Method and apparatus for producing a prototype

• US 20020129485A1
• Filed: 10/09/2001
• Published: 09/19/2002
• Est. Priority Date: 03/13/2001
• Status: Abandoned Application

• Current Assignee: Milling Systems and Concepts Pte Limited
• Original Assignee: Milling Systems and Concepts Pte Limited
• Inventors: Mok, Steven Siong Cheak, Toh, Da Jun, Chong, Yew Hing, Bong, Teck Keong
• Application Number:
  US09/974,583
• Publication Number:
  US 20020129485A1
• Time in Patent Office: Days
• US Class Current: 29/527.2
• 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 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/49017 DTM desktop manufacturing, prototyping
• CPC Class Codes: Y02P 80/40 Minimising material used in manufacturing processes
• CPC Class Codes: Y10T 29/49982 Coating

Abstract

An apparatus for producing a prototype, the apparatus comprising a headstock having a plurality of machining apparatuses for carrying out respective manufacturing processes on a prototype.

Also disclosed is a method of producing a prototype, comprising the steps of: forming a layer of the prototype; performing a machining process on the layer to remove a part of the layer, and subsequently forming a successive layer of the prototype on the layer of the prototype.

Claims

1. An apparatus for producing a prototype, the apparatus comprising a headstock having a plurality of machining apparatuses for carrying out respective manufacturing processes on a prototype.

2. An apparatus according to claim 1, further comprising a processor operable to control each of the machining apparatuses.

3. An apparatus according to claim 1, further comprising one of the group consisting of a three-axis and a five-axis positioning system, the positioning system positioning at least one of the machining apparatuses.

4. An apparatus according to claim 3, further comprising a processor, the processor being operable to control the positioning system.

5. An apparatus according to claim 4, further comprising an interface between the processor and the positioning system.

6. An apparatus according to claim 5, wherein the processor comprises part of a computer, and one of the group consisting of a parallel port and a network card of the computer is used to communicate between the processor and the interface.

7. An apparatus according to claim 5, wherein the processor comprises part of a computer, and the interface comprises an interface card mounted in the computer.

8. An apparatus according to claim 5, wherein the interface is operable to control motors to effect movement in the respective axes of the positioning system.

9. An apparatus according to claim 3, wherein the five-axis positioning system comprises means to move the headstock independently in three substantially orthogonal directions, and means to rotate a part of the headstock around an axis of rotation.

10. An apparatus according to claim 9, wherein two of the three substantially orthogonal directions are substantially horizontal, the third of the three substantially orthogonal directions being substantially vertical.

11. An apparatus according to claim 1, wherein at least one of the machining apparatuses is a material dispensing apparatus.

12. An apparatus according to claim 11, wherein material is supplied to the material dispensing system in the form of pellets, a filament, a liquid or a paste.

13. An apparatus according to claim 11, wherein the material dispensing apparatus is a build material dispensing apparatus.

14. An apparatus according to claim 11, wherein the build material dispensing system is operable to dispense a plastic build material, and further comprises:

a hot air blower;

a temperature control for the hot air blower; and

a temperature control for the plastic build material.

15. An apparatus according to claim 14, wherein the build material dispensing apparatus is operable to dispense a metal build material, and further comprises:

a plurality of storage means for storing respective metal powders; and

mixing means for mixing the metal powders prior to dispensing.

16. An apparatus according to claim 11, wherein the material dispensing apparatus is a support material dispensing apparatus.

