Method and device for decentralised automated additive manufacturing

Abstract

A device comprising; a controller arranged to receive data for an article to print; a sub-device comprising a resin source arranged to provide material for printing the article; a radiation source arranged to direct radiation for the printing of said article; a plurality of stations, said stations including a printing tank in which the article is printed, at least one cleaning station for cleaning the printed article and a curing station arranged to at least partially complete the curing of the printed article; a build surface upon which the article is arranged to be printed; wherein controller is arranged to move the build surface and the plurality of stations relative to each other.

Claims

1. An additive manufacturing device, comprising: a controller arranged to receive data for an article to print; a sub-device comprising a resin source arranged to provide a polymerizable material for printing the article; a radiation source arranged to direct radiation for the printing of the article from the polymerizable material; a plurality of stations comprising: a printing tank in which the article is printed, a first cleaning station for cleaning the printed article, a second cleaning station for further cleaning the printed article, wherein each of the first cleaning station and the second cleaning station comprises a different cleaning solution, a first curing station arranged to cure the printed article at least partially, and a second curing station arranged to completely cure the printed article, wherein the second curing station is a post-curing station, wherein the second curing station is distinct from the first curing station, and wherein the first curing station comprises an ultraviolet (UV) curing device distinct from the radiation source; and a build surface, wherein the build surface comprises a platform plate having a surface upon which the article is to be printed, wherein the controller is arranged to move the build surface and the plurality of stations relative to each other, wherein the plurality of stations are located on a moveable tray, the printing tank being located on a first location on the moveable tray, the first cleaning station being located on a second location on the moveable tray, the second cleaning station being located on a third location on the moveable tray, the first curing station being located on a fourth location on the moveable tray, and the second curing station being located on a fifth location on the moveable tray, wherein the printing tank, the first cleaning station, the second cleaning station, the first curing station, and the second curing station are arranged in a sequence that corresponds to a cycle of printing the article in the printing tank followed by washing the article in the first cleaning station followed by washing the article in the second cleaning station followed by curing the article in the first curing station and followed by post-curing the article in the second curing station, and wherein the moveable tray is arranged to rotate about a vertical axis, the build surface is located on a vertically oriented linear slide such that the moveable tray is arranged to sequentially rotate the plurality of stations, and the build surface is arranged to vertically deliver the article sequentially to the plurality of stations.

2. The additive manufacturing device of claim 1, wherein the plurality of stations further comprise an unloading station from where the printed article is unloaded in a finished state.

3. The additive manufacturing device of claim 1, wherein the printing tank comprises a resin vessel with a translucent or transparent bottom wall surface.

4. The additive manufacturing device of claim 1, wherein the printing tank comprises a resin vessel, the resin vessel comprising an external vessel.

5. The additive manufacturing device of claim 4, wherein the printing tank further comprises an internal vessel within the external vessel.

6. The additive manufacturing device of claim 5, wherein the internal vessel is arranged to be selectively removable from the external vessel.

7. The additive manufacturing device of claim 6, wherein the internal vessel is arranged to contain the polymerizable material.

8. The additive manufacturing device of claim 6, wherein the internal vessel comprises a coating on an internal surface of a bottom wall of the internal vessel.

9. The additive manufacturing device of claim 1, wherein the first cleaning station comprises an internal cleaning vessel that is arranged to be selectively removable from the first cleaning station.

10. The additive manufacturing device of claim 9, wherein the internal cleaning vessel is arranged to contain a cleaning solution for cleaning the printed article.

11. The additive manufacturing device of claim 1, further comprising: an electromagnetic release mechanism, wherein the electromagnetic release mechanism enables the build surface to release the platform plate at the end of a print, wash, cure, or post-curing cycle.

12. The additive manufacturing device of claim 1, wherein the radiation source is arranged below the linear slide.

13. The additive manufacturing device of claim 1, wherein the UV curing device comprises a container having at least one light emitter capable of polymerizing the polymerizable material being printed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) It will be convenient to further describe the present invention with respect to the accompanying drawings that illustrate possible arrangements of the invention. Other arrangements of the invention are possible and consequently, the particularity of the accompanying drawings is not to be understood as superseding the generality of the preceding description of the invention.

