Methods and apparatus for actuated fabricator

• US 10,391,550 B2
• Filed: 08/22/2017
• Issued: 08/27/2019
• 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:
  US15/683,520
• Publication Number:
  US 20180001375A1
• Time in Patent Office: 735 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. A method comprising, in combination:

(a) actuating linear motion of at least one tape out of a plurality of tapes;

(b) melting fusible material; and

(c) guiding the tapes, as the tapes undergo the linear motion, into a configuration in which edges of neighboring tapes are adjacent to each other during a time in which the fusible material cools and hardens to join neighboring tapes at the edges;

wherein

(i) the tapes, when joined by the fusible material, comprise walls of a hollow structure, and

(iii) the method further comprises shortening or dismantling the hollow structure by

(A) melting fusible material adjacent to the edges, and

(B) moving the edges apart from each other.

2. The method of claim 1, wherein the tapes comprise copper-clad steel.

3. The method of claim 1, wherein the melting is caused by heat from one or more thermoelectric heat pumps.

4. The method of claim 3, wherein each of the one or more thermoelectric heat pumps comprises a Peltier device.

5. The method of claim 1, wherein the method further comprises rotating a screw while a thread of the screw engages slots in the tapes, such that, as the screw undergoes rotation, the hollow structure increases or decreases in length, depending on the direction of rotation of the screw.

6. The method of claim 5, wherein the rotation of the screw causes the tapes to move simultaneously such that each tape is moving at a speed equal to that of each other tape.

7. The method of claim 6, wherein:

(a) the hollow structure is elongated along a longitudinal axis; and

(b) the axis is straight.

8. The method of claim 1, wherein a separate actuator actuates each of the tapes, respectively, causing the tapes to move simultaneously such that each tape is moving at a speed that is different than that of each other tape.

9. The method of claim 7, wherein edges of the hollow structure are curved.

10. The method of claim 1, wherein:

(a) a first set of rollers heat the fusible material to cause the fusible material to melt; and

(b) a second set of rollers cool the fusible material to solidify the fusible material.

11. The method of claim 1, wherein the tapes comprise titanium.

12. The method of claim 1, wherein the fusible material comprises solder.

13. The method of claim 1, wherein the fusible material comprises an alloy.

14. The method of claim 1, wherein the fusible material comprises a thermoplastic.

15. A method comprising, in combination:

(a) actuating linear motion of at least one tape out of a plurality of tapes;

(b) melting fusible material; and

(c) guiding the tapes, as the tapes undergo the linear motion, into a configuration in which edges of neighboring tapes are adjacent to each other during a time in which the fusible material cools and hardens to join neighboring tapes at the edges;

wherein

(i) the tapes, when joined by the fusible material, comprise walls of a hollow structure, and

(ii) the melting is caused by heat from one or more thermoelectric heat pumps.

16. The method of claim 15, wherein the method further comprises rotating a screw while a thread of the screw engages slots in the tapes, such that, as the screw undergoes rotation, the hollow structure increases or decreases in length, depending on the direction of rotation of the screw.

17. The method of claim 16, wherein the rotation of the screw causes the tapes to move simultaneously such that each tape is moving at a speed equal to that of each other tape.

18. The method of claim 15, wherein a separate actuator actuates each of the tapes, respectively, causing the tapes to move simultaneously such that each tape is moving at a speed that is different than that of each other tape.

19. The method of claim 18, wherein edges of the hollow structure are curved.

20. The method of claim 15, wherein the tapes comprise copper-clad steel.