3D PRINTING APPARATUS

Abstract

In general terms the present invention proposes a 3D printing apparatus 100 for printing a satellite component. The 3D printing apparatus comprises a housing 102, a seal 104 arranged movably inside the housing such that the seal partitions the housing into first and second chambers 106A, 106B that are fluidically isolated from each other, and a nozzle 108 in fluid connection with the second chamber 106B. The first chamber 106A comprises a gas having a pressure P.sub.1 and the second chamber 106B comprises a printing material. When the 3D printing apparatus 100 is exposed to an external environment having a pressure P.sub.2 being less than the pressure P.sub.1 of the gas in the first chamber 106A, the gas in the first chamber 106A exerts a force on the seal 104 which in turn exerts a force on the printing material thereby extruding the printing material out of the second chamber 106B through the nozzle 108 to print the satellite component.

Claims

1. A 3D printing apparatus for printing a satellite component, the 3D printing apparatus comprising: a housing; a seal arranged movably inside the housing such that the seal partitions the housing into first and second chambers that are fluidically isolated from each other, the first chamber comprising a gas having a pressure P.sub.1; the second chamber comprising a printing material; and a nozzle in fluid connection with the second chamber; wherein when the 3D printing apparatus is exposed to an external environment having a pressure P.sub.2 being less than the pressure P.sub.1 of the gas in the first chamber, the gas in the first chamber exerts a force on the seal which in turn exerts a force on the printing material thereby extruding the printing material out of the second chamber through the nozzle to print the satellite component.

2. A 3D printing apparatus of claim 1, wherein the nozzle comprises a temperature control module, optionally wherein the temperature control module comprises a Peltier module.

3. A 3D printing apparatus of claim 2, wherein the temperature control module is arranged to control the temperature of the printing material being extruded from the nozzle in a range of from ?50? C. to 150? C., optionally in a range of from ?20? C. to 150? C.

4. A 3D printing apparatus of claim 1, wherein the printing material comprises a liquid photopolymer.

5. A 3D printing apparatus of claim 1, wherein the gas comprises a noble gas, optionally wherein the gas comprises one or more of neon, argon, krypton, and/or xenon.

6. A 3D printing apparatus of claim 1, wherein the pressure P.sub.1 of the gas is less than 1 atm.

7. A 3D printing apparatus of claim 1, comprising a printing platform for receiving printing material extruded out of the second chamber through the nozzle, wherein the printing platform is positioned adjacent to the nozzle.

8. A 3D printing apparatus of claim 7, comprising a motor arranged to rotate the 3D printing apparatus with respect to the printing platform.

9. A 3D printing apparatus of claim 7, comprising a linear pushing mechanism arranged to move the printing platform away from the nozzle.

10. A 3D printing apparatus of claim 9, wherein the linear pushing mechanism comprises one or more motor driven wheels.

11. A 3D printing apparatus of claim 1, comprising a curing device for curing printing material extruded out of the second chamber through the nozzle.

12. A 3D printing apparatus of claim 11, wherein the curing device comprises an ultraviolet light source, and wherein the curing device comprises an opaque screen for shading at least a portion of the nozzle from the ultraviolet light source.

13. A 3D printing apparatus of claim 1, comprising a sealing element for reversibly sealing an end of the nozzle, wherein the sealing element comprises a plug.

14. A 3D printing apparatus of claim 1, comprising a first inlet in fluid connection with the first chamber for introducing the gas having a pressure P.sub.1 into the first chamber; and a second inlet in fluid connection with the second chamber for introducing the printing material into the second chamber.

15. A system for positioning a satellite component, the system comprising a 3D printing apparatus according to claim 1 and a satellite component attached between the printing platform and a fixed attachment point, wherein the 3D printing apparatus is arranged to print an elongate structure, and wherein printing of the elongate structure is arranged to move the printing platform away from the fixed attachment point to position the satellite component.

16. A system of claim 15, wherein positioning the satellite component comprises unfolding or unrolling the satellite component.

17. A system of claim 15, wherein the satellite component comprises a folded solar panel, and wherein printing of the elongate structure is arranged to move the printing platform away from the fixed attachment point to unfold the folded solar panel; or a stowed antenna, and wherein printing of the elongate structure is arranged to move the printing platform away from the fixed attachment point to unfold or unroll the stowed antenna.

18. A system of claim 15, wherein the printed elongate structure is a cylinder.

19. A method of 3D printing a satellite component, the method comprising the steps of providing an 3D printing apparatus according to claim 1; introducing a gas having a pressure P.sub.1 into the first chamber; introducing a printing material into the second chamber; exposing the 3D printing apparatus to an environment having a pressure P.sub.2 being less than the pressure P.sub.1 of the gas in the first chamber, such that the gas in the first chamber exerts a force on the seal, which in turn exerts a force on the printing material, thereby extruding the printing material out of the second chamber through the nozzle.