(2) FIG. 1 shows a workflow pertaining to conventional digital dentisty;

(3) FIG. 2 shows a workflow pertaining to chairside printing;

(4) FIG. 3 shows a workflow according to the present invention;

(5) FIG. 4 is a schematic view of a carousel system of an automated additive manufacturing device;

(6) FIG. 5 is a schematic view of a carousel system of an automated additive manufacturing device with the printed object(s) being transferred from the printing resin tank into a cleaning, washing or collecting vessel as the movable tray rotates;

(7) FIG. 6 is a schematic cross-sectional view of a carousel system of an automated additive manufacturing device;

(8) FIG. 7A is a schematic view of a linear system of an automated additive manufacturing device where the movable tray moves in a linear direction and facilitating the linear motion device with attached printed object(s) on the build surface;

(9) FIG. 7B is a schematic view of a linear system of an automated additive manufacturing device where a vertical and horizontal linear motion device with attached printed parts(s) on the build surface, moves in a bi-directional linear way;

(10) FIG. 8A is a schematic view of a separate linear actuator of an automated additive manufacturing device that comprises an arm capable of retrieving the platform plate(s) or build platform from the z-axis actuator in the printing area.

(11) FIG. 8B illustrates that the arm of the separate linear actuator may be capable of extending, retracting or move in a x-y direction to reach to the build platform or platform plate(s) from the printing area so as to avoid colliding or crashing against any of the interior subsystem components.

(12) FIG. 9 is a schematic view of an automated additive manufacturing device with a robotic arm mechanism.

DETAILED DESCRIPTION OF EMBODIMENTS

(13) Referring to FIG. 3, the invention comprises firstly capturing the patient's anatomy in the same way a clinician would normally do in the dental clinic, either by means of an intra-oral scanning or by creating a physical impression which may also be 3D scanned. Subsequently, the 3D data is sent out to an external facility, data/information support service, web portal, an area network (local or otherwise) or a cloud-based service, thus enabling actual work to be carried out from anywhere in the world. The work may also be partially, completely automated or completely non-automated (i.e. operated by humans at the back-end which may be centralized in one or more locations, or distributed decentralized as well), so that the outsourced software processes such as, but not limited to, file fixing, support generation (automatic or manual), parts arrangement, slicing to printable file, CAD design, exportation of digital data, pre-processing printing or exportation of printable data may be effectively and automatically conducted by a cloud-hosted artificial or machine intelligence, external facility, data/information support service, web portal or an area network (local or otherwise).

(14) In an embodiment where 3D data is sent out by the users via a web portal as an interface or 3D data might be uploaded via a direct connection of a scanner (intraoral or otherwise) with the cloud service so that a user does not need to export a scanned file and then upload that to a portal via a web browser, another person in a possibly remote location receives the input file(s), processes it accordingly and duly return it to the users through the same web portal. It is preferable that the file is transferred directly to a connected 3D printer, as opposed to having the users downloading it. In an alternative embodiment, the users may access a web portal through which another human being and/or an artificial intelligence will process the file. Performing such tasks or processes may be carried out in the form of an artificial/machine intelligence carrying some or all of the abovementioned tasks automatically, or a combination of both human effort and artificial/machine intelligence, with the extent of the latter depends on the maturity of the artificial intelligence.

(15) By automating the design and preprocessing steps (i.e. the above processes), the fast turnaround time to delivery of printable data is achieved based on the input using 3D scan data of the patients' anatomy. There may be one or multiple intermediate stages where the clinician is required or requested to provide further feedback in the form of comments, decisions or approvals for the proposed CAD design or treatment plans generated by the external outsourced software process service. After the export or delivery of printable data to the clinician, he/she may proceed or initiate with the 3D printing of the 3D object using an automated additive manufacturing device to streamline the process of a seamless and automated digital dentistry. The exported printable data from the cloud-based service, external facility, data/information support service, web portal or an area network (local or otherwise) may alternatively be uploaded directly onto an automated additive manufacturing device via an internet connection, wireless communications or remote access, ensuring that entire workflow is seamless, hands-off and automated. The uploading process can be done by the same person or artificial intelligence.

