Three dimensional printing on three dimensional objects

• US 10,532,523 B2
• Filed: 09/05/2016
• Issued: 01/14/2020
• Est. Priority Date: 09/06/2015
• Status: Active Grant

• Current Assignee: Shmuel Ur Innovations Ltd.
• Original Assignee: Shmuel Ur Innovations Ltd.
• Inventors: Ur, Shmuel
• Primary Examiner(s): Minskey, Jacob T
• Assistant Examiner(s): Tsui, Melody
• Application Number:
  US15/256,667
• Publication Number:
  US 20170066198A1
• Time in Patent Office: 1,226 Days
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/176 Sequentially
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29C 73/02 using liquid or paste-like material B29C73/16 takes precedence
• 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 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

Embodiments of the invention allow performing an additive manufacturing process using a base object. Some embodiments enable placement of a three-dimensional base object inside a three-dimensional printer and print on the base object to produce a three-dimensional product. One exemplary embodiment is a method including: obtaining a representation of a three-dimensional physical object as a base object; obtaining a representation of a three-dimensional physical object as a product producible by adding layers of material on the base object. A representation of a support structure configured to retain the base object position within an additive manufacturing apparatus is determined, and the support structure is produced using an additive manufacturing process. Alternatively, a representation of an on-object structure determined and the on-object structure is produced using an additive manufacturing process by adding one or more layers of material on the base object.

Claims

1. An apparatus comprising a processor and memory, wherein said processor is configured to perform the steps of:

obtaining a representation of a base object, wherein the base object is a three-dimensional physical object, wherein the base object is pre-existing;

obtaining a representation of a product, wherein the product is a three-dimensional physical object, wherein the product is producible by adding layers of material on the base object, wherein the product comprises, as a part thereof, the base object;

determining a representation of a support structure configured in size and shape to retain the base object in a position within an additive manufacturing apparatus, wherein the position is associated with producing the product;

producing the support structure using an additive manufacturing process.

2. The apparatus of claim 1, wherein the processor is further configured to perform the steps of, after the product is produced, notifying a user that the product can be removed from the support structure.

3. The apparatus of claim 1, wherein the support structure is dispensable after the product is produced.

4. The apparatus of claim 1, wherein said producing the support structure is performed by the additive manufacturing apparatus so as to be located in a location within the additive manufacturing apparatus, whereby the product can be produced without moving the support structure.

5. The apparatus of claim 1, wherein the support structure is configured to allow a human to place the base object within the additive manufacturing apparatus in a desired location and position with an accuracy of about a size of a voxel.

6. The apparatus of claim 1, wherein the support structure is configured to allow a human to place the base object within the additive manufacturing apparatus in a desired location and position with an accuracy of about 1 mm.

7. The apparatus of claim 1, wherein the support structure comprises a first and second positioning area which are configured to support a first and a second portions of the base object, respectively.

8. The apparatus of claim 1, wherein the support structure comprises a positioning area which is configured to support a portion of the base object, wherein the positioning area is located within a cone-like shape at a bottom portion of the cone-like shape, wherein a top portion of the cone-like shape comprises an opening through which the base object is placed on the support structure.

9. The apparatus of claim 1, wherein said obtaining the representation of the base object comprises scanning the base object.

10. An apparatus comprising a processor and memory, wherein the processor is configured to perform the steps of:

obtaining a representation of a base object, wherein the base object is a three-dimensional physical object, wherein the base object is pre-existing;

obtaining a representation of a product, wherein the product is a three-dimensional physical object, wherein the product is producible by adding layers of materials on the base object, wherein the product comprises, as a part thereof, the base object;

determining a representation of an on-object structure, wherein the on-object structure is configured to be produced on the base object, whereby assisting in placing the base object in a position which is suitable for producing the product;

producing the on-object structure using an additive manufacturing process by adding one or more layers of material on the base object.

11. The apparatus of claim 10, wherein the on-object structure is configured in size and shape to allow a human to place the base object within an additive manufacturing apparatus in a desired location and position, wherein the desired location and position are associated with producing the product.

12. The apparatus of claim 11, wherein desired location and position are of an accuracy of less than about 2 mm or of about two voxels.