17. An apparatus according to claim 11, wherein the material dispensing apparatus is a laser cladding system.

18. An apparatus according to claim 11, wherein the material dispensing apparatus is a liquid dispensing apparatus.

19. An apparatus according to claim 11, wherein the material dispensing apparatus is an extrusion apparatus.

20. An apparatus according to claim 11, wherein the material dispensing apparatus is a thermal spraying system.

21. An apparatus according to claim 11, wherein the material dispensing system is a welding system.

22. An apparatus according to claim 1, wherein at least one of the machining apparatuses is a profiling apparatus.

23. An apparatus according to claim 22, wherein the profiling apparatus is a milling apparatus.

24. An apparatus according to claim 23, wherein the milling apparatus is a micro-milling apparatus.

25. An apparatus according to claim 23, wherein the milling apparatus is a face-milling apparatus.

26. An apparatus according to claim 22, wherein the profiling apparatus is a drill and tap system.

27. An apparatus according to claim 22, wherein the profiling apparatus is a laser cutting apparatus.

28. An apparatus according to claim 1, wherein a least one of the apparatuses is a heating apparatus.

29. An apparatus according to claim 1, wherein at least one of the apparatuses is a suction device.

30. An apparatus according to claim 1, wherein at least one of the apparatuses is a piston actuator.

31. An apparatus according to claim 1, wherein at least one of the apparatuses is a compressed air dispensing apparatus.

32. An apparatus according to claim 1, further comprising five interface cards associated with the processor, each one of the interface cards being operable to control the movement associated with one axis of the positioning system.

85. A method according to claim 32, wherein the step of forming the layer comprises the step of depositing a pre-formed sheet.

86. A method according to claim 85, wherein the step of depositing a pre-formed sheet comprises the step of depositing a pre-formed metal or plastic sheet.

33. A method of producing a prototype, comprising the steps of:

forming a layer of the prototype;

performing a machining process on the layer to remove a part of the layer; and

subsequently forming a successive layer of the prototype on the layer of the prototype.

34. A method according to claim 33, wherein the step of performing a machining process on the layer comprises the step of applying a bit to the layer.

35. A method according to claim 34, wherein the step of applying a bit to the layer comprises the step of applying a micro bit to the layer

36. A method according to claim 34, further comprising the step of providing a tooling system comprising a plurality of bits having different dimensions and being operable to select an appropriate one of the bits to perform the machining process on the layer.

37. A method according to claim 34, wherein the depth of the layer or the successive layer is selected in dependence upon the length of the bit.

38. A method according to claim 34, further comprising the step of locating a suction device in proximity to the bit to remove small pieces of the layer produced by the action of the bit on the layer.

39. A method according to claim 33, wherein the step of performing a machining process on the layer comprises the step of utilising a machining apparatus comprising a positioning system.

40. A method according to claim 33, wherein the step of performing a machining process on the layer comprises the step of profiling the layer with a laser.

41. A method according to claim 40, wherein the step of profiling the layer with a laser comprises the step of profiling the layer with a laser from the group consisting of:

a Nd;

YAG laser and a CO₂ laser.

42. A method according to claim 40, wherein the step of profiling the layer with a laser comprises the step of profiling the layer with a five-axis laser cutting system.

43. A method according to claim 33, wherein the removal of the part of the layer gives the layer a required shape.

44. A method according to claim 33, wherein the removal of the part of the layer gives the layer a required depth.

45. A method according to claim 33, wherein the depth of the layer or the successive layer is selected in dependence upon considerations of accessibility of a tool to the layer or to the successive layer.

46. A method according to claim 33, wherein the depth of the layer or the successive layer is selected in dependence upon the geometry of the prototype.

47. A method according to claim 33, further comprising the step of curing the layer before the successive layer is formed.

48. A method according to claim 47, wherein the step of curing the layer comprises the step of blowing heated air onto the layer.

49. A method according to claim 48, wherein the layer comprises a metal powder and a binder, and wherein the step of blowing heated air onto the layer solidifies only the binder.

50. A method according to claim 47, wherein the step of curing the layer comprises the step of irradiating the layer with ultraviolet or infra-red light.

51. A method according to claim 47, wherein the step of curing the layer comprises the step of applying a chemical to the layer.

52. A method according to claim 47, wherein the step of curing the layer comprises the step of irradiating the layer with a laser.

53. A method according to claim 52, wherein the step of irradiating the layer with a laser comprises the step of irradiating the layer with a laser from the group consisting of:

a Nd;

YAG laser and a CO₂ laser.

54. A method according to claim 33, further comprising the step of depositing a quantity of a support material on the layer before the successive layer is formed.

55. A method according to claim 54, wherein the step of depositing a quantity of a support material on the layer comprises the step of depositing the support material only where support material is required to support the layer or the successive layer.