(16) In one embodiment of the invention, an automated additive manufacturing device comprises a vertical linear motion device 100 capable of moving an attached build surface 101 along the z-axis in an upward and downward vertical linear motion as shown in FIGS. 4 and 5. The vertical linear motion device may comprise a linear motor, ball screw, lead screw or belt and pulley system with stepper motor or servo motor, or any other linear actuator such as hydraulic, pneumatic or the like, or a combination thereof, or any other means capable of moving the build surface with sufficient accuracy and speed along the z-axis. The build surface 101 faces each of the vessels or devices and may comprise a platform plate having a surface upon which 3D printed object(s) 110 can adhere and moves vertically as the 3D object(s) is being printed layer by layer and subsequently being transferred from a series of vessels and devices to undergo a process of washing, curing or post-curing and collection of the 3D printed object(s). Various technologies and methods of 3D printing or additive manufacturing made widely available and known to the skilled person may be used in the automated additive manufacturing device. Additive manufacturing devices such as those disclosed in WO 2015/072921 and WO2016/122408 or SLA or DLP may be used. The platform plate may be made of, for example, steel, aluminium, glass, or any other materials which 3D printable polymers can adhere and/or may also comprise of one material and another material coating on the surface where printing will take place. The platform plate may be partially separable or fully separable from the printer bed and may further comprise a magnetic release mechanism or the use of other release mechanisms. The use of the magnetic release mechanism such as electro-magnetic mechanism or the like, or other variations of release mechanisms enables the build surface to pick or adhere, change and release different platform plates in a seamless process. In an example, during the start of a print cycle, the build surface picks or selects a clean platform plate from the vessel or device containing a stack of clean platform plates and releases each platform plate into the collection vessel or device after every cycle of print, wash, curing or post-curing.

(17) The device 100 also comprises a resin vessel, such as a printing tank 102, for the containment or holding of 3D printing article(s) 110 made of materials such as photopolymer material and produced by the irradiation of a photopolymer contained within resin vessel 102 or its internal vessel, with light of the appropriate wavelength from illumination source 103. The resin vessel 102 may have a substantially translucent or transparent lower wall surface that permits illumination to pass through it from below which subsequently targets the photopolymer resin. Preferably, the resin vessel 102 comprises of an external vessel 122 and an internal vessel 121 to facilitate the quick and easy exchange of materials. The external vessel may be rigid and permanent, made of steel, aluminium or engineering plastics whereas the internal vessel may be a disposable container made of low-cost plastic material that does not react with the photopolymer. The internal vessel 121 may also have a coating or film on its lower bottom internal surface to facilitate layer release while printing. The external vessel 122 may lack a bottom wall surface, such that the bottom surface of the internal vessel is the only boundary between the photopolymer material and the illumination source 103 below. The internal vessel 121 may be provided as a pre-sealed container or capsule with a seal that is removable by peeling, cutting or other means of destruction, or a removable lid or cover. The internal vessel may be provided as a pre-filled contained or capsule containing an appropriate quantity of the required photopolymer for a particular application. In such an embodiment, the substantially translucent bottom surface may also be covered with an external removable lid or cover, or a seal that is removable by peeling or cutting, so as to prevent ambient or other sources of illumination from prematurely polymerizing the contained photopolymer through the translucent bottom surface. The illumination device 103 (as shown in FIG. 6) comprises a laser diode with accompanying optics, but it can also be a DLP projector system, or a source of light or a multitude thereof, emitting light of a wavelength capable of polymerizing the photopolymer material. 113 is the light path being shown when the light source 103 is functioning, projecting an image or other illumination onto the polymer material in the resin vessel. The illumination device 103 may be equipped to selectively direct or expose regions of the build area, or regions of the bottom surface of the resin vessel 102. As shown in FIG. 6, the automated additive manufacturing device may be contained in a cubicle, enclosure or compartment to minimize contamination or interferences in the printing or processing of the 3D object(s) from external factors. Furthermore, the external body of the device should ideally be air-sealed and may contain air filtration systems to ensure that no odours or vapours from the resin and/or solvents are exchanged with the ambient air, so as to facilitate clean and safe operation in a clinical environment.