20. A method of claim 19, comprising controlling the temperature of the printing material being extruded from the nozzle in a range of from ?50? C. to 150? C., optionally in a range of from ?20? C. to 150? C.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0049] FIG. 1 is a schematic illustration of a 3D printing apparatus in accordance with a first embodiment of the invention;

[0050] FIG. 2 is an illustration of a cross-sectional view of a 3D printing apparatus in accordance with a second embodiment of the invention;

[0051] FIG. 3 is an illustration of a nozzle in accordance with an embodiment of the invention;

[0052] FIG. 4 is an illustration of a linear pushing mechanism in accordance with an embodiment of the invention;

[0053] FIGS. 5A and 5B illustrate a system for unfolding a solar panel comprising a 3D printing apparatus according to the second embodiment of the invention; and

[0054] FIG. 6 is an illustration of a flowchart depicting steps of a method for 3D printing in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

[0055] Referring to FIG. 1, a 3D printing apparatus 100 in accordance with a first embodiment of the invention comprises a housing 102, a seal 104 arranged movably inside the housing 102 such that the seal 104 partitions the housing 102 into a first chamber 106A and a second chamber 106B that are fluidically isolated from each other, and a nozzle 108 in fluid connection with the second chamber 106B.

[0056] The first chamber 106A comprises a gas having a pressure P.sub.1 and the second chamber 106B comprises a printing material 110. When the 3D printing apparatus 100 is exposed to an external environment having a pressure P.sub.2 being less than the pressure P.sub.1 of the gas in the first chamber 106A, the gas in the first chamber 106A expands. This exerts a force on the seal 104 which in turn exerts a force on the printing material 110, thereby extruding the printing material 110 out of the second chamber 106B through the nozzle 108.

[0057] Referring to FIG. 2, a 3D printing apparatus 200 in accordance with a second embodiment of the invention comprises a housing 202, a seal 204 arranged movably inside the housing 202 such that the seal 204 partitions the housing 202 into a first chamber 206A and a second chamber 206B that are fluidically isolated from each other, and a nozzle 208 in fluid connection with the second chamber 206B.

[0058] The first chamber 206A comprises argon gas having a pressure P.sub.1 and the second chamber 206B comprises a liquid photopolymer 210. In this example, the liquid photopolymer 210 comprises a mixture of styrene and benzophenone. When the 3D printing apparatus 200 is exposed to an external environment having a pressure P.sub.2 being less than the pressure P.sub.1 of the argon gas in the first chamber 206A, the argon gas in the first chamber 206A expands. This exerts a force on the seal 204 which in turn exerts a force on the liquid photopolymer 210, thereby extruding the liquid photopolymer 210 out of the second chamber 206B through the nozzle 208.

[0059] The 3D printing apparatus 200 further comprises a printing platform 212, a motor 214, a linear pushing mechanism 215 comprising two motor driven wheels 216A, 216B, a Peltier module 218, a UV light source 220, a plug 222, a first inlet 224 for introducing argon gas having a pressure P.sub.1 into the first chamber 206A, and a second inlet 226 for introducing the liquid photopolymer 210 into the second chamber 206B. The printing platform 212 is positioned adjacent to the nozzle 208 for receiving the liquid photopolymer 210 that is extruded out of the second chamber 206B through the nozzle 208, when the 3D printing apparatus 200 is in use.

[0060] The 3D printing apparatus 200 may be used to print a cylindrical beam (not shown in the FIG. 2). In order to achieve this, the motor 214 rotates the 3D printing apparatus 200 with respect to the printing platform 212, while the printing platform 212 is moved away from the nozzle 208 by the linear pushing mechanism 215. In this way, the 3D printing apparatus 200 prints in a spiral movement to generate the cylindrical beam. The ratio between the speed of rotation of the motor 214 and speed of the linear pushing of the printing platform 212 away from the 3D printing apparatus 200 can be tuned in order to increase or decrease the size of the layers of the liquid photopolymer 210 extruded from the nozzle 208.

[0061] Furthermore, the Peltier module 218 is used to control the temperature of the nozzle 208, which in turn controls the viscosity of the liquid photopolymer 210 extruded through the nozzle 208. The viscosity of the liquid photopolymer 210 is inversely proportional to the temperature of the nozzle 208. Hence, when the viscosity of the liquid photopolymer 210 is lower than a required viscosity, then the Peltier module 218 is used to increase the temperature of the nozzle 208 to increase the viscosity of the liquid photopolymer 210. Alternatively, when the viscosity of the printing material 210 is greater than a required viscosity, the Peltier module 218 decreases the temperature of the nozzle 108 to increase the viscosity of the liquid photopolymer 210.

