Method and apparatus for fabricating three dimensional models
First Claim
1. A method of fabricating a three dimensional model on a layer by layer basis, the method comprising, at each layer of the three dimensional model, the steps of:
- forming a mold with mold material; and
filling the mold with a model material deposited at a rate faster than a rate that the mold material is deposited.
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Abstract
An apparatus and method for fabricating a three dimensional model from a composite model formed or a plurality of successive layers of model material and sacrificial mold material. Each successive layer is constructed by depositing, drop-by-drop, at least one line of sacrifical mold material delineating at least one boundary of the model material within the layer and thereafter depositing the model material onto all delineated regions of the layer by spray deposition. Each successive layer is completed by a planing process which removes the undesired thickness of both the sacrificial and the model materials. Following completion of the composite model, the sacrificial mold material is removable from the composite model, by a process effecting only the sacrificial mold material, to produce the three dimensional model. A device, for depositing the model material at the rate faster than the rate that the mold material is deposited, is also described.
44 Citations
18 Claims
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1. A method of fabricating a three dimensional model on a layer by layer basis, the method comprising, at each layer of the three dimensional model, the steps of:
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forming a mold with mold material; and
filling the mold with a model material deposited at a rate faster than a rate that the mold material is deposited. - View Dependent Claims (2, 3, 4, 5)
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6. A method for fabricating a three dimensional model, the method comprising the steps of:
fabricating a composite model formed of a plurality of successive layers including a model material forming the three dimensional model and a sacrificial mold material forming a sacrificial mold for the model material, wherein each successive layer is formed by the steps of;
a) depositing at least one line of a sacrificial mold material delineating at least one boundary of the model material within the layer by a drop-by-drop deposition;
b) depositing the model material onto regions of the layer delineated by the at least one boundary of the model material at a rate faster than a rate at which the sacrificial mold material is deposited;
c) removing a thickness of the sacrificial mold material and the model material to reduce the fabricated layer to a selected thickness of the sacrificial mold material and the model material; and
d) repeating steps (a) through (c) until the three dimensional model is completed. - View Dependent Claims (7, 8, 9)
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10. A system for fabricating a three dimensional model on a layer by layer basis, the system comprising:
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a drop-on-demand device for forming a mold of mold material; and
a high deposition rate device for filling the mold with a model material at a rate faster than a rate at which the mold material is deposited. - View Dependent Claims (11, 12, 13, 14)
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15. A system for fabricating a three dimensional model formed of a plurality of successive layers including model material forming the three dimensional model and sacrificial mold material forming a sacrificial mold for the model material, the system comprising:
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a drop-on-demand device for depositing, via drop-by-drop deposition, at least one line of sacrificial mold material delineating at least one boundary of the model material within a layer;
a spray device for depositing the model material, by spray deposition, at least onto regions of the layer delineated by the at least one boundary of the model material; and
a removal device for removing a desired thickness of the sacrificial mold material and the model material to reduce the deposited layer to a selected thickness of the sacrificial mold material and the model material. - View Dependent Claims (16, 17, 18)
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Specification