Three-dimensional printing systems and methods

Abstract

This disclosure provides various systems and methods for three-dimensional printing in which data describing an object as a plurality of voxels is transferred as a print material to form the three-dimensional object independent of locking. That is, various systems and methods are provided herein in which the three-dimensional printing step is to transfer data representing various voxels into a corresponding physical object via a three-dimensional printer. The first step is repeated until all the voxels are printed without waiting for any of the voxels of print material to lock. Accordingly, the three-dimensional printer can be used to print at least one subsequent object while the first object finishes locking.

What is claimed is: 
     
         1 . A method of printing a three-dimensional object, comprising:
 inserting an array of injection printheads into a container to an initial depth;   depositing a fill material into the container around the injection printheads;   retracting the injection printheads to a first retraction depth within the container;   depositing a print material into the fill material via some of the injection printheads at the first depth;   retracting the injection printheads to each of a plurality of successive retraction depths within the container; and   depositing the print material into the fill material via various combinations of the injection printheads at each of the successive retraction depths within the container.   
     
     
         2 . The method of  claim 1 , further comprising depositing print material into the fill material at the initial depth prior to retracting the injection printheads to the first retraction depth. 
     
     
         3 . The method of  claim 1 , wherein the fill material comprises resin and the print material comprises a resin hardener. 
     
     
         4 . The method of  claim 1 , wherein the print material comprises concrete and the fill material comprises one of beads and gravel. 
     
     
         5 . The method of  claim 1 , wherein the fill material comprises a granulated material and the print material comprises a bonding agent. 
     
     
         6 . The method of  claim 5 , wherein the fill material comprises one of a plastic and a metal, and wherein the print material comprises a bonding agent to bond the granulated material. 
     
     
         7 . The method of  claim 1 , wherein the array of injection printheads comprises a one-dimensional array of injection printheads. 
     
     
         8 . The method of  claim 1 , wherein the array of injection printheads comprises a two-dimensional array of injection printheads. 
     
     
         9 . The method of  claim 1 , further comprising: allowing the print material to lock. 
     
     
         10 . The method of  claim 9 , further comprising printing a second three-dimensional object prior to allowing the print material of the three-dimensional object to lock. 
     
     
         11 . A method of printing a three-dimensional object, comprising:
 conceptually dividing a three-dimensional object into a plurality of voxels;   depositing unlocked print material within a container at each location corresponding to the voxels to form the three-dimensional object;   providing a support material within the container at each location where the print material is not deposited to form the three-dimensional object, wherein the support material supports the unlocked print material in the shape of the three-dimensional object;   locking the unlocked print material within the container while supported by the support material; and   removing the locked print material from the container and the support material.   
     
     
         12 . The method of  claim 11 , wherein conceptually dividing the three-dimensional object into a plurality of voxels comprises a plurality of layers of voxels. 
     
     
         13 . The method of  claim 11 , wherein the print material comprises concrete and wherein the support material comprises one of beads and gravel. 
     
     
         14 . The method of  claim 11 , wherein providing the support material comprises filling the container with the support material prior to depositing the unlocked print material. 
     
     
         15 . The method of  claim 11 , wherein providing the support material comprises depositing fill material on a layer-by-layer basis proximate the unlocked print material. 
     
     
         16 . A three-dimensional printing system, comprising:
 an array of injection printheads to be selectively inserted and retracted with respect to a first container; and   an electronic controller to:
 cause the injection printheads to be inserted to an initial depth within the first container, 
 determine that a fill material has been deposited around the injection printheads in the container, 
 cause the injection printheads to be retracted to a first depth within the container in response to the determination that the fill material has been deposited around the injection printheads in the container, 
 cause the injection printheads to deposit a print material into the fill material via some of the injection printheads at the first depth, 
 cause the injection printheads to be retracted to each of a plurality of successive retraction depths within the container, and 
 cause the injection printheads to deposit the print material into the fill material via various combinations of the injection printheads at each of the successive retraction depths within the container. 
   
     
     
         17 . The system of  claim 16 , wherein the fill material comprises a granulated material and the print material comprises a bonding agent. 
     
     
         18 . The system of  claim 17 , wherein the fill material comprises one of a plastic and a metal, and wherein the print material comprises a bonding agent to bond the granulated material. 
     
     
         19 . The system of  claim 16 , wherein the array of injection printheads comprises a one-dimensional array of injection printheads. 
     
     
         20 . The system of  claim 16 , wherein the first container is removable from three-dimensional printing system to allow a second container to be placed in the three-dimensional printing system for printing to be initiated while the print material in the first container is locking.