposing the first end of the primary channel. In some embodiments, at least one gas exhaust channel may be coupled to a side of the primary channel such that the at least one gas exhaust channel is oriented away from the electronic component.

Following below are more detailed descriptions of various concepts related to, and embodiments of, techniques for gas purging of an electronic component. It should be appreciated that various aspects described herein may be implemented in any of numerous ways. Examples of specific implementations are provided herein for illustrative purposes only. In addition, the various aspects described in the embodiments below may be used alone or in any combination, and are not limited to the combinations explicitly described herein.

An illustrative sensor module <NUM> is illustrated in <FIG>, in accordance with some embodiments of the technology described herein. In the example of <FIG>, module <NUM> includes a gas intake channel <NUM> and a gas exhaust channel <NUM>, both of which are coupled to a primary channel <NUM>. Herein, the term "coupled" may refer to a direct coupling (e.g., direct attachment between components) and/or to an indirect coupling (e.g., indirect attachment between components, such as through a spacer component, tubing, wiring, etc.). An electronic component <NUM> is arranged within primary channel <NUM> at a first end 102a of primary channel <NUM> and opposite a second end 102b of primary channel <NUM>. An orifice <NUM> is disposed at first end 102a.

In the example of <FIG>, solid arrows depict an illustrative direction of net gas flow of clean gas within module <NUM> from the gas intake channel <NUM>, past the electronic component <NUM>, and out through the gas exhaust channel <NUM> and/or the orifice <NUM>. Dashed arrows depict an illustrative direction of net gas flow of contaminated gas from the orifice <NUM> to the primary channel <NUM>. As discussed above, it may be advantageous to configure sensor module <NUM> to minimize the amount of net gas flow of potentially contaminated gas or particulates from outside the orifice <NUM> into the primary channel <NUM>, as this may limit contamination from entering the sensor module and reaching the electronic component <NUM>. As such, a rate of the gas flow represented by the dashed arrow may be small. In some cases, a rate of gas flowing from the primary channel <NUM> out through the orifice <NUM> (represented by two solid arrows in <FIG>) may also be small. For instance, gas flow from the gas intake channel <NUM> through the primary channel <NUM> and out through the gas exhaust channel <NUM> may be such that a pressure boundary is created at the orifice <NUM> which limits gas from entering and exiting the sensor module through the orifice.

In some embodiments, module <NUM> may include one or more devices configured to produce gas flow within and/or through the module <NUM>. Such devices may include any number of devices arranged within module <NUM> (referred to subsequently as "internal" devices) and any number of devices arranged separately from, but coupled to, module <NUM> (referred to subsequently as "external" devices). The internal and/or external devices may include devices configured to push air into the module <NUM> (e.g., through the gas intake channel <NUM>) and/or may include devices configured to pull air out of the module <NUM> (e.g., through the gas exhaust channel <NUM>). Combinations of these types of devices may also be envisioned to produce a desired gas flow within the module <NUM>.

For example, module <NUM> may include one or more internal fans coupled to gas intake channel <NUM> and/or gas exhaust channel <NUM>. Fans may be oriented to produce a desired gas flow direction by pushing air through the fan in a desired direction. As another example, module <NUM> may be coupled to one or more external devices to provide a gas flow through the module. For instance, one or more external fans, gas compressors, and/or pressurized gas tanks may be coupled to gas intake channel <NUM> and may be operated to direct gas through gas intake channel <NUM> and into the primary channel <NUM>. In some cases, module <NUM> may comprise a fan and/or a vacuum pump coupled to gas exhaust <NUM>, which may be operated to pull gas through module <NUM>. The gas may be any suitable gas, including air and/or an inert, purified gas (e.g., nitrogen or argon).

As shown in the example of <FIG>, a gas intake channel <NUM> may be coupled to a side of primary channel <NUM>. In some embodiments, a gas intake channel may be coupled to the second end 102b of primary channel <NUM> such that the gas intake is positioned behind the electronic component <NUM>, as described in <FIG>. In general, any number of gas intake channels may be coupled to the primary channel and at any locations, such that gas may be directed into the primary channel from the gas intake channel(s).