[0062] Significantly, the Peltier module 218 can be used to cool the nozzle to temperatures below 0? C., which allows the viscosity of the liquid photopolymer 210 to be increased sufficiently in order to make it solid enough to be extruded via the nozzle 208 and for it to stay in place on the printing platform 212 after extrusion so that it can be hardened in its extruded form.

[0063] The UV light source 220 emits ultraviolet light, thereby curing (i.e. hardening) the liquid photopolymer 210 extruded out of the second chamber 206B through the nozzle 208. The UV light source 220 is arranged to be directed towards a region in proximity of an end of the nozzle 208 from which the printing material 210 is extruded. The UV light source 220 is partially covered by an opaque screen 228. The opaque screen 228 is positioned to provide a partially shaded region around the end of the nozzle 208 from the UV light source 220, when the 3D printing apparatus 200 is in use.

[0064] The plug 222 is used to reversibly seal an end of the nozzle 208. When the plug 222 is sealing an end of the nozzle 208, extrusion of the printing material from the second chamber 206B out of the nozzle 208 is prevented when the 3D printing apparatus is exposed to an external environment having a pressure P.sub.2 being less than the pressure P.sub.1 of the gas in the first chamber.

[0065] Referring to FIG. 3, a nozzle 308 in accordance with an embodiment of the invention comprises a Peltier module 318 and a plurality of radiator fins 302 which act as a heat exchanger. The Peltier module 318 is used to control the temperature of the printing material being extruded from the nozzle in a range of from ?50? C. to 150? C. The Peltier module 318 may generate heat and/or remove heat by regulating a voltage that may be applied to a power input of the Peltier module. Significantly, the Peltier module 318 can be used to cool the nozzle 308 to temperatures below 0? C., which allows the viscosity of the printing material to be increased sufficiently in order to make it solid enough to be extruded via the nozzle 308 and for it to stay in place (i.e. maintain its physical form) after extrusion from the nozzle 308 so that it can be hardened in its extruded form.

[0066] Referring to FIG. 4, a linear pushing mechanism 415 in accordance with an embodiment of the invention comprises a plurality of motor driven wheels 402, which are positioned around the sides of a cylindrical printing platform 412 at an angle. The plurality of motor driven wheels 402 are each in contact with the printing platform 412. The plurality of motor driven wheels 402 spin around and, due to their angled orientation, exert a linear force on the printing platform 412, thereby moving the printing platform 412 in a linear direction.

[0067] Referring collectively to FIGS. 5A and 5B, a system 50 for unfolding a folded solar panel 52 comprises a 3D printing apparatus 200 in accordance with the second embodiment of the invention and a folded solar panel 52. The folded solar panel 52 is attached between the printing platform 212 of the 3D printing apparatus 200 and an attachment point 54 fixed to the 3D printing apparatus 200.

[0068] FIG. 5B provides a perspective view of the system 50 in a deployed configuration, wherein the folded solar panel 52 has been unfolded once the 3D printing apparatus 200 has printed a cylinder 56. During printing of the cylinder by the 3D printing apparatus 200, the 3D printing apparatus 200 is rotated relative to the printing platform 212 in directions corresponding to the X and Y axis. Simultaneously, the printing platform 212 is gradually moved away from the fixed attachment point 54 in the Z axis by the linear pushing mechanism 215. The printing platform 212 is of equal diameter to the diameter of the printed cylinder 56. The cylinder 56 is printed in a layer-by-layer manner, so that the cylinder 56 slowly extends outward from the 3D printing apparatus 200 with each printed layer. Hence, printing of the cylinder 56 by 3D printing apparatus 200 gradually unfolds the folded solar panel 52.

[0069] FIG. 6 provides a flowchart depicting the steps of a method 6000 of 3D printing a satellite component, in accordance with an embodiment of the invention. At step 6002, a 3D printing apparatus is provided, the 3D printing apparatus comprising: a housing; a seal arranged movably inside the housing such that the seal partitions the housing into first and second chambers that are fluidically isolated from each other; and a nozzle in fluid connection with the second chamber. At step 6004, a gas having a pressure P.sub.1 is introduced into the first chamber. At step 6006, a printing material is introduced into the second chamber. At step 6008, the 3D printing apparatus is exposed to an external environment having a pressure P.sub.2 being less than the pressure P.sub.1 of the gas in the first chamber, such that the gas in the first chamber exerts a force on the seal, which in turn exerts a force on the printing material, thereby extruding the printing material out of the second chamber through the nozzle.