56. A method according to claim 54, wherein the step of depositing a quantity of a support material on the layer comprises the step of depositing a quantity of a wire-form support material on the layer.

57. A method according to claim 54, wherein the step of depositing a quantity of a wire-form support material comprises the step of depositing a quantity of a wire-form support material around a periphery of the layer, thereby substantially surrounding the layer.

58. A method according to claim 54, wherein the step of depositing a quantity of a support material on the layer comprises the step of depositing a metal or plastic support material on the layer.

59. A method according to claim 54, wherein the step of depositing a quantity of a support material on the layer comprises the step of depositing a powder support material on the layer.

60. A method according to claim 54, wherein the step of depositing a quantity of a support material on the layer comprises the step of depositing a liquid support material on the layer.

61. A method according to claim 54, further comprising the step of supplying the support material as pellets, a filament or a liquid.

62. A method according to claim 54, further comprising the step of curing the support material before the successive layer is formed.

63. A method according to claim 62, wherein the step of curing the support material comprises the step of blowing heated air onto the support material.

64. A method according to claim 62, wherein the step of curing the support material comprises the step of irradiating the support material with ultraviolet or infra-red light.

65. A method according to claim 62, wherein the step of curing the support material comprises the step of applying a chemical to the support material.

66. A method according to claim 62, wherein the step of curing the support material comprises the step of irradiating the support material with a laser.

67. A method according to claim 66, wherein the step of irradiating the support material with a laser comprises the step of irradiating the support material with a laser from the group consisting of:

a Nd;

YAG laser or a CO₂ laser.

68. A method according to claim 62, wherein the step of curing the support material comprises the step of heating the support material with a hotplate.

69. A method according to claim 54, further comprising the step of removing the support material after the successive layer is formed.

70. A method according to claim 69, wherein the step of removing the support material comprises the step of applying a solvent to the support material to dissolve the support material.

71. A method according to claim 70, wherein the step of applying a solvent to the support material comprises the step of applying water to the support material.

72. A method according to claim 69, wherein the step of removing the support material comprises the step of melting the support material.

73. A method according to claim 69, wherein the step of removing the support material comprises the step of oscillating the support material ultrasonically.

74. A method according to claim 33, wherein the step of forming a layer of the prototype comprises the step of depositing a quantity of a build material.

75. A method according to claim 74, wherein the step of depositing a quantity of a build material comprises the step of depositing the build material only where the build material is required to form the layer.

76. A method according to claim 74, wherein the build material comprises a plastic build material.

77. A method according to claim 76, wherein the plastic build material comprises a wire-form plastic build material.

78. A method according to claim 76, wherein the plastic build material comprises a powder plastic build material.

79. A method according to claim 76, wherein the plastic build material comprises a liquid plastic build material.

80. A method according to claim 74, wherein the build material comprises a metal build material.

81. A method according to claim 80, wherein the metal build material comprises a metal powder and a plastic binder.

82. A method according to claim 80, wherein the metal build material comprises a metal powder.

83. A method according to claim 80, wherein the metal build material comprises a metal paste.

84. A method according to claim 74, wherein the build material is in the form of pellets, a filament or a liquid.

87. A method according to claim 33, further comprising the step of welding the layer and the successive layer to one another.

88. A method according to claim 87, wherein the step of welding the layer and the successive layer to one another comprises the step of ultrasonically welding the layer and the successive layer to one another.

89. A method according to claim 33, further comprising the step of heating the prototype in a furnace.

90. A method according to claim 89, wherein the step of heating the prototype in a furnace comprises the step of melting or removing a binder from a build material from which the layer or the successive layer is formed.

91. A method according to claim 90, wherein the step of heating the prototype in a furnace comprises the step of sintering a steel powder from which the layer or the successive layer is formed.

92. A method according to claim 90, wherein the step of heating the prototype in a furnace comprises the step of infiltrating a build material from which the layer or the successive layer is formed with bronze.

93. A method according to claim 33, further comprising the step of heating the layer and a material from which the successive layer is to be formed to substantially the same temperature before forming the successive layer.