Methods and apparatus for actuated fabricator

• US 10,189,076 B2
• Filed: 08/05/2016
• Issued: 01/29/2019
• Est. Priority Date: 04/04/2012
• Status: Active Grant

• Current Assignee: Massachusetts Institute of Technology
• Original Assignee: Massachusetts Institute of Technology
• Inventors: Peters, Benjamin, Oxman, Neri
• Primary Examiner(s): Patel, Vishal I
• Application Number:
  US15/229,728
• Publication Number:
  US 20160339510A1
• Time in Patent Office: 907 Days
• CPC Class Codes: B22D 11/01 without moulds, e.g. on molten surfaces
• CPC Class Codes: B22D 11/1206 for plastic shaping of strands rolling mills B21B1/46
• CPC Class Codes: B22D 11/14 Plants for continuous casting
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/141 using only solid materials
• CPC Class Codes: B29C 64/147 using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
• CPC Class Codes: B29C 70/52 Pultrusion, i.e. forming and compressing by continuously pulling through a die
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: E04G 21/04 Devices for both conveying and distributing concrete pumps F04

Abstract

In exemplary implementations of this invention, an actuated fabricator deposits structural elements (e.g., tensile structural elements) in a 3D pattern over large displacements. The fabricator is supported by at least three elongated support members. It includes onboard actuators that translate the fabricator relative to the ends of the support members. The fabricator is configured, by actuating different translations along different support members, to translate itself throughout a 3D volume. In some implementations, each of the actuators use fusible material to fuse metal tapes together, edge-to-edge, to form a hollow structure that can be shortened or lengthened.

Claims

1. An apparatus for fabrication, wherein:

(a) the apparatus is configured to deposit a first material to fabricate a tensile structure;

(b) weight of the apparatus is supported by at least three tensile elements;

(c) the apparatus includes actuators that are onboard the apparatus; and

(d) the onboard actuators are configured to actuate movements of the apparatus along the at least three tensile elements, such that the apparatus moves to different points in a three-dimensional volume while the first material is deposited; and

(e) the apparatus includes a sieve configured to spin fibers that are deposited to fabricate the tensile structure.

2. An apparatus for fabrication, wherein:

(a) the apparatus is configured to deposit a first material to fabricate a tensile structure;

(b) weight of the apparatus is supported by at least three tensile elements;

(c) the apparatus includes actuators that are onboard the apparatus; and

(d) the onboard actuators are configured to actuate movements of the apparatus along the at least three tensile elements, such that the apparatus moves to different points in a three-dimensional volume while the first material is deposited; and

(e) the apparatus is configured

(i) to heat the first material to the first material'"'"'s glass transition temperature and to spin the first material into fibers, and

(ii) to wind the fibers into tensile elements that are deposited to fabricate the tensile structure.

3. An apparatus for fabrication, wherein:

(a) the apparatus is configured to deposit a first material to fabricate a tensile structure;

(b) weight of the apparatus is supported by at least three tensile elements;

(c) the apparatus includes actuators that are onboard the apparatus; and

(d) the onboard actuators are configured to actuate movements of the apparatus along the at least three tensile elements, such that the apparatus moves to different points in a three-dimensional volume while the first material is deposited; and

(e) the apparatus is configured to pull film from an interface between two chemically reacting liquids and to form the film into filaments that are deposited to fabricate the tensile structure.