In the example of <FIG>, gas intake channel <NUM> is shown coupled to the side of primary channel <NUM> at an orthogonal angle, α, in accordance with some embodiments described herein. However, is to be appreciated that in some embodiments, gas intake channel <NUM> may be coupled to primary channel <NUM> at an obtuse angle (e.g., wherein α is between <NUM>° and <NUM>°) such that the gas intake channel <NUM> is oriented away from first end 102a of the primary channel <NUM>. Further, though only a single gas intake channel <NUM> is shown in the example of <FIG>, it is to be appreciated that multiple gas intake channels <NUM> could be employed, as described in <FIG> and <FIG>. In such embodiments, the gas intake channels <NUM> may be disposed on different sides (e.g., opposite sides) of the primary channel <NUM> and/or may be arrayed along the length of the primary channel <NUM> from second end 102b to first end 102a. As referred to herein, opposing sides may refer to two sides disposed such that the primary channel is positioned in between the two sides.

As shown in the example of <FIG>, electronic component <NUM> may be arranged within primary channel <NUM> at the second end 102b of primary channel <NUM>. In other embodiments, electronic component <NUM> may be arranged only partially within primary channel <NUM>. In some embodiments, electronic component <NUM> may comprise one or more sensors, such as but not limited to an optical sensor, a temperature sensor, a sound sensor, a motion sensor, a pressure sensor, a force sensor, a capacitance sensor, or combinations thereof. For instance, in some embodiments electronic component <NUM> may be, or may comprise, an optical sensor arranged to detect and/or monitor a temperature (e.g., a pyrometer, an infrared sensor). In general, however, electronic component <NUM> may include any electronic component for which it is desirable to avoid contamination of the component, which is not limited to sensors.

In some embodiments, and as shown in the example of <FIG>, electronic component <NUM> may be arranged within primary channel <NUM> a distance L1 from first end 102a and orifice <NUM>. Distance L1 may be selected based on a desired field-of-view (FOV) of electronic component <NUM>. In some embodiments, distance L1 may be greater than or equal to <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. In some embodiments, distance L1 may be less than or equal to <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. Any suitable combinations of the above-referenced ranges are also possible (e.g., L1 is greater than or equal to <NUM> and less than or equal to <NUM> or L1 is greater than or equal to <NUM> and less than or equal to <NUM>). Alternatively or additionally, in some embodiments the FOV may be determined according to an angle φ formed by a width of the orifice <NUM>. In some embodiments, the angle φ of the electronic component may be greater than or equal to <NUM>°, <NUM>°, <NUM>°, or <NUM>°. In some embodiments, the angle φ may be less than or equal to <NUM>°, <NUM>°, <NUM>°, <NUM>°, <NUM>°, <NUM>°, <NUM>°, or <NUM>°. Any suitable combinations of the above-referenced ranges are also possible (e.g., the angle φ is greater or equal to <NUM>° and less than or equal to <NUM>° or the angle φ is greater or equal to <NUM>° and less than or equal to <NUM>°).

Gas exhaust channel <NUM> may be coupled to a side of primary channel <NUM>, in accordance with some embodiments of the technology described herein. Gas exhaust channel <NUM> may be coupled to a same side of primary channel <NUM> as gas intake channel <NUM> or, as shown in the example of <FIG>, a different side of primary channel <NUM> as gas intake channel <NUM>. In some embodiments, gas exhaust channel <NUM> may be coupled to a side of primary channel <NUM> which opposes the side which is coupled to gas intake channel <NUM>. It may be appreciated that while the example of <FIG> shows a single gas exhaust channel <NUM>, in some embodiments there may be multiple gas exhaust channels <NUM>, as described in connection with <FIG> and <FIG>. Alternatively, in some embodiments, rather than comprising one or more discrete exhaust channels as shown in the examples of <FIG> and <FIG>, gas exhaust channel <NUM> may comprise a continuous exhaust channel which encircles or partially encircles the primary channel <NUM>.

