US 8,747,097 B2
`(10) Patent No.:
`a2) United States Patent
`Pettis
`(45) Date of Patent:
`*Jun. 10, 2014
`
`
`US008747097B2
`
`(54) NETWORKED THREE-DIMENSIONAL
`PRINTER WITH THREE-DIMENSIONAL
`SCANNER
`-
`
`(75)
`
`\
`,
`Inventor: Nathaniel B. Pettis, Brooklyn, NY (US)
`
`(*) Notice:
`
`(73) Assignee: MakerBotIndustries, LLC. Brooklyn,
`NY (US)
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`oo
`j a
`This patent is subject to a terminal dis-
`elaimer:
`
`(21) Appl. No.: 13/556,368
`
`(22)
`
`Filed:
`
`Jul. 24, 2012
`
`(65)
`
`Prior Publication Data
`US 2012/0286453 Al
`Nov. 15, 2012
`
`Related U.S. Application Data
`
`(63) Continuation of application No. 13/314,337, filed on
`Dec. 8, 2011, which is a continuation-in-part of
`application No. 12/858,622, filed on Aug. 18, 2010,
`now Pat. No. 8,282,380.
`Int. Cl.
`AOLT 21/00
`(52) U.S. Cl.
`USPC.
`ssssve: 425/375; 425/131.1; 264/40.1; 700/98;
`700/118
`
`(2006.01)
`
`(51)
`
`(58) Field of Classification Search
`USPC sesne 425/131.1, 375; 264/40.1; 700/98, 118
`See applicationfile for complete search history.
`.
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`Primary Examiner — Joseph S Del Sole
`Assistant Examiner — David N Brown, II
`(74) Attorney, Agent, or Firm — Strategic Patents, P.C.
`
`(57)
`
`ABSTRACT
`
`Three-dimensional fabrication resources are improved by
`adding networking capabilities to three-dimensionalprinters
`and providing a variety of tools for networked use ofthree-
`dimensional printers. Web-based servers or the like can pro-
`vide a single point of access for remote users to manage
`accessto distributed content on one hand, and to manageuse
`of distributed fabrication resources on the other.
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`Shenzhen Tuozhu 1001
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`1
`
`Shenzhen Tuozhu 1001
`
`

`

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`
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`* cited by examiner
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`OTHER PUBLICATIONS
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`(56)
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`References Cited
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`U.S. PATENT DOCUMENTS
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`U.S. Patent Jun. 10,2014—-Sheet 2 of 6 US 8,747,097 B2
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`US8,747,097 B2
`
`1
`NETWORKED THREE-DIMENSIONAL
`PRINTER WITH THREE-DIMENSIONAL
`SCANNER
`
`
`
`RELATED APPLICATIONS
`
`
`This application is a continuation of U.S. patent applica-
`tion Ser. No. 13/314,337 filed Dec. 8, 2011. which is a con-
`tinuation-in-part of U.S. patent application Ser. No. 12/858,
`622,filed onAug. 18, 2010,the entire content ofeach ofthese
`applications is hereby incorporated byreference.
`
`BACKGROUND
`
`2
`while the exemplary embodiments below emphasize fabrica-
`tion techniques using extrusion,the principles of the inven-
`tion may be adapted to a wide variety of three-dimensional
`fabrication processes, and in particular additive fabrication
`processesincluding without limitation selective laser sinter-
`ing, fused deposition modeling, three-dimensionalprinting,
`and the like. All such variations that can be adapted to use
`with a networked fabrication resource as described herein are
`intendedto fall within the scopeof this disclosure. It should
`also be understood that any reference herein to a fabrication
`process such as printing or three-dimensional printing is
`intended to refer to any and all such additive fabrication
`process unlessa different meaningis explicitly stated or oth-
`erwise clear from the context. Thus by way of example and
`not of limitation, a three-dimensional printer (or simply
`“printer”’) is now described that may be used in a networked
`sing networked resources.
