SYSTEM AND METHOD FOR ADDITIVE MANUFACTURING OF AN OBJECT

• US 20140036455A1
• Filed: 04/17/2012
• Published: 02/06/2014
• Est. Priority Date: 04/17/2011
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Napadensky, Eduardo
• Granted Patent: US 9,649,811 B2
• Time in Patent Office: Days
• US Class Current: 361/748
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• 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 64/112 using individual droplets, e.g. from jetting heads
• 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 64/336 of two or more materials
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29K 2995/0005 Conductive
• CPC Class Codes: B29L 2031/3425 Printed circuits
• 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 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: H05K 1/092 Dispersed materials, e.g. conductive pastes or inks
• CPC Class Codes: H05K 1/16 incorporating printed electric components, e.g. printed resistor, capacitor, inductor
• CPC Class Codes: H05K 3/125 by ink-jet printing
• CPC Class Codes: H05K 3/1283 After-treatment of the printed patterns, e.g. sintering or curing methods
• CPC Class Codes: Y10T 428/24917 including metal layer

Abstract

A method of additive manufacturing of a three-dimensional object is disclosed. The method comprises sequentially forming a plurality of layers each patterned according to the shape of a cross section of the object. In some embodiments, the formation of at least one of the layers comprises performing a raster scan to dispense at least a first building material composition, and a vector scan to dispense at least a second building material composition. The vector scan is optionally along a path selected to form at least one structure selected from the group consisting of (i) an elongated structure, (ii) a boundary structure at least partially surrounding an area filled with the first building material, and (iii) an inter-layer connecting structure.

Claims

1. A method of additive manufacturing of a three-dimensional object, comprising sequentially forming a plurality of layers each patterned according to the shape of a cross section of the object, thereby forming the object;

wherein for at least one of said plurality of layers, said formation of said layer comprises operating a first dispensing head to perform a raster scan while dispensing at least a first building material composition, and opening a second dispensing head to perform a vector scan while dispensing at least a second building material composition.

2. The method according to claim 1, wherein said first building material composition is different from said second building material composition.

3. The method according to claim 1, wherein said first building material composition is generally non-electrically conductive, and said second building material is generally electrically conductive.

4. The method according to claim 1, wherein at least one of said first and said second building material compositions comprises a UV curable component.

5. The method according to claim 1, wherein said first and said second building material compositions are at different temperatures during said dispensing.

6. The method according to claim 1, wherein said structure is embedded within an area formed by said raster scan.

7. The method according to claim 1, wherein said structure is a peripheral with respect to said layer.

8. The method according to claim 1, wherein said path is selected to form a plurality of lines embedded in an area formed by said raster scan.

9. The method according to claim 1, wherein said vector scan is at least partially simultaneous with said raster scan.

10. The method according to claim 1, wherein said vector scan and said raster scan are performed sequentially.

11. The method according to claim 1, wherein said at least one layer is an inner layer within said plurality of layers.

12. The method according to claim 1, wherein said at least one layer is a topmost or a bottommost layer among said plurality of layers.

13. The method according to claim 1, wherein said at least one layer comprises at least two layers.

14. The method according to claim 1, further comprising evaporating solvent from said second building material.

15. The method according to claim 14, wherein said solvent comprises water.

16. A circuitry producible by a method according to claim 3.

20. A system comprising the circuitry according to claim 16, wherein said system is selected from the group consisting of a sensor system, a diode system, a transistor system, a memory system, an imaging system, a display system, a projector display system, an identification tag system, a smart card system and a battery system.

49. The method according to claim 1, wherein said vector scan is along a path selected to form at least one structure selected from the group consisting of (i) an elongated structure, (ii) a boundary structure at least partially surrounding an area filled with said first building material, and (iii) an inter-layer connecting structure.

17-19. -19. (canceled)

21-30. -30. (canceled)

31. A system for additive manufacturing of a three-dimensional object, comprising:

a first dispensing head configured for performing a raster scan and dispensing a first building material composition during said raster scan;

a second dispensing head configured for performing a vector scan and dispensing a second building material composition during said vector scan; and

a controller for controlling said first dispensing head and said second dispensing head to sequentially form a plurality of layers in a configured pattern corresponding to the shape of the object;

wherein said controller is configured to control said raster scan of first dispensing head, and said vector scan of said second dispensing head.

32. The system according to claim 31, wherein said controller is configured to form at least one layer by establishing a raster scan of said first head to dispense a non-electrically conductive modeling material and a vector scan of said second head to dispense an electrically conductive material.

33. The system according to claim 31, wherein at least one of said first and said second building materials is UV curable, and said system further comprises a radiation source.

36. The system according to claim 31, wherein said first and said second heads are configured to move independently.

37. The system according to claim 31, wherein said first head is rigidly attached to said second head.

34. (canceled)

35. (canceled)

38-42. -42. (canceled)

43. A method of additive manufacturing of a three-dimensional object, comprising sequentially forming a plurality of layers each patterned according to the shape of a cross section of the object, thereby forming the object;

wherein for at least one of said plurality of layers, said formation of said layer comprises dispensing at least a first building material composition at a temperature above 60°

C. and at least a second building material composition at a temperature below 40°

C.

44-48. -48. (canceled)