Removable build plate for three-dimensional printers

Abstract

A removable and replaceable build plate for a three-dimensional printer supports magnetic coupling to a printer and advantageous adhesion for an initial layer of build material.

1 . A method comprising:
 coupling a build plate to a backbone structure via a magnetic force between the build plate and the backbone structure, the magnetic force exerted in a first direction on a build section of the build plate;   delivering a build material along the build section of the build plate coupled to the backbone structure;   with the build material along the build section of the build plate, decoupling the build plate from the backbone structure through movement including sliding the build plate relative to the backbone structure in a second direction perpendicular to the first direction of the magnetic force; and   removing the build material from the build section of the build plate decoupled from the backbone structure.   
     
     
         2 . The method of  claim 1 , wherein delivering the build material along the build section of the build plate includes thermally expanding the build plate, and a force of thermal expansion of the build plate moving the build section relative to the backbone structure in the second direction perpendicular to the first direction of the magnetic force with the build plate coupled to the backbone structure. 
     
     
         3 . The method of  claim 2 , wherein, under the force of thermal expansion of the build plate moving the build section relative to the backbone structure, the build section of the build plate retains a flatness of greater than about 0.2 mm and less than about 0.4 mm at a temperature of about 80° Celsius. 
     
     
         4 . The method of  claim 1 , wherein decoupling the build plate from the backbone structure includes moving the build plate along a ramp defined by the backbone structure. 
     
     
         5 . The method of  claim 4 , wherein the ramp includes a predetermined angle and length such that the sliding of the build plate relative to the backbone structure promotes vertical movement of the build plate relative to the backbone structure. 
     
     
         6 . The method of  claim 4 , wherein the build plate includes a ramp on a bottom surface thereof structurally configured to cooperate with the ramp defined by the backbone structure. 
     
     
         7 . The method of  claim 1 , wherein the backbone structure defines a cutout sized and shaped to receive the build plate. 
     
     
         8 . The method of  claim 1 , wherein removing the build material from the build section includes providing a torque to the build plate. 
     
     
         9 . The method of  claim 8 , wherein the torque applied to the build plate is created by a user grasping opposing ends of the build plate and applying a force sufficient to bow the build section into one or more of a concave or convex shape. 
     
     
         10 . The method of  claim 1 , wherein the build plate includes a sheet of an elastically flexible material including a ferromagnetic metal and a frame around at least a portion of a perimeter of the sheet, the frame formed of an elastomeric material that elastically flexes with the sheet, the elastomeric material positioned to insulate an exposed surface of the frame from a temperature of the sheet. 
     
     
         11 . The method of  claim 10 , wherein sliding of the build plate relative to the backbone structure is provided by a user grasping at least a portion of the elastomeric material while applying a force to slide the build plate. 
     
     
         12 . The method of  claim 10 , wherein the frame defines a recess graspable by fingertips of a user. 
     
     
         13 . (canceled) 
     
     
         14 . The method of  claim 10 , wherein the build plate further includes one or more tabs of the elastomeric material extending from the frame to provide gripping surfaces for decoupling of the build plate from the backbone structure. 
     
     
         15 . (canceled) 
     
     
         16 . The method of  claim 10 , wherein, in response to torque about any axis extending through the sheet and the frame at room temperature, the sheet has a first torsional stiffness, and the frame has a second torsional stiffness less than or equal to the first torsional stiffness of the sheet. 
     
     
         17 . The method of  claim 1 , wherein the backbone structure includes a substantially planar surface, and wherein the sliding of the build plate relative to the backbone structure includes sliding the build plate in the second direction along the substantially planar surface. 
     
     
         18 . The method of  claim 1 , wherein coupling the build plate to the backbone structure further includes coupling a mechanical anchor of the build plate with an opening in the backbone structure. 
     
     
         19 . A build plate for a three-dimensional printer, the build plate comprising:
 a sheet of an elastically flexible material including a ferromagnetic metal having a first thermal conductivity, the sheet having a top surface exposed to form a build section that is substantially planar in the absence of an external force;   a frame disposed entirely around a perimeter of the sheet, the frame formed of an elastomeric material that elastically flexes with the sheet, the elastomeric material having a second thermal conductivity that is less than the first thermal conductivity of the sheet; and   a ramp formed on a surface of the build plate opposing the top surface, the ramp structurally configured to cooperate with a corresponding ramp defined by a backbone structure in a build volume of the three-dimensional printer to displace the build plate in a z-axis direction away from the backbone structure in response to a movement of the build plate within a plane of the sheet.   
     
     
         20 . The build plate of  claim 19 , wherein the ramp is structurally configured to facilitate removal of the build plate from the backbone structure by opposing a magnetic force coupling the ramp to the backbone structure. 
     
     
         21 . A backbone structure for a three-dimensional printer, the backbone structure comprising:
 a body including a substantially planar surface structurally configured to receive a build plate thereon;   a plurality of magnets supported by the body for coupling the build plate to the backbone structure via a magnetic force of the plurality of magnets exerted in a first direction on a ferromagnetic component of the build plate; and   a ramp on the substantially planar surface disposed adjacent to a rear portion thereof, the ramp oriented to separate a region of the build plate from the backbone structure as the build plate is moved in a second direction away from the substantially planar surface, the second direction substantially perpendicular to the first direction of the magnetic force.   
     
     
         22 . The backbone structure of  claim 21 , further comprising a heater structurally configured to heat the build plate when positioned on the backbone structure.