System and Method for Printing Three-Dimensional Parts with Magnetic Support Media

Abstract

An additive manufacturing method and system for printing a three-dimensional part, which includes generating a magnetic field in a build chamber, printing layers of the three-dimensional part in the build chamber, and transferring layers of a magnetic support media to the build chamber in coordination with the printing of the layers of the three-dimensional part. The method also includes magnetically coupling the transferred layers of the magnetic support media in the build chamber with the generated magnetic field to produce a self-supporting bed of the magnetically-coupled media.

1 . A system for printing a three-dimensional part, the system comprising:
 a build chamber;   a media hopper configured to provide a supply of a magnetic support media;   a transfer zone interconnecting the build chamber and the media hopper;   one or more print heads that are configured to print layers of the three-dimensional part from one or more part materials in the build chamber;   a transfer mechanism configured to transfer layers of a magnetic support media from the media hopper, across the transfer zone, and into the build chamber; and   a plurality of magnets configured to generate a magnetic field in the build chamber.   
     
     
         2 . The system of  claim 1 , wherein the one or more print heads comprise one or more extrusion heads, one or more jetting heads, or combinations thereof. 
     
     
         3 . The system of  claim 1 , and further comprising:
 a platen disposed in the build chamber;   a platen gantry configured to move the platen along a printing axis in the build chamber.   
     
     
         4 . The system of  claim 3 , wherein the platen comprises a flexible gasket perimeter for maintaining a seal with walls of the build chamber. 
     
     
         5 . The system of  claim 1 , and further comprising one or more additional print heads for printing layers of a support structure from one or more soluble support materials that at least partially interface between the layers of the three-dimensional part and the magnetic support media. 
     
     
         6 . The system of  claim 1 , and further comprising one or more heating units configured to heat at least the build chamber and the media hopper. 
     
     
         7 . The system of  claim 1 , wherein the magnetic support media comprises one or more ferromagnetic materials. 
     
     
         8 . The system of  claim 1 , wherein the plurality of magnets comprise a plurality of electromagnets. 
     
     
         9 . A system for printing a three-dimensional part, the system comprising:
 a build chamber;   a media hopper configured to retain a supply of a magnetic support media;   one or more print heads that are configured to print layers of the three-dimensional part from one or more part materials in the build chamber;   a planarizing mechanism configured to apply layers of the magnetic support media from the media hopper to the build chamber; and   a plurality of magnets configured to generate a magnetic field in the build chamber.   
     
     
         10 . The system of  claim 9 , and further comprising a transfer zone interconnecting the build chamber and the media hopper; 
     
     
         11 . The system of  claim 9 , and further comprising:
 a platen disposed in the build chamber;   a platen gantry configured to move the platen along a printing axis in the build chamber.   
     
     
         12 . The system of  claim 11 , wherein the platen comprises a flexible gasket perimeter for maintaining a seal with walls of the build chamber. 
     
     
         13 . The system of  claim 9 , and further comprising one or more heating units configured to heat at least the build chamber and the media hopper. 
     
     
         14 . A method for printing a three-dimensional part, the method comprising:
 generating a magnetic field in a build chamber of an additive manufacturing system;   printing one or more first layers of the three-dimensional part in the build chamber;   transferring a first layer of a magnetic support media to the build chamber such that the transferred first layer of the magnetic support media is substantially level with the one or more printed first layers of the three-dimensional part; and   magnetically coupling the transferred first layer of the magnetic support media in the build chamber with the generated magnetic field to produce a self-supporting bed of the magnetically-coupled media.   
     
     
         15 . The method of  claim 14 , and further comprising:
 printing a one or more second layers of the three-dimensional part in the build chamber over the one or more printed first layers of the three-dimensional part, over the transferred first layer of the magnetic support media, or a combination thereof;   transferring a second layer of a magnetic support media to the build chamber such that the transferred second layer of the magnetic support media is substantially level with the one or more printed second layers of the three-dimensional part; and   magnetically coupling the transferred second layer of the magnetic support media in the build chamber to itself and the magnetically-coupled media of the transferred first layer with the generated magnetic field to grow the self-supporting bed of the magnetically-coupled media.   
     
     
         16 . The method of  claim 14 , wherein transferring the first layer of the magnetic support media to the build chamber comprises moving the magnetic support media from a media hopper located separately from the build chamber and across a transition zone that interconnects the build chamber and the media hopper. 
     
     
         17 . The method of  claim 16 , and further comprising heating the build chamber. 
     
     
         18 . The method of  claim 17 , and further comprising heating the media hopper and optionally heating the transition zone. 
     
     
         19 . The method of  claim 14 , and further comprising printing one or more layers of a support structure from a soluble support material such that the one or more layers of the support structure at least partially interface between the one or more printed first layers of the three-dimensional part and the plurality of magnets. 
     
     
         20 . The method of  claim 14 , wherein the magnetic support media comprises one or more ferromagnetic materials.