Gas exhaust channel <NUM> may be coupled to the side of primary channel <NUM> at an angle θ relative to the side of primary channel <NUM>, in accordance with some embodiments. The gas exhaust channel may be oriented away from electronic component <NUM>. The angle θ may be selected to harness the Coand<IMG> effect, in which fluid flow tends to follow a convex surface, such that the gas flowing through module <NUM> may follow the surface of the gas exhaust channel <NUM> while exiting the module <NUM>. The angle θ may also be selected to reduce or eliminate gas exchange through orifice <NUM>. The angle θ may accordingly be an obtuse angle (e.g., between <NUM>° and <NUM>°) such that gas exhaust <NUM> is oriented away from electronic component <NUM>.

In some embodiments, gas exhaust channel <NUM> may be straight. As referred to herein, "straight" may refer to a channel which may be completely straight, approximately straight, or that includes a plurality of straight portions with one or more bends in between. In the example of <FIG>, in which the gas exhaust channel <NUM> includes at least one straight portion as pictured, an angle θ may be formed between the primary channel <NUM> and the gas exhaust channel <NUM>. While in the example of <FIG>, the angle θ is formed at a point at which the gas exhaust channel <NUM> and primary channel <NUM> meet, it will be appreciated that the angle θ may also be formed between the sides of gas exhaust channel <NUM> and primary channel <NUM>, which may be joined by a continuously curved or sloping surface at the location of the coupling between primary channel <NUM> and gas exhaust channel <NUM>, as shown in the examples of <FIG> and <FIG>. Such a curved surface may enhance the Coand<IMG> effect, increasing the amount of gas flow directed out of module <NUM> through gas exhaust channel <NUM>. In such embodiments, gas exhaust channel <NUM> may also be curved, or may include at least one curved portion.

As discussed above, in the example of <FIG>, orifice <NUM> is disposed at the first end 102a of primary channel <NUM>. Orifice <NUM> may open into a coupled system (e.g., into a chamber or other portion of a device the module <NUM> may be coupled to). Orifice <NUM> may provide an opening so that electronic component <NUM> may perform a function (e.g., monitoring, detecting) within the coupled system.

When coupled to another system, the net gas flow within the module <NUM> may reduce or eliminate contaminated gas flow into the module <NUM> through the orifice <NUM>, in accordance with some embodiments. The gas exhaust channels <NUM> may be sloped such that the Coand<IMG> effect channels gas out through the gas exhaust channels <NUM>, maintaining a positive pressure of clean gas flow within the module <NUM>. Such a positive pressure may prevent contaminated gas from a coupled system from entering the module <NUM> and/or from adhering to electronic component <NUM>. In some embodiments, and as shown in the example of <FIG>, first end 102a and orifice <NUM> may be disposed a distance L2 along the primary channel from the location where the gas exhaust channel <NUM> is coupled to the primary channel <NUM>. The distance L2 may be any suitable distance, and in some embodiments may be greater than or equal to <NUM>, <NUM>, or <NUM>. In some embodiments, the distance L2 may be less than or equal to <NUM>, <NUM>, or <NUM>. Any suitable combinations of the above-referenced ranges are also possible (e.g., L2 is greater than or equal to <NUM> and less than or equal to <NUM>, or L2 is greater than or equal to <NUM> and less than or equal to <NUM>). In some embodiments, the distance L2 may be less than <NUM>, such that the orifice <NUM> is disposed proximate the gas exhaust channel <NUM>.

<FIG> depicts an example of an sensor module 200a, in accordance with some embodiments of the technology described herein. Module 200a includes two gas intake channels <NUM> and two gas exhaust channels <NUM>, each coupled to primary channel <NUM>. The two gas intake channels <NUM> may be coupled to a second end 102b of primary channel <NUM>, and the two gas exhaust channels <NUM> may be coupled to sides of primary channel <NUM> proximate a first end 102a of primary channel <NUM>. Module 200a further includes an electronic component <NUM> disposed within the primary channel <NUM>. Arrows show a direction of gas flow within module <NUM> from the gas intake channels <NUM>, past the electronic component <NUM>, and out through the gas exhaust channels <NUM>.

