Creating objects through X and Z movement of print heads

• US 20040005374A1
• Filed: 05/14/2003
• Published: 01/08/2004
• Est. Priority Date: 05/16/2002
• Status: Abandoned Application

• Current Assignee: Phillipe Guerit, Subhash Narang, Susanna Ventura
• Original Assignee: Phillipe Guerit, Subhash Narang, Susanna Ventura
• Inventors: Guerit, Phillipe, Ventura, Susanna, Narang, Subhash
• Application Number:
  US10/438,678
• Publication Number:
  US 20040005374A1
• Time in Patent Office: Days
• US Class Current: 425/375
• CPC Class Codes: B22F 10/12 by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
• CPC Class Codes: B22F 10/18 by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
• CPC Class Codes: B22F 10/22 Direct deposition of molten metal
• CPC Class Codes: B22F 10/40 Structures for supporting workpieces or articles during manufacture and removed afterwards
• CPC Class Codes: B22F 12/222 for motion along a direction orthogonal to the plane of a layer
• CPC Class Codes: B22F 12/224 for motion along a direction within the plane of a layer
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B29C 31/044 with moving heads for distributing liquid or viscous material into the moulds
• CPC Class Codes: B29C 31/047 combined with moving moulds B29C31/044, B29C31/048 take precedence
• CPC Class Codes: B29C 35/08 by wave energy or particle radiation B29C64/00, B29C71/04 take precedence
• CPC Class Codes: B29C 41/36 Feeding the material on to the mould, core or other substrate
• 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 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: C23C 4/12 characterised by the method of spraying
• CPC Class Codes: G03F 7/0037 Production of three-dimensional images
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

Methods and devices for creating three-dimensional objects using selective deposition, wherein deposition is accomplished by moving one or more deposition nozzles in X and Z axes, but not in a Y axis. Three dimensionality is accomplished by moving the work surface in the Y axis.

Claims

1. A method of creating a three-dimensional object using selective deposition, comprising:

providing a substantially planar substrate defining an X and a Y axis;

moving a print head back and forth in the X axis, not the Y axis; and

moving the print head back and forth in a Z axis, orthogonal to both the X axis and the Y axis.

2. The method of claim 1, further comprising moving the substrate in the Y axis.

3. The method of claim 1, further comprising the step of printing an entire layer of the three dimensional object before printing a subsequent layer.

4. The method of claim 1, further comprising at least one additional print head moving in the X axis and in the Z axis, not in the Y axis.

5. The method of claim 1, further comprising the step of extruding a material and curing the material within 5 seconds of extruding.

6. The method of claim 5, wherein the step of curing includes irradiating the material with emissions from a diode.

7. The method of claim 1, further comprising depositing a plurality of substantially different materials from a plurality of print heads.

8. The method of claim 7, wherein each of the substantially different materials is solidified by at least one of radiation, laser cure, and heat.

9. The method of claim 7, wherein each of the substantially different materials is deposited from a different one of the plurality of print heads.

10. The method of claim 7, further comprising storing each of the substantially different materials in a different reservoir.

11. The method of claim 7, wherein the substantially different materials are selected from the group comprising a metal, a ceramic, and a plastic.

12. The method of claim 1, further comprising a guide that inhibits the print head from movement in the Y axis.

13. The method of claim 1, further comprising a guide that limits movement of the substrate to the Y axis.

14. The method of claim 1, wherein the object comprises at least one of a metal, a ceramic, and a plastic.

15. The method of claim 1, further comprising:

producing a bottom by repeatedly depositing thin layers of a coating material;

producing sides by repeatedly depositing a thin layer of the coating material around a thin layer of the coating material;

depositing an active material inside the sides; and

producing a top by repeatedly depositing thin layers of the coating material.

16. The method of claim 1, further comprising:

depositing at least two materials onto a substrate to form a layer; and

reacting the materials at least partly as a function of a curing process.

17. The method of claim 16, wherein the step of reacting further comprising adding a catalyst.

18. The method of claim 16, wherein the curing process is at least 90% complete within 5 seconds of the step of depositing.

19. A three dimension deposition system comprising:

a work surface adapted to move along a first axis; and

a material deposition head adapted to move along a second axis and a third axis while depositing material on the work surface;

wherein

movement along the third axis involves a change in the distance between the work surface and the material deposition head; and

wherein

the first, second, and third axis are orthogonal.