US 11,998,982 B2
System and method for controlling powder bed density for 3D printing
George Hudelson, Billerica, MA (US); Emanuel M. Sachs, Newton, MA (US); Glenn A. Jordan, Harvard, MA (US); and Midnight Zero, Wilmington, MA (US)
Assigned to Desktop Metal, Inc., Burlington, MA (US)
Filed by Desktop Metal, Inc., Burlington, MA (US)
Filed on Feb. 3, 2021, as Appl. No. 17/166,475.
Application 17/166,475 is a continuation of application No. 16/166,968, filed on Oct. 22, 2018, granted, now 10,940,533.
Claims priority of provisional application 62/610,461, filed on Dec. 26, 2017.
Prior Publication US 2021/0154735 A1, May 27, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. B33Y 30/00 (2015.01); B22F 1/10 (2022.01); B22F 3/00 (2021.01); B22F 3/16 (2006.01); B22F 3/18 (2006.01); B22F 3/24 (2006.01); B22F 10/00 (2021.01); B22F 10/14 (2021.01); B22F 10/37 (2021.01); B22F 12/52 (2021.01); B22F 12/57 (2021.01); B22F 12/63 (2021.01); B29C 64/194 (2017.01); B29C 64/214 (2017.01); B29C 64/218 (2017.01); B29C 64/236 (2017.01); B29C 64/329 (2017.01); B29C 64/343 (2017.01); B33Y 10/00 (2015.01); B33Y 40/00 (2020.01); H05K 3/10 (2006.01); H05K 3/12 (2006.01); B22F 10/28 (2021.01); B22F 12/00 (2021.01); B29C 64/165 (2017.01); B33Y 50/02 (2015.01)
CPC B22F 3/004 (2013.01) [B22F 1/10 (2022.01); B22F 3/16 (2013.01); B22F 3/18 (2013.01); B22F 3/24 (2013.01); B22F 10/00 (2021.01); B22F 10/14 (2021.01); B22F 10/37 (2021.01); B22F 12/52 (2021.01); B22F 12/57 (2021.01); B22F 12/63 (2021.01); B29C 64/194 (2017.08); B29C 64/214 (2017.08); B29C 64/218 (2017.08); B29C 64/236 (2017.08); B29C 64/329 (2017.08); B29C 64/343 (2017.08); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 40/00 (2014.12); H05K 3/102 (2013.01); H05K 3/1275 (2013.01); B22F 2003/247 (2013.01); B22F 10/28 (2021.01); B22F 12/224 (2021.01); B22F 2998/10 (2013.01); B22F 2999/00 (2013.01); B29C 64/165 (2017.08); B33Y 50/02 (2014.12); H05K 2203/0126 (2013.01); H05K 2203/0143 (2013.01); H05K 2203/1131 (2013.01)] 13 Claims
OG exemplary drawing
 
1. A binder jet system for additive manufacturing of a three-dimensional object, the system comprising:
a hopper configured to deposit an amount of powder material onto a powder print bed and to move across the powder print bed in a direction of travel;
a first compaction roller having a circular cross-section positioned downstream of the hopper relative to the direction of travel, wherein the first compaction roller is configured to traverse the amount of powder material to remove excess powder material from the powder print bed;
a spreading apparatus positioned downstream of the first compaction roller in the direction of travel, wherein the spreading apparatus is configured to spread the powder material to form a layer of the powder material across the powder print bed, wherein the spreading apparatus includes a roller that is configured to move in the direction of travel, wherein an axis of rotation of the roller is angled at a non-perpendicular angle relative to the direction of travel, and wherein the roller is configured to direct powder material in a direction in the non-perpendicular angle relative to the direction of travel;
a printing apparatus configured to deposit a fluid to at least one region of the layer to bind the powder material in the at least one region of the layer; and
a controller configured to control one or more of the hopper, the first compaction roller, the spreading apparatus, or the printing apparatus.