In the example of <FIG>, the electronic component <NUM> is shown as a sensor <NUM> including an optical window <NUM>, but the electronic component <NUM> may be any suitable electronic device as described previously in connection with <FIG>. Optical window <NUM> may comprise, or may consist of, an optically transparent material so that optical window <NUM> may protect sensor <NUM> while still allowing sensor <NUM> to perform a desired function. Optical window <NUM>, for example, may comprise any suitable optically transparent material, such as but not limited to silica, silicon, N-BK7, B270, sodium chloride, zinc selenide, zinc sulfide, magnesium fluoride, calcium fluoride, barium fluoride, germanium, sapphire, or combinations thereof. In some embodiments, the sensor <NUM> may be an optical sensor configured to detect a temperature (e.g., a pyrometer or an infrared sensor). In such embodiments, the optical window <NUM> may be a germanium optical window.

In some embodiments, the sensor <NUM> may have a field of view (FOV) <NUM> through the orifice <NUM> and out of the module 200a. The FOV <NUM> may be defined by an angle φ. The angle φ may be determined by a width of orifice <NUM> and/or the distance L1 between orifice <NUM> and the sensor <NUM>. For example, in some embodiments the angle φ of the electronic component may be greater than or equal to <NUM>°, <NUM>°, <NUM>°, or <NUM>°. In some embodiments, the angle φ may be less than or equal to <NUM>°, <NUM>°, <NUM>°, <NUM>°, <NUM>°, <NUM>°, or <NUM>°. Any suitable combinations of the above-referenced ranges are also possible (e.g., the angle φ is greater or equal to <NUM>° and less than or equal to <NUM>° or the angle φ is greater or equal to <NUM>° and less than or equal to <NUM>°).

In some embodiments, a width of the orifice <NUM> may be greater than or equal to <NUM>, <NUM>, or <NUM>. In some embodiments, the width of the orifice <NUM> may be less than or equal to <NUM>, <NUM>, or <NUM>. Any suitable combinations of the above-referenced ranges are also possible (e.g., the width of orifice <NUM> may be greater than or equal to <NUM> and less than or equal to <NUM> or the width of the orifice <NUM> may be greater than or equal to <NUM> and less than or equal to <NUM>).

<FIG> depicts an example of a sensor module 200b, in accordance with some embodiments of the technology described herein. In the example of <FIG>, module 200b includes two gas intake channels <NUM> coupled to sides of primary channel <NUM> and proximate a second end 102a of primary channel <NUM>. The gas intake channels <NUM> are shown as being coupled to the primary channel <NUM> at an orthogonal angle, α. However, as described in connection with <FIG>, the angle α may be an obtuse angle (between <NUM>° and <NUM>°).

Additionally, as shown in the example of <FIG>, gas intake channels <NUM> are coupled to different sides of primary channel <NUM>. In some embodiments, the different sides may be opposing sides. Alternatively, in other embodiments, the gas intake channels <NUM> may be coupled to a same side of the primary channel <NUM> and arrayed along the length of primary channel <NUM>.

<FIG> depicts an example of a sensor module 200c, in accordance with some embodiments of the technology described herein. In the example of <FIG>, module 200c includes a single gas intake channel <NUM> and a single gas exhaust channel <NUM>, both coupled to primary channel <NUM>. The gas exhaust channel <NUM> is coupled to the primary channel <NUM> at a location a distance L2 from the orifice <NUM>, as described in connection with <FIG>.

In the example of <FIG>, the electronic component <NUM> is partially disposed within primary channel <NUM>, in accordance with some embodiments. For example, in an optical sensing application, the optical window <NUM> may be disposed within the module 200c while the sensor <NUM> is disposed outside of the module. Such an arrangement may reduce a distance L1 between the sensor <NUM> and the orifice <NUM> such that the FOV <NUM> of the electronic component <NUM> may be increased. Alternatively, such an arrangement may reduce the overall size of the sensor module 200c and/or allow for configurations of other components (e.g., external electronics, electronic connections) around the sensor <NUM>.