`three-dimensionalprinting environment.
`A variety ofthree-dimensional fabrication techniques have
`FIG.11s a block diagram ofa three-dimensionalprinter. In
`been devised to support rapid prototyping from computer
`general, the printer 100 may include a build platform 102,a
`nodels. These techniques have been refined over the years to
`conveyor104, an extruder 106, an x-y-z positioning assembly
`increase accuracy, working volume, and the variety of build
`108, and a controller 110 that cooperate to fabricate an object
`naterials available in a rapid prototyping environment. While
`112 within a working volume 114oftheprinter 100.
`hese increasingly sophisticated and expensive machines
`The build platform 102 mayinclude a surface 116 that is
`appear regularly in commercial design and engineeringset-
`rigid and substantially planar. The surface 116 may support
`ings, amore recent trend has emerged toward low-cost three-
`25
`the conveyer 104 in orderto provideafixed, dimensionally
`dimensional prototyping devices suitable for hobbyists and
`and positionallystable platform on whichto build the object
`ome users. As these resources become morereadily and
`112.
`widely available, a need has emerged for networking capa-
`The build platform 102 may includeathermal element 130
`bilities and network management for three-dimensional
`printers.
`that controls the temperature of the build platform 102
`through one or more active devices 132 such asresistive
`elements that convert electrical current
`into heat, Peltier
`effect devices that can create a heating or cooling effect, or
`any other thermoelectric heating and/or cooling devices.
`Thus the thermal element 130 maybe a heating elementthat
`providesactive heating to the build platform 102,a cooling
`element that provides active cooling to the build platform
`102, ora combinationofthese. The heating element 130 may
`be coupled in a communicatingrelationship with the control-
`ler 110 in order for the controller 110 to controllably impart
`heat to or remove heat from the surface 116 of the build
`
`The invention relates to three-dimensional fabrication
`
`
`
`SUMMARY
`
`Three-dimensionalfabrication resources are improved by
`adding networking capabilities to three-dimensionalprinters
`and providing a variety of tools for networked use of three-
`dimensionalprinters. Web-basedserversor thelike can pro-
`vide a single point of access for remote users to manage
`access to distributed content on one hand, and to manage use
`of distributed fabrication resources on the other.
`
`20
`
`30
`
`35
`
`40
`
`
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`The foregoing and other objects, features and advantages
`of the invention will be apparent from the following descrip-
`tion of particular embodiments thereof, as illustrated in the
`accompanying drawings. The drawingsare not necessarilyto
`scale, emphasis instead being placed uponillustrating the
`principles of the invention.
`FIG.1 is a block diagramofa three-dimensionalprinter.
`FIG.2 is an isometric viewof a conveyer for an automated
`build process.
`FIG. 3 depicts a networked three-dimensional printing
`environment.
`FIG.4 is a flowchart of a method for using a three-dimen-
`sionalprinter, such as any ofthe three-dimensional printers
`described above, when coupled to a data network.
`FIG. 5 depicts a user interface for management ofnet-
`worked printing.
`FIG.6 is a flowchart of a method for operating a three-
`dimensionalprinter coupled to a network.
`FIG.7 is a flowchart of a method for operating a three-
`dimensionalprinter coupled to a network.
`
`DETAILED DESCRIPTION
`
`Described herein are devices and methods for using net-
`worked three-dimensionalprinters. It will be understood that
`
`platform 102. Thus the thermal element 130 mayinclude an
`active cooling element positioned within or adjacentto the
`build platform 102 to controllably cool the build platform
`102.
`
`It will be understoodthata variety of other techniques may
`be employed to control a temperature of the build platform
`102. For example, the build platform 102 may use a gas
`cooling or gas heating device such as a vacuum chamberor
`the like in an interior thereof, which may be quickly pressur-
`ized to heat the build platform 102 or vacatedto cool the build
`platform 102 as desired. As another example, a stream of
`heated or cooled gas may be applied directly to the build
`platform 102 before, during, and/orafter a build process.Any
`device or combination of devices suitable for controlling a
`temperature ofthe build platform 102 maybe adapted to use
`as the thermal element 130 described herein.