(18) The device 100 further comprises a movable tray 104, preferably movable in a rotary direction or otherwise movable to a set of desired positions, upon which multiple stations, may be permanently or non-permanently mounted on and may be rotated against an (imaginary) axis located in the vertical linear motion device 100, thereby directed towards the path of the vertically moving build surface 101. Said stations may comprise vessels and/or devices for the relevant aforementioned functions. Alternatively, the vertical stage may be mounted outside the rotary circle, e.g. in a corner, and a square-shaped external body may be built around the printer. For this arrangement, the stage need not be at the center of the machine, and so the axis of rotation need not coincide with it. The movable tray may be rigid and have sufficient stiffness and flatness to facilitate the alignment of the build plate surface and the resin vessel internal bottom printing surface. As shown mounted on the movable tray in

(19) FIGS. 4 and 5, the stations include a resin vessel 102, two cleaning vessels 107 and 111, and a UV curing device 105, but there may be more or fewer vessels or devices provided. In this embodiment, the multitude of stations, including vessels or devices, may be fixed in space whereas the vertical linear motion device 100 and build surface 101 are mounted upon movable tray 104 such that it may be moved (preferably in a rotary direction) to a desired position relative to each of the vessels or devices. In an exemplary example, movable tray 104 has been rotated by a difference of 90 degrees as shown in FIGS. 4 and 5, and resulting in the build surface 101 being effectively transferred from moving into or out of the resin vessel 102 after the printing process, to moving into or out of the cleaning vessel 111 for washing. Washing typically takes place in a solvent such as isopropyl alcohol, or the like and a second washing stage with the same, or another solvent, or with water may also be conducted. The movement of the movable tray may be dependent upon the various sequences of washing or curing steps and procedures required for the processing and preparation of the 3D printed object(s).

(20) In another embodiment, the movable tray 104 may be arranged in a linear manner as opposed to the rotary direction as described above. In this linear arrangement and referring to FIG. 7A, movable tray 104 moves in a linear manner and may be bi-directional, therefore facilitating the transfer of the multiple vessels or devices towards the vertical linear motion device 100 (z-axis). In an alternative embodiment, the linear movable tray remains stationary and the linear motion device 100 is replaced with a vertical and horizontal linear motion device 200 that moves in an axis perpendicular to the axis which the build surface 101 moves (FIG. 7B). The vertical and horizontal linear motion device 200 moves in a bi-directional horizontal manner, concurrently transferring the attached build surface 101 along the different segments of the linear tray and thereby undergoing the various sequences of washing or curing steps and procedures required for the processing and preparation of the 3D printed object(s). In other embodiments, the automated additive manufacturing device may comprise of both a movable tray and a vertical and horizontal linear motion device to expedite the printing and various sequences of washing or curing steps and procedures required for the 3D printed object(s). In the embodiment where the movable tray 104 moves in the presence of the vertical linear motion device 100 (z-axis) is viewed as being more advantageous since this facilitates the easy alignment of the vertical linear motion device if it moves just in one axis.

(21) In another embodiment, the printing, washing, curing and post-curing vessels may be arranged in a vertical, linear manner. In this present embodiment, a separate linear actuator 300 moves vertically in a z-direction (as shown in FIG. 8A and 8B) and may be in the form of a linear motor, ball screw, lead screw, or belt and pulley system with stepper or servo motor or any other linear actuator such as hydraulic or pneumatic or the like, or a combination thereof, or any other means capable of moving the build surface or platform plate(s) with sufficient accuracy and speed along the z-axis. The separate linear actuator comprises an arm 301 that is capable of retrieving the platform plate(s) or build platform from the z-axis actuator in the printing area. The arm 301 may be capable of extending, retracting or move in a x-y direction to reach to the build platform or platform plate(s) from the printing area so as to avoid colliding or crashing against any of the interior subsystem components. The platform plate(s) or build surface may be secured and released quickly with electromagnetic means, any other means capable of achieving such an effect, or as disclosed in prior inventor's patent filings. The build surface may comprise of one or more platform plates. Subsequently, the arm will move vertically to the next vessel(s), which may be the washing vessel(s), curing and/or post curing vessel (as shown in FIG. 8B). After the whole process of printing, washing and post curing is completed, the arm will then move to the dispense area where the finished build platform or platform plate(s) containing the printed part may be ejected and/or collected. The advantages of such embodiment, among other things, are to achieve a compact footprint, which at times can be a precious commodity in a dental practitioner's office and providing a stationary printing station which helps with the stability and repeatability of the machine due to fixed alignment.

