Patent Document

FIELD OF THE INVENTION 
       [0001]    This disclosure relates to additive manufacturing, more particularly to additive manufacturing with curing capabilities. 
       BACKGROUND 
       [0002]    Traditional 3D printing systems typically user layer-by-layer construction to build up an object. A 3D printing system typically breaks the object down into 2D slices and lays them down, one layer at a time. If the material is a UV or thermoset material, the system will cure the slices prior to laying down the next slices. 
         [0003]    These systems may involve multi-jet modeling systems that print UV polymers out of an inkjet printhead. The curing lamp typically follows the print head in the print direction in one axis. Since the system consistently moves along a single axis, fixing the print heads in location to the UV curing lamp to get a consistent cure becomes a relatively simple task, regardless of the device under construction. 
         [0004]    A new class of printers have emerged that use 6-axis robots to deposit material in space. These machines have the capability of printing non-planar layers, which can increase the efficiency of the build and enable greater functionality of the deposition process. These systems usually work in one of two ways. In one approach, they cure along the print axis, so from the perspective of the deposition head the motion essentially looks one dimensional. Other systems exist that print in complete 3D space, where the printing path can follow any path in 3D dimensions. These systems have typically been limited to material systems in which the material solidifies without the need for additional input energy, which has restricted the material set significantly. 
         [0005]    The ability to use 6-axis additive manufacturing systems with UV and thermoset materials, which require outside energy to solidify, would have many uses. It also useful to be able to control when the material cures. Ideally the material would cure slightly after is has been deposited on the substrate. This allows the material to merge and bond to the adjacent layers and increase the overall mechanical strength of the part. 
       SUMMARY 
       [0006]    One embodiment consists of a curing device includes a curing platform having at least one curing component arranged on a surface of the curing platform facing a print direction and at least one actuator connecting the curing platform to a dispensing tip. 
         [0007]    Another embodiment consists of a three dimensional printing system includes a reservoir of curable material, a dispensing tip connected to the reservoir, a curing platform surrounding the dispensing tip, the curing platform having at least one curing component arranged on a surface of the curing platform facing a print direction, and at least one actuator connecting the curing platform to the dispensing tip. 
         [0008]    Another embodiment consists of a curing device having a curing platform having at least one curing component arranged on a surface of the curing platform facing a print direction, three linear actuators connecting the curing platform to a dispensing tip, and a ball joint connecting the actuator to the curing platform. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  shows a prior art embodiment of a photopolymer deposition system. 
           [0010]      FIG. 2  shows an axis diagram relative to a deposition point. 
           [0011]      FIGS. 3-5  show representations of an object under construction relative to the axis of deposition. 
           [0012]      FIGS. 6-9  show examples of a curing path versus a deposition path. 
           [0013]      FIGS. 10-13  show embodiment of a curing device integrated with a deposition head. 
           [0014]      FIG. 14-15  show views of an embodiment of actuators attached to a curing platform. 
           [0015]      FIG. 16  shows an embodiment of a 3D curing system having an integrated curing device. 
           [0016]      FIGS. 17-18  show views of an embodiment of a curing system using an optical fiber bundle. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0017]      FIG. 1  shows a currently available photopolymer deposition system  10 . The system has a manufacturing table  12  that can move up and down as needed, and a deposition surface  14 . The object under construction  16  results from the print head  18  that deposits the material for the object and any supporting materials from reservoirs  22  and  24 . The curing system  20  follows the print head, typically along the same axis of travel as the print head. The curing system  20  cures the deposited polymer at a fixed point in space and time from the printhead. Since the printhead follows the same linear, single axis path each time it prints, the spacing between the printhead and curing system can be fully optimized. 
         [0018]    With the advent of 6-axis, robotic deposition heads, the need exists for the curing device to move independently of the deposition, or print, head in more axes of motion.  FIG. 2  shows a diagram of the three linear axes of motion, x-y-z. The disk  30  represents the print head and point  32  represents the point of deposition. The embodiments here detail a curing system for a 6-axis robotic system integrated into the deposition head, but with independent motion. With an offset curing system, such as a laser, held in a fixed position relative to a print head along a non-planar path, the laser spot position has inconsistent fixing points, as shown in  FIGS. 3-5 . 
         [0019]    In  FIG. 3 , as the print head  30  moves, it leaves behind the deposited material  36 . The curing component directs a beam of light  34  to cure the material  36 . The curing component, such as a laser, has a fixed spatial relationship with the deposition point  32 . This works in some positions, but not in others. As shown in  FIG. 3 , the light  34  (or heat) reaches the deposited material as intended. However, as shown in  FIG. 4 , the light or heat does not strike any of the deposited material. In  FIG. 5 , it now strikes the material again, but a significant portion of the material between the two points in  FIG. 3  and  FIG. 5  does not receive any curing energy. 