`
`The conveyer 104 may be formed ofa sheet 118 ofmaterial
`that movesin a path 120 through the working volume 114.
`Within the working volume 114, the path 120 maypass proxi-
`mal to the surface 116 of the build platform 102—thatis,
`resting directly on or otherwise supported by the surface
`116—1norderto providea rigid, positionally stable working
`surface for a build. It will be understood that while the path
`120 is depicted as a unidirectional arrow,the path 120 maybe
`bidirectional, such that the conveyer 104 can movein either of
`two opposing directions through the working volume 114. It
`will also be understoodthat the path 120 may curvein any of
`
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`US8,747,097 B2
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`3
`a variety of ways, such as bylooping underneath and around
`the build platform 102, over and/or underrollers, or around
`delivery and take up spools for the sheet 118 of material.
`Thus, while the path 120 maybe generally(but not necessar-
`ily) uniform through the working volume 114, the conveyer
`104 may move in any direction suitable for moving com-
`pleted items from the working volume 114. The conveyor
`nay include a motoror other similar drive mechanism (not
`shown) coupled to the controller 110 to control movement of
`he sheet 118 of material along the path 120. Various drive
`nechanisms are shown and described in further detail below.
`In general, the sheet 118 may be formed ofa flexible
`naterial such as amesh material, a polyamide, a polyethylene
`erephthalate (commercially available in bi-axial form as
`MYLAR), a polyimidefilm (commerciallyavailable as KAP-
`TON), or any othersuitably strong polymerorother material.
`The sheet 118 may have a thickness of about three to seven
`housandthsof an inch,or anyother thickness that permits the
`sheet 118 to follow the path 120 of the conveyer 104. For
`example, with sufficiently strong material, the sheet 118 may
`ave a thicknessof oneto three thousandths of an inch. The
`
`
`
`sheet 118 mayinstead be formedofsectionsofrigid material
`joined by flexible links.
`Aworking surface of the sheet 118 (e.g., an area on the top
`surface ofthe sheet 118 within the working volume 114) may
`be treated in a variety of manners to assist with adhesion of
`build material to the surface 118 and/or removal ofcompleted
`objects from the surface 118. For example, the working sur-
`face may be abraded or otherwise textured (e.g., with
`grooves, protrusions, and the like) to improve adhesion
`between the working surface and the build material.
`A variety ofchemical treatments may be used on the work-
`ing surface of the sheet 118 of material to further facilitate
`build processes as described herein. For example,the chemi-
`cal treatment mayinclude a deposition ofmaterial that can be
`chemically removed fromthe conveyer 104 by use of water,
`solvents,or the like. This mayfacilitate separation of a com-
`pleted object from the conveyer by dissolving thelayer of
`chemical treatment between the object 112 and the conveyor
`104. The chemical treatments may include deposition of a
`material that easily separates from the conveyer such as a
`wax, mild adhesive,or the like. The chemicaltreatment may
`include a detachable surface such as an adhesive that is
`
`sprayed on to the conveyer 104 prior to fabrication of the
`object 112.
`In one aspect, the conveyer 104 may be formed ofa sheet of
`disposable, one-use material that is fed from a dispenser and
`consumed with each successive build.
`In one aspect, the conveyer 104 may include a number of
`different working areas with different surface treatments
`adapted for different build materials or processes. For
`example, different areas mayhavedifferent textures (smooth,
`abraded, grooved, etc.). Different areas may be formed of
`different materials. Different areas may also have orreceive
`different chemical treatments. Thus a single conveyer 104
`may be used in a variety of different build processes by
`selecting the various working areas as neededordesired.