(22) The UV curing device 105 comprises a container having at least one or preferably a plurality of light emitters which may be diodes or other types of bulbs, emitting a wavelength capable of polymerizing the photopolymer material being printed. The device 105 may also comprise emitters of heat or infrared radiation so as to increase the temperature of items placed in the device, particularly after the processing of washing. The UV curing device may have a substantially translucent or transparent lower surface that permits illumination to pass through it from below which subsequently targets the items contained in the device. The device 105 may further consist of an external vessel and an internal vessel 106 to facilitate quick and easy cleaning of the internal walls. The external vessel may lack a bottom surface, such that the bottom surface of the internal vessel is the only boundary between the photopolymer and an illumination source below.

(23) Each of the cleaning vessels 107 and 111 comprises a vessel for the containment of alcohol or other cleaning solutions. The vessels may consist of an external vessel and an internal vessel 108 or 112 to facilitate quick and easy exchange of alcohol or other cleaning solutions. The cleaning vessel may or may not be equipped with sonicating devices or other means of aggravating the cleaning solution to ensure a more thorough and quicker cleaning of any items placed within the cleaning vessel or its internal vessel. The internal vessel 108 or 112 may be provided as a pre-sealed container with a seal that is removable by peeling, cutting or other means of destruction. The internal vessel may be provided as a pre-filled contained or capsule containing an appropriate quantity of the required photopolymer for a particular application. In addition, during a printing process, the users may interact with the interface of the automatic additive manufacturing device via an external display 120, which may be either a LCD or OLED type of display and may feature touch-screen control. The external display comprises of an operating system that aids in the uploading of printable data from the outsourced software processes and may update the users on the progress of the printing and processing of the printed object(s). Users may also set instructions in the operation system of the automated additive manufacturing machine via the external display. There may also be a system of internal electronics and an operating system that regulates both this external display (UI) as well as the actual internal moving parts and illumination or projection system.

(24) Referring now to FIG. 9, the automated additive manufacturing device may comprise of an articulated arm, said articulated arm 400, which may include 6 degrees of freedom to an end effector located at the end of said arm. Said end effector may be a build surface for which the articulated arm provides several degrees of freedom. For instance, the articulated arm may provide movement of said build surface having up to 6 degrees of freedom, including translation along 3 principal axes, and rotation about said 3 principal axes. Thus, in one embodiment, the articulated arm may be a 6-axis robotic arm with novel quick release mechanism or the like that transfers removable build surface or platform plate(s) 401 to the different sections arranged around the robotic arm. Each of these sections may comprise of areas for carrying out VAT/tank 402, washing area 403, post curing 404 and/or retrieval 405, or other 3D processing procedures required for the making of the printed 3D object(s). The arm can be a robotic arm with multiple axis which allows total freedom in the placement or arrangement of the different sections, including more degrees of motion to facilitate layer release in the 3D printing process, such as for example a rotary motion component to allow for a peeling action to more gradually remove a printed layer off the print surface on the internal bottom wall of the resin vessel.

(25) After the completion of the process of washing and curing or post-curing of the 3D printed object(s) in the automated additive manufacturing device, the customized patient-specific 3D object(s) is ready for use or implantation as part of the treatment procedure for the patient.

(26) Although particular embodiments have been described and illustrated herein, it will be appreciated by those of ordinary skill in the art that various modifications and combinations of features of the above embodiments are possible without departing from the spirit or essential characteristics thereof. For example, the present invention may be applicable to other fields and not limited to dental or oral health applications and therefore the term “3D object(s) or 3D printed object(s)” may also encompass any 3D part(s) or appliance(s) that result from the applications in the different fields. In addition, the term clinician is not only limiting to medical clinicians but also comprises anyone who works in a clinician setting, laboratory technologist, clinician technologist, nurse or users of the automated additive manufacturing device and/or workflow. The foregoing embodiments, therefore, are to be considered in all respects illustrative rather than limiting the invention described herein and the scope of the invention is indicated by the appended claims.