<FIG> depicts an example of a sensor module 200d, in accordance with some embodiments of the technology described herein. Module 200d is similar to module 200c of <FIG>, but includes two gas intake channels <NUM> and two gas exhaust channels <NUM> coupled to the primary channel <NUM>. The gas exhaust channels <NUM> are coupled to the primary channel <NUM> at a location proximate the orifice (e.g., L2 approximately equal to <NUM>).

An illustrative conventional selective laser sintering (SLS) additive fabrication device is illustrated in <FIG>. In the example of <FIG>, SLS device <NUM> comprises a laser <NUM> paired with a computer-controlled scanner system <NUM> disposed to operatively aim the laser <NUM> at the fabrication bed <NUM> and move over the area corresponding to a given cross-sectional area of a computer aided design (CAD) model representing a desired part. Suitable scanning systems may include one or more mechanical gantries, linear scanning devices using polygonal mirrors, and/or galvanometer-based scanning devices.

In the example of <FIG>, the material in the fabrication bed <NUM> is selectively heated by the laser in a manner that causes the powder material particles to fuse (sometimes also referred to as "sintering" or "consolidating") such that a new layer of the object <NUM> is formed. SLS is suitable for use with many different powdered materials, including any of various forms of powdered nylon. In some cases, areas around the fabrication bed (e.g., the interior of the chamber <NUM>, the walls <NUM>, the platform <NUM>, etc.) may include heating elements to heat the powder in the fabrication bed. Such heaters may be used to preheat unconsolidated material prior to consolidation via the laser.

Once a layer has been successfully formed, the fabrication platform <NUM> may be lowered a predetermined distance by a motion system (not pictured in <FIG>). Once the fabrication platform <NUM> has been lowered, the material deposition mechanism <NUM> may be moved across the fabrication bed <NUM>, spreading a fresh layer of material across the fabrication bed <NUM> to be consolidated as described above. Mechanisms configured to apply a consistent layer of material onto the fabrication bed may include the use of wipers, rollers, blades, and/or other levelling mechanisms for moving material from a source of fresh material to a target location.

As discussed above, it is highly desirable in a system such as system <NUM> shown in <FIG> to wait for unconsolidated material that is delivered onto the fabrication bed <NUM> to reach a consistent temperature before consolidating the material with the laser <NUM>. In some additive fabrication systems, the unconsolidated material is preheated to a temperature that is sufficiently high so as to require minimal additional energy exposure to trigger consolidation. For instance, some SLS devices use radiating heating elements (not shown) that aim to consistently and uniformly heat both the uppermost layer and the volume of the material to a temperature below, but close to, the critical temperature for consolidation. Since consolidation of material typically occurs at or above a critical temperature, producing parts as intended requires effective management of temperature within the material.

For these reasons, it may be desirable to monitor the temperature of the uppermost layer of unconsolidated material during an additive fabrication process. In some instances, such monitoring may be performed by an electronic component of the additive fabrication device. The electronic component (e.g., an optical sensor) may be positioned with a FOV directed towards the uppermost layer of the unconsolidated material. However, maintaining the unconsolidated material at an elevated temperature may cause the unconsolidated material and/or other components of the system to outgas contaminants into chamber <NUM>. The contaminant may then subsequently condense or otherwise settle on the electronic component.

In the example of <FIG>, such an electronic component may be shielded from contamination by gas flow within sensor module <NUM>, which may be coupled to an exterior of the SLS device <NUM> such that the sensor module is connected to the chamber <NUM>. Sensor module <NUM> may be any one of sensor modules <NUM>, 200a-d, or any suitable combination of features of said modules <NUM> and/or 200a-d, as described in connection with <FIG> and <FIG>. Sensor module <NUM> may be arranged so that the electronic component (e.g., electronic component <NUM>) may monitor the uppermost layer of the unconsolidated material from directly above (as shown in <FIG>) or at an angle to the uppermost layer of the unconsolidated material (e.g., from the side of the fabrication powder bed <NUM>). In some embodiments, multiple sensor modules <NUM> may be coupled to the SLS device <NUM>, the multiple sensor modules comprising the same or different electronic components than one another, and configured to perform the same or different functions than one another within the SLS device <NUM>.