`The extruder 106 may include a chamber 122in an interior
`thereofto receive a build material. The build material may, for
`example, include acrylonitrile butadiene styrene (“ABS”),
`high-density polyethylene (“HDPL”), polylactic acid, or any
`othersuitable plastic, thermoplastic, or other material that can
`usefully be extruded to form a three-dimensional object. The
`extruder 106 may include anextrusiontip 124orother open-
`ing that includes an exit port with a circular, oval, slotted or
`other cross-sectional profile that extrudes build material in a
`desired cross-sectional shape.
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`The extruder 106 mayinclude a heater 126 to melt thermo-
`plastic or other meltable build materials within the chamber
`122 for extrusion through an extrusion tip 124 in liquid form.
`While illustrated in block form, it will be understoodthat the
`heater 126 may include, e.g., coils of resistive wire wrapped
`about the extruder 106, one or more heating blocks with
`resistive elements to heat the extruder 106 with applied cur-
`rent, an inductive heater, or anyother arrangementof heating
`elements suitable for creating heat within the chamber 122 to
`melt the build material for extrusion. The extruder 106 may
`also or instead include a motor 128 orthe like to pushthe build
`material into the chamber 122 and/orthroughthe extrusion tip
`124.
`
`In general operation (and by way of example rather than
`limitation), a build material such as ABS plastic in filament
`form may be fed into the chamber 122 froma spoolorthelike
`by the motor 128, melted by the heater 126, and extruded
`from the extrusion tip 124. By controlling a rate of the motor
`128, the temperature of the heater 126, and/or other process
`parameters, the build material maybe extruded at a controlled
`volumetric rate. It will be understood that a variety of tech-
`niques may also or instead be employed to deliver build
`material at a controlled volumetric rate, which may depend
`upon the type of build material, the volumetric rate desired,
`and any other factors. All such techniques that might be
`suitably adapted to delivery of build material for fabrication
`of a three-dimensional object are intendedto fall within the
`scope of this disclosure. As noted above, other techniques
`may be employed for three-dimensional printing, including
`extrusion-based techniques using a build materialthat is cur-
`able and/or a build material of sufficient viscosity to retain
`shapeafter extrusion.
`The x-y-z positioning assembly 108 may generally be
`adaptedto three-dimensionally position the extruder 106 and
`the extrusion tip 124 within the working volume 114. Thus by
`controlling the volumetric rate of delivery for the build mate-
`rial and the x,y, z position of the extrusion tip 124, the object
`112 maybe fabricated in three dimensions by depositing
`successive layers of material in two-dimensional patterns
`derived, for example, from cross-sections of a computer
`modelor other computerized representation ofthe object 112.
`A varietyofarrangements and techniques are knownin the art
`to achieve controlled linear movement along one or more
`axes. The x-y-z positioning assembly 108 may, for example,
`include a number of stepper motors 109 to independently
`control a position of the extruder within the working volume
`along each ofan x-axis, a y-axis, and a z-axis. More generally,
`the x-y-z positioning assembly 108 may include withoutlimi-
`tation various combinations of stepper motors, encoded DC
`motors, gears, belts, pulleys, worm gears, threads, and so
`forth. Any such arrangement suitable for controllably posi-
`tioning the extruder 106 within the working volume 114 may
`be adapted to use with the printer 100 described herein.
