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Extrusion-based additive manufacturing system and method

  • US 10,427,352 B2
  • Filed: 07/24/2014
  • Issued: 10/01/2019
  • Est. Priority Date: 08/06/2013
  • Status: Active Grant
First Claim
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1. A method of manufacturing an object, the method comprising:

  • extruding material from an extrusion head onto a non-planar surface of a three-dimensional tool, the extrusion head having an extrusion axis along which the material flows as it exits the extrusion head;

    moving the extrusion head relative the tool as the material is extruded so that the material is deposited as a series of layers, wherein the material cures on or after deposition so that the layers are fused together, andcontrolling the extrusion of the material and the relative movement so that the series of layers are shaped in accordance with a stored three-dimensional model of the object,wherein at least some of the layers are non-planar layers, and the relative movement during the deposition of each non-planar layer includes at least an element of rotation which causes an orientation between the extrusion axis and the tool to change at the same time as the material is deposited,wherein at least a first layer of the object is a non-planar layer that conforms to the shape of the three-dimensional tool, andwherein at least a portion of the at least first layer of the object extends to an underside of the tool.

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