APPARATUS AND METHOD FOR MAKING AN OBJECT

• US 20140191442A1
• Filed: 08/17/2012
• Published: 07/10/2014
• Est. Priority Date: 08/20/2011
• Status: Active Grant

• Current Assignee: Zydex Pty Ltd
• Original Assignee: Zydex Pty Ltd
• Inventors: Elsey, Justin
• Granted Patent: US 9,802,361 B2
• Time in Patent Office: Days
• US Class Current: 264/401
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/147 using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
• CPC Class Codes: B29C 64/214 Doctor blades
• CPC Class Codes: B29C 64/223 Foils or films, e.g. for transferring layers of building material from one working station to another
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• 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

Abstract

A method for making an object and an apparatus (100) for making the object in accordance with the method is disclosed. A section (124) of the object is formed by irradiating a layer of material (104) with a radiation (116), the layer of material being disposed on a material receiving surface (102) of a flexible element (101) shaped by a shaping member (110) contacting the flexible element (102). The radiation (116) passes through the member (110) and the flexible element (101). The member (110) is tilted to induce a peeling separation of the member (110) from the element (101).

Claims

1. A method for making an object, the method comprising the steps of:

forming a section of the object by irradiating a material with a radiation, the material being disposed on a material receiving surface of a flexible element, the shape of the flexible element being affected by contact between a shaping member and the flexible element; and

tilting at least one of the shaping member and the flexible element to induce a peeling separation of the shaping member from the flexible element.

2. A method defined by claim 1 wherein the radiation passes through the shaping member and the flexible element.

3. A method defined by claim 2 wherein during the step of forming a section the material receiving surface is upwardly facing, and the shaping member Contacts a downwardly facing surface of the flexible element directly beneath the object being made to prevent the upwardly facing surface sagging.

4. A method defined by claim 1 wherein prior to the step of forming the section is a step of tilting at least one of the shaping member and the flexible element so that they contact to shape the flexible element.

5. A method defined by claim 4 wherein the shaping of the flexible element flattens the material receiving surface.

6. A method defined by claim 1 comprising the step of displacing the flexible element together with the shaping member which is pressed to the flexible element by atmospheric pressure, the displacement of the shaping member is constrained such that the shaping member is caused to tilt.

7. A method defined by claim 1 wherein the material is in contact with the object being made during the step of forming the section.

8. An apparatus for making an object, the apparatus comprising:

a flexible element having a material receiving surface for receiving a material from which the object is made; and

a shaping member that is arranged to contact the flexible element, the shape of the flexible element being affected when the shaping member contacts the flexible element, at least one of the shaping member and the flexible element can be tilted to induce a peeling separation of the shaping member from the flexible element.

9. An apparatus defined by claim 8 configured such that in use the material receiving surface is upwardly facing and the member contacts a downwardly facing surface of the flexible element directly beneath the object being made to prevent the element sagging.

10. An apparatus defined by claim 8 wherein at least one of the shaping member and the flexible element can be tilted into contact with the other.

11. An apparatus defined by claim 8 wherein the shaping member is a flexible element flattening member.

12. An apparatus defined by claim 8 wherein the flexible element can be moved with the shaping member pressed thereto by atmospheric pressure, and a constraint constrains the movement of the shaping member such that the shaping member is caused to tilt.

13. An apparatus defined by claim 8 comprising a radiation source arranged to irradiate the material so received through the shaping member and the flexible element to form a section of the object.

14. An apparatus defined by claim 8 comprising a radiation source arranged to irradiate the material so received to form a section of the object, the radiation source being arranged to irradiate the material when the object being made is in contact with the material.

15. An apparatus defined by claim 8 configured such that the flexible element forms at least part of a vessel configured to contain the material.

16. An apparatus defined by claim 8 wherein the flexible element comprises a flexible sheet.

17. An apparatus defined by claim 8 comprising a flexible element tensioner.

18. An apparatus defined by claim 8 comprising a controller configured to receive instructions for making the object.

19. A method for making an object, the method comprising the steps of:

on a material receiving surface of a flexible element, disposing a material used to make the object; and

causing relative movement between a shaping member and the flexible element, wherein during the relative movement, the shaping member affects the shape of the flexible element.

20. An apparatus for making an object, the apparatus comprising:

a flexible element having a material receiving surface for disposing thereon a material used to make the object; and

a shaping member that is arranged to contact the flexible element to affect the shape of the flexible element.