`Byway of example and not limitation, the conveyor 104
`may beaffixed to a bed that provides x-y positioning within
`the planeof the conveyor 104, while the extruder 106 can be
`independently moved along a z-axis. As another example, the
`extruder 106 maybestationary while the conveyor 104 is x,y,
`and z positionable. As another example,the extruder 106 may
`be x, y, and z positionable while the conveyer 104 remains
`fixed (relative to the working volume 114). In yet another
`example, the conveyer 104 may, by movement of the sheet
`118 of material, control movement in one axis (e.g., the
`y-axis), while the extruder 106 movesin the z-axis as well as
`one axis in the plane of the sheet 118. Thusin one aspect, the
`conveyor 104 maybeattached to and movewith at least one
`of an x-axis stage (that controls movement along the x-axis),
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`a y-axis stage (that controls movement along a y-axis), and a
`z-axis stage (that controls movement along a z-axis) of the
`X-y-z positioning assembly 108. More generally, any arrange-
`ment of motors and other hardware controllable by the con-
`troller 110 mayserve as the x-y-z positioning assembly 108 in
`the printer 100 described herein. Still more generally, while
`an X, y, Z coordinate system serves as a convenientbasis for
`positioning within three dimensions, any other coordinate
`system or combination of coordinate systems may also or
`instead be employed, such as a positional controller and
`assembly that operates according to cylindrical or spherical
`coordinates.
`
`The controller 110 maybeelectrically coupled in a com-
`municatingrelationship with the build platform 102, the con-
`veyer 104, the x-y-z positioning assembly 108, andthe other
`various components of the printer 100. In general, the con-
`troller 110 is operable to control the componentsofthe printer
`100, such as the build platform 102, the conveyer 104, the
`X-y-z positioning assembly 108, and any other components of
`the printer 100 described herein to fabricate the object 112
`from the build material. The controller 110 mayinclude any
`combination of software and/or processing circuitry suitable
`for controlling the various components of the printer 100
`described herein including without limitation microproces-
`sors, microcontrollers, application-specific integrated cir-
`cuits, programmable gate arrays, and anyotherdigital and/or
`analog components, as well as combinationsofthe foregoing,
`along with inputs and outputs for transceiving controlsignals,
`drive signals, powersignals, sensor signals, and so forth. In
`oneaspect, the controller 110 mayinclude a microprocessor
`or other processing circuitry with sufficient computational
`powerto providerelated functions such as executing an oper-
`ating system, providing a graphical user interface(e.g., to a
`display coupledto the controller 110 or printer 100), convert
`three-dimensional models into tool instructions, and operate
`a web server or otherwise host remote users and/oractivity
`throughthe network interface 136 described below.
`A variety of additional sensors maybe usefully incorpo-
`rated into the printer 100 described above. These are generi-
`cally depicted as sensor 134 in FIG.1, for whichthe position-
`ing and mechanical/electrical
`interconnections with other
`elements of the printer 100 will depend upon the type and
`purpose of the sensor 134 and will be readily understood and
`appreciated by one ofordinary skill in the art. The sensor 134
`mayinclude a temperature sensor positioned to sense a tem-
`perature ofthe surfaceofthe build platform 102. This may,for
`example, include a thermistororthe like embedded within or
`attached below the surface of the build platform 102. This
`mayalso or instead include an infrared detectororthe like
`directed at the surface 116 of the build platform 102 or the
`sheet 118 of material of the conveyer 104. Other sensors that
`maybeusefully incorporatedinto the printer 100 as the sensor
`134 include a heat sensor, a volumeflowrate sensor, a weight
`sensor, a sound sensor, and a light sensor. Certain more spe-
`cific examplesare provided below by way ofexample and not
`oflimitation.
`
`The sensor 134 may include a sensorto detect a presence
`(or absence) ofthe object 112 at a predetermined location on
`the conveyer 104. This may include an optical detector
`arranged in a beam-breaking configuration to sense the pres-
`ence of the object 112 at a location such as an end ofthe
`conveyer 104. This may also or instead include an imaging
`device and imageprocessing circuitry to capture an image of
`the working volume 114 and analyzethe image to evaluate a
`position of the object 112. This sensor 134 may be used for
`example to ensure that the object 112 is removed from the
`conveyor 104 prior to beginning a newbuild at that location
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`on the working surface such as the surface 116 of the build
`platform 102. Thus the sensor 134 may be used to determine
`whether an object is present that should not be, or to detect
`when an object is absent. The feedback from this sensor 134
`maybe used by the controller 110 to issue processing inter-
`rupts or otherwise control operation of the printer 100.
