Method for forming objects

• US 20070164485A1
• Filed: 03/16/2007
• Published: 07/19/2007
• Est. Priority Date: 10/27/2003
• Status: Abandoned Application

• Current Assignee: Sheng-Jye Hwang
• Original Assignee: Sheng-Jye Hwang
• Inventors: Lee, Sen-Yung, Hsieh, Chen, Lai, Wei-Hsiang, Chen, Chieh-Li, Hwang, Sheng-Jye, Wang, Cheng-Chien, Wang, Chun-S, Chen, Chu-Yung, Leu, Tsong-Shyng, Cheng, Chun-I, Wang, Muh-Rong
• Application Number:
  US11/723,048
• Publication Number:
  US 20070164485A1
• Time in Patent Office: Days
• US Class Current: 264/401
• CPC Class Codes: B29C 2035/0838 using laser
• CPC Class Codes: B29C 41/12 Spreading-out the material on a substrate , e.g. on the surface of a liquid
• 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 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/194 during lay-up
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof

Abstract

A method for forming objects includes a step of spreading a base material layer on a surface, a step of initiating a first physical or chemical change of the base material layer by exposure to one of ultra violet beams or infra-red beams so as to become a gelled material, a step of initiating a second physical or chemical change by application of a laser beam to selected areas of the gelled base material layer to make each selected area to become hardened in mature, a step of repeating steps 1-3 a pre-determined number of times, each newly added base material layer being laminated on a preceding layer to form a plurality of stacked layers, the hardened selected areas of the plurality of stacked layers defining a solid object, and a step of removing the portions of base material layers remaining in gelled form to obtain a final prototype.

Claims

1. A method for forming objects comprising:

step 1;

spreading a base material layer on a surface by a nozzle;

step 2;

initiating a first physical or chemical change of the base material layer by exposure to one of ultra violet beams or infra-red beams, the base material layer thereby becoming a gelled material;

step 3;

initiating a second physical or chemical change by application of a laser beam to selected areas of the gelled base material layer, the second physical or chemical change being a change to the gelled material at each selected area to become hardened in nature;

step 4;

repeating steps 1-3 a pre-determined number of times, each newly added base material layer being laminated on a preceding layer to form a plurality of stacked layers, the hardened selected areas of the plurality of stacked layers defining a solid object, and

step 5;

removing the portions of base material layers remaining in gelled form after initiation of the second physical or chemical change to obtain a final prototype.

2. The method as claimed in claim 1, wherein the base material layer in step 1 is rolled to define a flat surface by rollers.

3. The method as claimed in claim 1, wherein the base material layer in step 1 is spread by the nozzle and then rolled to be a flat surface by rollers.

4. A method for forming objects comprising:

step 1;

spreading a base material layer on a surface by a nozzle;

step 2;

initiating a first physical or chemical change of the base material layer by exposure to one of ultra violet beams or infra-red beams, the base material layer thereby becoming a gelled material;

step 3;

initiating a second physical or chemical change by adding a material composition to selected areas of the gelled base material layer, the second physical or chemical change being a change to the gelled material at each selected area to become hardened in nature;

step 4;

repeating steps 1-3 a pre-determined number of times, each newly added base material layer being laminated on a preceding layer to form a plurality of stacked layers, the hardened selected areas of the plurality of stacked layers defining a solid object, and

step 5;

removing the portions of base material layers remaining in gelled form after initiation of the second physical or chemical change to obtain a final prototype.

5. The method as claimed in claim 4, wherein the base material layer in step 1 is rolled to define a flat surface by rollers.

6. The method as claimed in claim 4, wherein the base material layer in step 1 is spread by the nozzle and then rolled to be a flat surface by rollers.