METHOD AND APPARATUS FOR THREE-DIMENSIONAL PRINTING

• US 20100215856A1
• Filed: 02/24/2009
• Published: 08/26/2010
• Est. Priority Date: 02/24/2009
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Objet Ltd. (Stratasys Incorporated)
• Inventors: KRITCHMAN, Eliahu M.
• Granted Patent: US 8,147,910 B2
• Time in Patent Office: Days
• US Class Current: 427/277
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing

Abstract

Embodiments of the invention are directed to a system and method to fabricate three-dimensional objects, layer by layer, by selectively dispensing material from a printing head onto a transfer platform to form a cross-sectional layer of the object that has a pre-determined non-uniform surface. Each layer may then be transferred from the transfer platform to previously formed layers that are carried by a fabrication platform by contacting an exposed surface of a previously formed layer to the layer on the transfer platform.

Claims

1. A method of producing, layer by layer, a three-dimensional object, the method comprising:

selectively dispensing material from a printing head onto a transfer platform to form a cross-sectional layer of the object having a pre-determined non-uniform surface;

transferring the layer from the transfer platform to the object being produced by contacting a surface of a previously formed layer of the object and the non-uniform surface of the layer.

2. The method of claim 1, comprising dispensing the material based on printing information for the layer such that the non-uniform surface of the layer comprises voids.

3. The method of claim 1, comprising dispensing the material based on printing information for the layer such that the non-uniform surface of the layer is a rough surface.

4. The method of claim 1, comprising dispensing the material based on printing information for the layer such that the layer has a non-uniform thickness.

5. The method of claim 1, comprising dispensing the material based on printing information for the layer such that the layer is defined by a matrix of a plurality of pixels and wherein selectively dispensing material comprises dispensing different amounts of material at each of the plurality of pixels.

6. The method of claim 1, wherein the non-uniform surface of the layer is in the form of peaks and valleys.

7. The method of claim 6, wherein the peaks and valleys are formed by dispensing material from the printing head at a variable flow rate.

8. The method of claim 6, wherein the peaks and valleys are formed by dispensing material from the printing head at a plurality of passes.

9. The method of 1, wherein the material is a photopolymer.

10. The method of 1, wherein the material is a wax material.

11. The method of 1, wherein the non-uniform surface of the layer becomes uniform as a result of contacting the surface of a previously formed layer.

12. The method of 1, wherein a portion of material in a plurality of high spots of said non-uniform surface is squeezed into a plurality of low spots of said non-uniform surface during attachment to a previously formed layer.

13. The method of 1, wherein the surface of the other side of said layer being transferred is smooth

14. The method of 1, wherein the surface at the rim of the surface is high.

15. The method of 1, wherein said layer is at least partially solidified before being transferred.

16. The method of 1, wherein said layer comprises more than one dispensed material.