`The sensor 134 mayinclude a sensorthat detects a position
`of the conveyer 104 along the path. This information may be
`obtained froman encoderin a motorthat drives the conveyer
`104, or using any other suitable technique such as a visual
`sensor and corresponding fiducials (e.g., visible patterns,
`holes, or areas with opaque, specular, transparent, or other-
`wise detectable marking) on the sheet 118.
`The sensor 134 may include a heater (instead of or in
`addition to the thermal element 130) to heat the working
`volume 114 such as a radiant heater or forced hot air to
`
`maintain the object 112 at a fixed, elevated temperature
`throughout a build. The sensor 134 may also or instead
`include a cooling element to maintain the object 112 at a
`predetermined sub-ambient temperature throughout a build.
`The sensor 134 mayalso or instead include at least one
`video camera. The video camera may generally capture
`images of the working volume 114, the object 112, or any
`other hardware associated with the printer 100. The video
`camera may provide a remote video feed through the network
`interface 136, which feed maybe available to remote users
`through a userinterface maintainedby,e.g., remote hardware
`such as the print servers described below with reference to
`FIG.3, or within a web page provided by a webserverhosted
`bythe three-dimensionalprinter 100. Thusin one aspectthere
`is disclosed herein a userinterface adapted to present a video
`feed from at least one video cameraof a three-dimensional
`printer to a remote user througha user interface.
`The sensor 134 mayinclude may also include more com-
`plex sensing andprocessing systemsor subsystems, suchas a
`three-dimensional scanner using optical techniques(e.g., ste-
`reoscopic imaging, or shape from motion imaging), struc-
`tured light techniques, or any other suitable sensing and pro-
`cessing hardware that might extract
`three-dimensional
`information from the working volume114. In another aspect,
`the sensor 134 mayinclude a machine vision system that
`captures images and analyzes image content to obtain infor-
`mation aboutthe status of a job, working volume 114, or an
`object 112 therein. The machinevision system maysupport a
`variety of imaging-based automatic inspection, process con-
`trol, and/or robotic guidance functions for the three-dimen-
`sional printer 100 including withoutlimitation pass/fail deci-
`sions, error detection (and corresponding audible or visual
`alerts), shape detection, position detection, orientation detec-
`tion, collision avoidance, and so forth.
`Other components, generically depicted as other hardware
`135, mayalso be included, such as input devices including a
`keyboard, touchpad, mouse, switches, dials, buttons, motion
`sensors, and the like, as well as output devices such as a
`display, a speaker or other audio transducer, light emitting
`diodes, and so forth. Other hardware 135 mayalso or instead
`include a variety of cable connectionsand/or hardware adapt-
`ers for connectingto, e.g., external computers, external hard-
`ware, external instrumentation or data acquisition systems,
`and so forth.
`Theprinter 100 mayinclude,or be connected in a commu-
`nicating relationship with, a network interface 136. The net-
`work interface 136 may include any combination ofhardware
`and software suitable for coupling the controller 110 and
`other components ofthe printer 100 to a remote computerin
`a communicating relationship through a data network. By
`way of example and notlimitation, this mayinclude electron-
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`ics for a wired or wireless Ethernet connection operating
`according to the IEEE 802.11 standard (or any variation
`thereof), or any other short or long range wireless networking
`componentsor the like. This may include hardwarefor short
`range data communications such as BlueTooth or an infrared
`transceiver, which may be used to couple into a local area
`network orthe like that is in turn coupled to a data network
`such as the Internet. This may also or instead include hard-
`ware/software for a WiMax connection or a cellular network
`
`connection (using, e.g., COMA, GSM, LTE, or any other
`suitable protocol or combination ofprotocols). Consistently,
`the controller 110 maybe configuredto control participation
`by the printer 100 in any network to which the network
`interface 136 is connected, such as by autonomously connect-
`ing to the networkto retrieve printable content, or respondi