US 11,806,937 B2
Method for creating structures of two or more materials using a multi-material three-dimensional printer
Philip Eugene Rogren, Half Moon Bay, CA (US); and Morteza Vatani, Los Gatos, CA (US)
Assigned to Sakuu Corporation, San Jose, CA (US)
Filed by Sakuu Corporation, San Jose, CA (US)
Filed on Oct. 20, 2022, as Appl. No. 17/970,347.
Application 17/970,347 is a continuation of application No. 17/592,297, filed on Feb. 3, 2022, granted, now 11,504,913.
Application 17/592,297 is a continuation of application No. 16/167,088, filed on Oct. 22, 2018, granted, now 11,273,608, issued on Mar. 15, 2022.
Claims priority of provisional application 62/682,067, filed on Jun. 7, 2018.
Prior Publication US 2023/0039713 A1, Feb. 9, 2023
Int. Cl. B29C 64/379 (2017.01); B29C 64/209 (2017.01); B29C 64/165 (2017.01); B33Y 40/00 (2020.01); B33Y 30/00 (2015.01); B29C 64/171 (2017.01); B29C 64/236 (2017.01); B29C 64/245 (2017.01); B29C 64/336 (2017.01); B22F 10/14 (2021.01); B22F 12/00 (2021.01); B22F 12/33 (2021.01); B22F 12/53 (2021.01); B22F 12/60 (2021.01); B22F 12/84 (2021.01); B22F 12/88 (2021.01); B33Y 10/00 (2015.01); B33Y 50/02 (2015.01); B33Y 70/10 (2020.01); B22F 12/63 (2021.01)
CPC B29C 64/379 (2017.08) [B22F 10/14 (2021.01); B22F 12/22 (2021.01); B22F 12/224 (2021.01); B22F 12/33 (2021.01); B22F 12/53 (2021.01); B22F 12/60 (2021.01); B22F 12/84 (2021.01); B22F 12/88 (2021.01); B29C 64/165 (2017.08); B29C 64/171 (2017.08); B29C 64/209 (2017.08); B29C 64/236 (2017.08); B29C 64/245 (2017.08); B29C 64/336 (2017.08); B33Y 30/00 (2014.12); B33Y 40/00 (2014.12); B22F 12/63 (2021.01); B33Y 10/00 (2014.12); B33Y 50/02 (2014.12); B33Y 70/10 (2020.01)] 23 Claims
OG exemplary drawing
 
1. A method for creating structures of two or more materials using a multi-material three-dimensional printing apparatus, the method comprising:
receiving print instructions to direct and coordinate operation of the multi-material three-dimensional printing apparatus to print a three-dimensional part, the three-dimensional part made up of two or more materials and having at least two print thickness layers, each of the at least two print thickness layers having at least one single material pattern;
sending a first print instructions for a first single material pattern of the at least one single material pattern to a first print station within the multi-material three-dimensional printing apparatus;
dispersing material of the at least one single material pattern on a first substrate;
indexing the first substrate to move the dispersed material, via a first carrier device, to a first compaction apparatus where the material is compacted;
indexing the first substrate to move the compacted material, to a printing apparatus where a binder is dispersed in a predetermined pattern on the compacted material;
sending a second print instructions for a second single material pattern of the at least one single material pattern to a second print station within the multi-material three-dimensional printing apparatus;
dispersing material of the second single material pattern of the at least one single material pattern on a second substrate;
moving the dispersed material of the second single material pattern, via a second carrier device, to a second compaction apparatus where the material is compacted; and
transferring the at least two print thickness layers to a build substrate by using a transfer device, wherein the transfer device is positioned such that at any given time it has access to any one of the at least two print thickness layers, the transfer device configured to transfer the two print thickness layers in any desired order.
 
14. The method of claim 1, wherein the first print instructions are either same as the second print instructions or the first print instructions are different from the second print instructions.