13. The apparatus of claim 10, wherein the on-object structure is configured in size and shape to mate with scaffolding which is configured to position the base object in the position.

14. The apparatus of claim 10, wherein the on-object structure is a visible marker that visually indicates to a human an accurate placing of the base object so as to be in the position.

15. The apparatus of claim 10, wherein said apparatus is configured to:

after the base object is placed in the position using the on-object structure, produce the product by adding one or more layers of materials on the base object.

16. The apparatus of claim 10, wherein said apparatus is configured to:

after the base object is placed in the position using the on-object structure, add one or more layers of material on the base object;

produce a second on-object structure, wherein the second on-object structure is configured to be produced on the base object, whereby assisting in placing the base object in a second position which is suitable for producing the product;

after the base object is placed in the second position using the second on-object structure, add one or more layers of material on the base object;

whereby the product is produced in an iterative process in which two different positions are used to add material to the base object.

17. The apparatus of claim 10, wherein said apparatus is configured to:

produce the product using the base object and the on-object structure; and

after said producing, said processor is configured to notify a user that the on-object structure can be removed from the product.

18. The apparatus of claim 10, wherein said apparatus is configured to produce the product using the base object and the on-object structure, wherein the product comprises the on-object structure which is irremovable therefrom.

19. A computer program product comprising a non-transitory computer readable storage medium retaining program instructions, which program instructions when read by a processor, cause the processor to perform a method comprising:

obtaining a representation of a base object, wherein the base object is a three-dimensional physical object, wherein the base object is pre-existing;

obtaining a representation of a product, wherein the product is a three-dimensional physical object, wherein the product is producible by adding layers of materials on the base object, wherein the product comprises, as a part thereof, the base object;

determining a representation support structure configured in size and shape to retain the base object in a position within an additive manufacturing apparatus, wherein the position is suitable for producing the product; and

outputting the representation to be used in production of the product.

20. The computer-program product of claim 19, wherein said outputting comprises instruction an additive manufacturing apparatus to product the support structure.

21. A method comprising:

obtaining a representation of a base object, wherein the base object is a three-dimensional physical object, wherein the base object is pre-existing;

obtaining a representation of a product, wherein the product is a three-dimensional physical object, wherein the product is producible by adding layers of material on the base object, wherein the product comprises, as a part thereof, the base object;

determining a representation of a support structure configured in size and shape to retain the base object in a position within an additive manufacturing apparatus, wherein the position is associated with producing the product; and

producing the support structure using an additive manufacturing process.

22. The method of claim 21, wherein the support structure is dispensable after the product is produced.

23. The method of claim 21, wherein said producing the support structure is performed by the additive manufacturing apparatus so as to be located in a location within the additive manufacturing apparatus, whereby the product can be produced without moving the support structure.

24. The method of claim 21, wherein said obtaining the representation of the base object comprises scanning the base object.

25. A method comprising:

obtaining a representation of a base object, wherein the base object is a three-dimensional physical object, wherein the base object is pre-existing;

obtaining a representation of a product, wherein the product is a three-dimensional physical object, wherein the product is producible by adding layers of materials on the base object, wherein the product comprises, as a part thereof, the base object;

determining a representation of an on-object structure, wherein the on-object structure is configured to be produced on the base object, whereby assisting in placing the base object in a position which is suitable for producing the product; and

producing the on-object structure using an additive manufacturing process by adding one or more layers of material on the base object.

26. The method of claim 25 wherein the on-object structure is configured in size and shape to allow a human to place the base object within an additive manufacturing apparatus in a desired location and position, wherein the desired location and position are associated with producing the product.

27. The method of claim 25, wherein the on-object structure is a visible marker that visually indicates to a human an accurate placing of the base object so as to be in the position.

28. The method of claim 25 further comprises:

placing the base object in the position using the on-object structure; and

producing the product by adding one or more layers of materials on the base object.

29. The method of claim 25 further comprises:

placing the base object in the position using the on-object structure;

adding one or more layers of material on the base object when position in the position;

placing the base object in a second position that is suitable for producing the product; and

adding one or more layers of material on the base object when positioned in the second position;

whereby the product is produced in an iterative process in which two different positions are used to add material to the base object.

30. The method of claim 25, wherein the product comprises the on-object structure which is irremovable therefrom.