         [0020]    In the embodiments discussed here, the curing device  40  can move in an arbitrary path with respect to the x/y plane. With fixed curing, curves in the deposition process prevent the laser from properly being directed to the deposited material.  FIG. 6  shows a graphical representation of this problem. On the far left side of the diagram, the curing platform  40  has a curing component  46 , such as a UV LED or heating element, which falls in line with the deposition path, shown by the line  42 . The circle  44  represents the dispensing tip. As can be seen in the middle diagram, as the dispensing tip moves along the deposition path, the curing component no longer lies in line with the deposition path. In the left diagram, the curing component  46  lies even further off the deposition path  42 . 
         [0021]      FIG. 7  shows one embodiment of the curing platform  40  having an array of LEDs such as  46 . Similar to  FIG. 6 , the right side diagram shows the curing component  46  in line with the deposition path  42 . In the middle diagram, as the dispensing tip moves along the deposition path, and it lies between two of the array, but in the right diagram as the path curves, another component  50  has moved into the deposition path. By providing an array of curing components, the amount of deposited material that goes uncured, or that has a delay before curing, had been reduced considerably. 
         [0022]      FIG. 8  shows another embodiment of a platform having a single curing component but now has the ability to rotate as needed. In  FIG. 8 , in the middle diagram, as the print head moves along the deposition path  42 , the platform  40  rotates to keep the curing component in line with the deposition tip. As the print head continues to move along the deposition, the platform rotates as needed to ensure the component remains in line.  FIG. 9  shows an approach that combines the array of components and rotation. This reduces the number of LEDs needed as compared to the embodiments of  FIG. 7  and the additional LEDs reduce the amount of rotation needed as compared to the embodiments of  FIG. 8  while still maintaining the integrity of the curing path relative to the deposition path. 
         [0023]      FIGS. 10 and 11  shows one embodiment of a curing device that integrates with, but moves independently of, the print head. The curing device  60  has a dispensing tip  62  that dispenses material received from at least one reservoir coupled to the non-dispensing end  62 . The platform  40  connects to the dispensing tip through one or more linear actuators such as  68 . The platform  40  has at least one curing component, such as  66  that is on a surface of the curing component  40 . In one embodiment, the curing component has an array of curing components, and the curing components may be LEDs, heaters or other types of curing components. 
         [0024]    The array of curing components may be positioned to provide curing at different distances from the dispensing tip. For example, the array of curing components may form circles or rings around the dispensing tip, each at a different distance from the tip. The system could then select which circle to activate depending upon the material being cured. 
         [0025]    The array of curing components can also be spaced so that each curing component provides a curing area that is equidistant when perpendicular to the nozzle, but at a different angular alignment to the tip. In this case, the curing device which lines closest the the direction of motion can be used. 
         [0026]    The actuators such as  68  define the plane of the curing component as well as control the rotation.  FIGS. 12 and 13  show side views of the curing device  60 . In one embodiment, the actuators cause the platform  40  to undergo a plane change from tilted from left to right in  FIG. 12  to being tilted from right to left in  FIG. 13 . 
         [0027]    These actuators are connected to both the dispensing component and the curing plane through a joint capable of motion in 3 axis. This joint can be a ball-joint, with rotational freedom. Because the joint has rotational freedom, controlling the length of the linear actuator can control both the rotation and angle relative to the dispensing tip of the curing plane. For example, if the length of a single actuator is increased the angle of the plane will change such that point closer to the actuator whose length is changed in closer to the dispensing tip. If the length of all three linear actuators is changed, the relative alignment of the curing plane will not change, but instead the plane will rotate around the axis of the dispensing tip. In this manner, the direction of any curing energy can be directed in all directions independently of the axis of dispensing with minimal points of control and complexity. 
         [0028]      FIGS. 14 and 15  show a top view of the curing component. The three linear actuators can cause rotation by having a bias slightly to one side, or a stop, on the actuators. The bias may occur by making one of the actuators  68 ,  70  or  72 , longer equally. As platform moves, the difference in lengths will cause the disk to rotate. As shown in these figures, the curing platform consists of a disk, either circular as shown or any shape, having an aperture  78  through which the dispensing tip  62  inserts. 
         [0029]      FIG. 16  shows a portion of an embodiment of a 3D depositing system having an integrated, independent, curing device. In the system  80 , the reservoirs  84  and  82  provide the construction and supporting materials as needed to the end  62  of the dispensing tip  64 . The curing platform  40  surrounds the dispensing tip  62 . The platform has at least one curing component  66 . As the print head moves to deposit the material that constructs the object, the platform moves, shifts and rotates as needed to allow the curing energy to be applied to the material. 
         [0030]      FIGS. 17-18  show an alternative embodiment of a curing platform  90 . In this embodiment, the curing platform consists of a bundle of optical fibers coupled to the platform  40 . The platform allows light from the laser  92 , coupled to the bundle of fibers  96  through a lens  94 . This allows the curing energy to reach the deposition surface.  FIG. 18  shows an end view of the bundle from the perspective of the dispensing tip. The platform  40  allows the ends of the fibers to face the deposition surface. 
         [0031]    In this manner, a curing device that functions independently from, but is integrated with, the deposition tip moves to allow curing. The curing components have a dynamic relationship with the dispensing tip being able to move independently to provide curing in all orientations and positions of the deposition head. 
         [0032]    It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

Technology Category: b