System for building three-dimensional objects containing embedded inserts, and method of use thereof

• US 20090177309A1
• Filed: 01/08/2008
• Published: 07/09/2009
• Est. Priority Date: 01/08/2008
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Kozlak, David M.
• Granted Patent: US 8,070,473 B2
• Time in Patent Office: Days
• US Class Current: 700/119
• 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 64/321 Feeding
• CPC Class Codes: B29C 70/70 Completely encapsulating inserts B29C70/86 takes precedence
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

A system for building a three-dimensional object with a layer-based additive technique, the system comprising a controller configured to receive build sequence data for the three-dimensional object, a head assembly in signal communication with the controller and configured to form a plurality of layers of the three-dimensional object based on the build sequence data, and an insert placement apparatus in signal communication with the controller and configured to place at least one insert in the plurality of formed layers based on the build sequence data.

Claims

1. A system for building a three-dimensional object, the system comprising:

a controller configured to receive build sequence data for the three-dimensional object, the build sequence data being generated using a layer-based additive technique;

a build chamber;

a head assembly at least partially disposed in the build chamber and in signal communication with the controller, the moveable head being configured to form a plurality of layers of the three-dimensional object based on the build sequence data; and

an insert placement apparatus disposed in the build chamber and in signal communication with the controller, the insert placement apparatus being configured to place at least one insert in the plurality of formed layers based on the build sequence data.

2. The system of claim 1, wherein the head assembly comprises an extrusion head having at least one extrusion tip for depositing a build material to form the plurality of layers of the three-dimensional object.

3. The system of claim 1, wherein the insert placement apparatus comprises:

a base portion operably mounted within the build chamber at an offset location from the head assembly;

at least one arm portion pivotally connected to the base portion; and

an effector pivotally connected to the at least one arm portion.

4. The system of claim 1, wherein the insert placement apparatus comprises:

a base portion;

a plurality of arm segments configured to move between a retracted position and an extended position, wherein the plurality of arm segments are at least partially disposed within the base portion while in the retracted position; and

an effector connected to the plurality of arm segments.

5. The system of claim 1, wherein the insert placement apparatus comprises:

a spool mount configured to receive and retain an insert spool, wherein the insert spool contains a tape of contiguous inserts;

a compression mechanism configured to press the contiguous inserts from the tape of contiguous inserts; and

a channel for guiding at least a portion of the tape of contiguous inserts to the compression solenoid.

6. The system of claim 1, wherein the insert placement apparatus is secured to the head assembly.

7. The system of claim 1, wherein the build chamber is maintained at an elevated temperature while the head assembly forms the plurality of layers of the three-dimensional object.

8. The system of claim 1, wherein the insert placement apparatus comprises an attachment point configured to connect to a plurality of interchangeable effectors.

9. A system for building a three-dimensional object, the system comprising:

a controller configured to receive build sequence data for the three-dimensional object, the build sequence data being generated using a layer-based additive technique;

a build chamber;

a substrate platform disposed in the build chamber and in signal communication with the controller;

a gantry system at least partially disposed in the build chamber and in signal communication with the controller;

a deposition head at least partially disposed in the build chamber and supported by the gantry system for movement within the build chamber, the deposition head being in signal communication with the controller for depositing a build material to form a plurality of layers of the three-dimensional object on the substrate platform based on the build sequence data; and

an insert placement apparatus disposed in the build chamber and in signal communication with the controller, the insert placement apparatus being configured to place at least one insert in the plurality of formed layers based on the build sequence data.

10. The system of claim 9, wherein the insert placement apparatus comprises:

a base portion operably mounted within the build chamber at an offset location from the moveable head;

at least one arm portion pivotally connected to the base portion; and

an effector pivotally connected to the at least one arm portion.

11. The system of claim 9, wherein the insert placement apparatus comprises:

a base portion;

a plurality of arm segments configured to move between a retracted position and an extended position, wherein the plurality of arm segments are at least partially disposed within the base portion while in the retracted position; and

an effector connected to the plurality of arm segments.

12. The system of claim 9, wherein the insert placement apparatus comprises:

a spool mount configured to receive and retain an insert spool, wherein the insert spool contains a tape of contiguous inserts;

a compression mechanism configured to press the contiguous inserts from the tape of contiguous inserts; and

a channel for guiding at least a portion of the tape of contiguous inserts to the compression mechanism.

13. The system of claim 9, wherein the insert placement apparatus is secured to the deposition head.

14. The system of claim 9, wherein the build chamber is maintained at an elevated temperature while the moveable head forms the plurality of layers of the three-dimensional object and while the insert placement apparatus places the at least one insert in the plurality of formed layers.

15. A method for building a three-dimensional object, the method comprising:

generating build sequence data for the three-dimensional object, the build sequence data comprising first data relating to formation of layers of the three-dimensional object with a layer-based additive technique and second data relating to placement of at least one insert in the formed layers of the three-dimensional object;

relaying the generated build sequence data to a controller in signal communication with a head assembly and an insert placement apparatus;

forming layers of the three-dimensional object with the head assembly based on the first data; and

placing at least one insert in the formed layers of the three-dimensional object with the insert placement apparatus based on the second data.

16. The method of claim 15, wherein the head assembly and the insert-placement apparatus are disposed in a build chamber, the method further comprising maintaining the build chamber at an elevated temperature while forming layers of the three-dimensional object and while placing the at least one insert in the formed layers of the three-dimensional object.

17. The method of claim 15, further comprising retrieving the at least one insert with the insert placement apparatus from an insert supply component.

18. The method of claim 15, wherein the insert placement apparatus is secured to the head assembly.

19. The method of claim 15, wherein the head assembly is a deposition head, and wherein forming the layers of the three-dimensional object comprises depositing a build material in a layer-by-layer manner based on the first data.

20. The method of claim 15, wherein placing the at least one insert in the formed layers of the three-dimensional object comprises:

feeding a tape of contiguous inserts from an insert spool;

guiding at least a portion of the tape of contiguous inserts to a compression mechanism; and

pressing the portion of the tape of contiguous inserts with the compression mechanism.