In the example of <FIG>, the sensor module <NUM> may be arranged so that the opening within the walls <NUM> between the sensor module and the chamber <NUM> acts as the orifice of any of the sensor modules <NUM> and/or 200a-d, as described in connection with <FIG> and <FIG>. In some cases, the orifice of the sensor module may be coupled to the opening of the chamber <NUM>. For instance, the orifice of the sensor module may include a mating connector and the opening of the chamber may include a corresponding mating connector such that the sensor module may be removably coupled to the chamber.

In some embodiments, sensor module <NUM> may be coupled to an external gas flow module <NUM>. Gas flow module <NUM> may include one or more gas flow mechanisms including fans, gas compressors, and/or vacuum pumps to direct gas through sensor module <NUM>, as discussed in connection with <FIG>. Alternatively, sensor module <NUM> may include an integrated gas flow mechanism (e.g., a fan, pump, and/or compressor, not shown) such that an external gas flow module <NUM> is not needed to direct gas through sensor module <NUM> during operation.

<FIG> depicts a flowchart describing a process <NUM> for purging a sensor module such as modules <NUM> and/or modules 200a-d, in accordance with some embodiments of the technology described herein.

At act <NUM>, a gas may be directed into the module through at least one gas intake channel (e.g., gas intake channel(s) <NUM>), in accordance with some embodiments. The at least one gas intake channel may be coupled to a primary channel (e.g., primary channel <NUM>) of the module such that gas flows from the gas intake channel into the primary channel. The gas may be directed into the gas intake channel by means of one or more gas flow mechanisms (e.g., a fan, a compressor, and/or a vacuum pump).

In some embodiments, the gas flow mechanism may be operated in response to computer-implemented instructions from a processor coupled to the module, to the gas flow mechanism, and/or to a system coupled to the module (e.g., additive fabrication device <NUM> of <FIG>). The computer-implemented instructions may thereby, when executed, cause gas to flow through the module in a continuous manner over a period of time. The period of time may coincide with a function of the system coupled to the module (e.g., a manufacturing process). For example, when coupled to an additive fabrication device, the computer-implemented instructions may cause gas to flow through the module in a continuous manner while the additive fabrication device performs an additive manufacturing process (as described in connection with <FIG>).

At act <NUM>, the gas may be directed through the primary channel past an electronic component (e.g., electronic component <NUM>), in accordance with some embodiments. The electronic component may be arranged at least partially within the primary channel. For example, the electronic component may be arranged completely within the primary channel (e.g., as in the examples of <FIG>, <FIG>, and <FIG>) or may have only a portion arranged within the primary channel (e.g., as in the examples of <FIG> and <FIG>).

At act <NUM> the gas may be directed out from the primary channel away from the electronic component. The gas may be directed out of the module through at least one gas exhaust channel (e.g., gas exhaust channel <NUM>). The gas exhaust channel may be coupled to a side of the primary channel so that the gas is directed away from the electronic component. Such a gas flow pattern as described in process <NUM> may reduce the amount of contaminants that reach and/or adhere to the electronic component.

<FIG> is a block diagram of a system suitable for practicing aspects of the invention, according to some embodiments. System <NUM> illustrates a system suitable for generating instructions to perform additive fabrication by a device including a gas-purged sensor module, and subsequent operation of the additive fabrication device to fabricate an object. For instance, instructions to fabricate the object using an additive fabrication device, such as device <NUM> shown in <FIG>, may comprise instructions to operate one or more gas flow mechanisms (e.g., to operate gas flow module <NUM> or to operate integrated gas flow mechanisms within sensor module <NUM>). In some cases, the instructions may also, when executed by the additive fabrication device, cause the additive fabrication device to operate an energy source in concert with the gas flow mechanisms.

