High-Temperature modeling method

• US 20040104515A1
• Filed: 11/26/2003
• Published: 06/03/2004
• Est. Priority Date: 06/23/1999
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: LaBossiere, Joseph E., Swanson, William J., Turley, Patrick W., Skubic, Robert L., Karwoski, Peter J., Leavitt, Paul J.
• Granted Patent: US 7,297,304 B2
• Time in Patent Office: Days
• US Class Current: 264/497
• CPC Class Codes: B29C 2071/022 Annealing
• CPC Class Codes: B29C 2791/005 Using a particular environment, e.g. sterile fluids other than air
• CPC Class Codes: B29C 41/36 Feeding the material on to the mould, core or other substrate
• CPC Class Codes: B29C 41/52 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• 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 71/02 Thermal after-treatment B29C71/0063 and B29C71/0072 take 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 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: G05B 2219/49019 Machine 3-D slices, to build 3-D model, stratified object manufacturing SOM
• CPC Class Codes: Y10S 264/57 Processes of forming layered products

Abstract

A method for three-dimensional modeling builds up three-dimensional objects in a heated build chamber by dispensing modeling material from a dispensing head onto a base in a predetermined pattern. Physical and thermal separation are maintained between the heated build chamber and motion control components that control the motion of the dispensing head and the base. Thermal isolation of the motion control components from the build chamber allows the chamber to be maintained at a high temperature, and has other practical advantages as well.

Claims

1. A method for three-dimensional modeling comprising the steps of heating a build chamber to an elevated temperature, dispensing modeling material from an outlet of a dispensing head onto a base provided in the build chamber, and moving the dispensing head and the base in three-dimensions with respect to one another in synchrony with the dispensing of modeling material so as to build up a three-dimensional object of predetermined shape on the base, characterized by:

maintaining physical and thermal separation between the heated build chamber and a gantry that controls motion of the dispensing head.

2. The method of claim 1, wherein the gantry further controls motion of the base.

3. The method of claim 1, and further characterized by:

maintaining physical and thermal separation between the heated build chamber and a lift that controls motion of the base.

4. The method of claim 1, wherein the build chamber is heated to a temperature greater than 200°

C.

5. The method of claim 1, wherein the dispensing head is moved in an x-y plane and the base is moved along a z-axis.

6. The method of claim 1, and further characterized by:

providing a feedstock of modeling material to an inlet of the dispensing head located external to the build chamber.

7. The method of claim 1, wherein the build chamber is heated by convection such that an air flow pattern is created in the build chamber, and further characterized by:

deflecting air in the flow pattern towards the dispensing head outlet.

8. A method for three-dimensional modeling comprising the steps of:

heating a build chamber to an elevated temperature;

dispensing modeling material from an outlet of a dispensing head onto a base provided in the build chamber;

moving the dispensing head and the base in three-dimensions with respect to one another in synchrony with the dispensing of modeling material so as to build up a three-dimensional object of predetermined shape on the base;

controlling the motion of the dispensing head and the base with motion control components located external to the build chamber; and

maintaining thermal isolation between the external motion control components and the build chamber.

9. The method of claim 8, wherein the build chamber is heated to a temperature greater than 150°

C.

10. The method of claim 8, wherein the build chamber is heated to a temperature greater than 200°

C.

11. The method of claim 8, wherein the dispensing head is moved in an x-y plane and the base is moved along a z-axis.

12. The apparatus of claim 8, and further comprising the step of:

providing a feedstock of modeling material to an inlet of the dispensing head located external to the build chamber.

13. The method of claim 8, wherein the build chamber is heated by convection such that an air flow pattern is created in the build chamber, and further characterized by:

deflecting air in the flow pattern towards the dispensing head outlet.

14. A method for three-dimensional modeling comprising the steps of:

heating a build chamber to an elevated temperature;

dispensing modeling material from an outlet of a dispensing head onto a base provided in the build chamber; and

moving the dispensing head and the base in three-dimensions with respect to one another in synchrony with the dispensing of modeling material so as to build up a three-dimensional object of predetermined shape on the base;

wherein the motion of the dispensing head and the base are controlled by motion control components located external to and in thermal isolation from the build chamber.

15. The method of claim 14, wherein the build chamber is heated to a temperature greater than 150°

C.

16. The method of claim 14, wherein the build chamber is heated to a temperature greater than 2000°

C.

17. The method of claim 14, wherein the dispensing head is moved in an x-y plane and the base is moved along a z-axis.

18. The method of claim 14, and further comprising the step of:

providing a feedstock of modeling material to an inlet of the dispensing head located external to the build chamber.

19. The method of claim 14, and further comprising the step of:

removing a build-up of modeling material from the dispensing head outlet by driving the dispensing head outlet against a rotating member of a cleaning assembly.