According to some embodiments, computer system <NUM> may execute software that generates two-dimensional layers that may each comprise sections of the object. Instructions may then be generated from this layer data to be provided to an additive fabrication device, such as additive fabrication device <NUM>, that, when executed by the device, fabricates the layers and thereby fabricates the object. Such instructions may be communicated via link <NUM>, which may comprise any suitable wired and/or wireless communications connection. In some embodiments, a single housing holds the computing device <NUM> and additive fabrication device <NUM> such that the link <NUM> is an internal link connecting two modules within the housing of system <NUM>.

<FIG> illustrates an example of a suitable computing system environment <NUM> on which the technology described herein may be implemented. For example, computing environment <NUM> may form some or all of the computer system <NUM> shown in <FIG>. The computing system environment <NUM> is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the technology described herein. Neither should the computing environment <NUM> be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary operating environment <NUM>.

The technology described herein is operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well-known computing systems, environments, and/or configurations that may be suitable for use with the technology described herein include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.

The computing environment may execute computer-executable instructions, such as program modules. The technology described herein may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote computer storage media including memory storage devices.

With reference to <FIG>, an exemplary system for implementing the technology described herein includes a general purpose computing device in the form of a computer <NUM>. Components of computer <NUM> may include, but are not limited to, a processing unit <NUM>, a system memory <NUM>, and a system bus <NUM> that couples various system components including the system memory to the processing unit <NUM>. The system bus <NUM> may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Association (VESA) local bus, and Peripheral Component Interconnect (PCI) bus also known as Mezzanine bus.

Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by computer <NUM>. Communication media typically embodies computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of the any of the above should also be included within the scope of computer readable media.

The computer <NUM> may also include other removable/non-removable, volatile/nonvolatile computer storage media. By way of example only, <FIG> illustrates a hard disk drive <NUM> that reads from or writes to non-removable, nonvolatile magnetic media, a flash drive <NUM> that reads from or writes to a removable, nonvolatile memory <NUM> such as flash memory, and an optical disk drive <NUM> that reads from or writes to a removable, nonvolatile optical disk <NUM> such as a CD ROM or other optical media. Other removable/non-removable, volatile/nonvolatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like. The hard disk drive <NUM> is typically connected to the system bus <NUM> through a non-removable memory interface such as interface <NUM>, and magnetic disk drive <NUM> and optical disk drive <NUM> are typically connected to the system bus <NUM> by a removable memory interface, such as interface <NUM>.

Operating system <NUM>, application programs <NUM>, other program modules <NUM>, and program data <NUM> are given different numbers here to illustrate that, at a minimum, they are different copies. A user may enter commands and information into the computer <NUM> through input devices such as a keyboard <NUM> and pointing device <NUM>, commonly referred to as a mouse, trackball or touch pad. Other input devices (not shown) may include a microphone, joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit <NUM> through a user input interface <NUM> that is coupled to the system bus, but may be connected by other interface and bus structures, such as a parallel port, game port or a universal serial bus (USB). A monitor <NUM> or other type of display device is also connected to the system bus <NUM> via an interface, such as a video interface <NUM>.

The computer <NUM> may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer <NUM>. The remote computer <NUM> may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above relative to the computer <NUM>, although only a memory storage device <NUM> has been illustrated in <FIG>. The logical connections depicted in <FIG> include a local area network (LAN) <NUM> and a wide area network (WAN) <NUM>, but may also include other networks. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.

Claim 1:
An additive fabrication device (<NUM>) configured to produce three-dimensional objects by sintering a source material, the additive fabrication device comprising:
a chamber (<NUM>);
a material deposition mechanism;
a fabrication platform (<NUM>) arranged within the chamber configured to receive source material from the material deposition mechanism; and
an electronic component module (<NUM>, <NUM>) coupled to the chamber opposite the fabrication platform, characterized in that the electronic component module comprises:
at least one gas intake channel (<NUM>);
a primary channel (<NUM>) coupled to the at least one gas intake channel and comprising an orifice (<NUM>) at a first end (102a);
an electronic component (<NUM>) arranged at least partially within the primary channel at a second end (102b) of the primary channel, the second end opposing the first end of the primary channel; and
at least one gas exhaust channel coupled to a side of the primary channel, wherein the at least one gas exhaust channel is oriented away from the electronic component.