METHODS FOR ADDITIVE MANUFACTURING PROCESSES INCORPORATING ACTIVE DEPOSITION

• US 20150217517A1
• Filed: 07/01/2014
• Published: 08/06/2015
• Est. Priority Date: 02/05/2014
• Status: Active Grant

• Current Assignee: Rem Sleep Medicine, PC
• Original Assignee: Metamason, Inc.
• Inventors: Karpas, Leslie Oliver, Ryan, Aaron M.
• Granted Patent: US 9,102,099 B1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/10 Pre-treatment
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]

Abstract

Systems and methods in accordance with embodiments of the invention implement additive manufacturing processes whereby the constituent material of an object to be fabricated is manipulated prior to, or during, the respective deposition process such that different portions of the deposited constituent material can be made to possess different material properties. In one embodiment, an additive manufacturing apparatus includes: a nozzle configured to accommodate the extrusion of a constituent material through it and deposit the constituent material onto a surface in accordance with an additive manufacturing process to build up an object to be fabricated; and a subassembly configured to manipulate the material properties of some portion of the constituent material such that different portions of the deposited constituent material can be made to possess different material properties; where the subassembly is configured to begin said manipulation prior to, or concurrently with, its deposition onto a surface.

Claims

1. An additive manufacturing apparatus comprising:

a nozzle configured to accommodate the extrusion of a constituent material through the nozzle and deposit the constituent material onto a surface in accordance with an additive manufacturing process to build up an object to be fabricated; and

at least one subassembly configured to manipulate the material properties of at least some portion of the constituent material such that different portions of the deposited constituent material can be made to possess different material properties;

wherein the at least one subassembly is configured to begin the manipulation of the material properties of the at least some portion of the constituent material prior to, or concurrently with, its deposition onto a surface.

2. The additive manufacturing apparatus of claim 1, wherein the subassembly is configured to begin the manipulation of the material properties of the at least some portion of the constituent material after it is extruded through the nozzle.

3. The additive manufacturing apparatus of claim 2, wherein the subassembly comprises at least one of:

an electromagnetic wave source configured to subject at least some portion of the constituent material to electromagnetic waves to begin the manipulation of its material properties;

a magnetizing source configured to begin the magnetization of the at least some portion of the constituent material;

a source of gas configured to subject the at least some portion of the constituent material to the gas that begins the manipulation of its material properties;

a vibrating apparatus configured to vibrate the at least some portion of the constituent material to thereby begin the manipulation of its material properties; and

a heating source configured to heat the at least some portion of the constituent material to thereby begin the manipulation of its material properties.

4. The additive manufacturing apparatus of claim 3 further comprising a spatial-orientation mechanism configured to orient the subassembly relative to the nozzle.

5. The additive manufacturing apparatus of claim 3, wherein the subassembly comprises at least one electromagnetic wave source.

6. The additive manufacturing apparatus of claim 5 wherein the electromagnetic wave source is coupled to the nozzle.

7. The additive manufacturing apparatus of claim 5, wherein the electromagnetic wave source is independent of the nozzle, such that the nozzle can move independently of the electromagnetic wave source during the buildup of an object to be fabricated.

8. The additive manufacturing apparatus of claim 7, wherein the subassembly further comprises fiber optic cables configured to transmit electromagnetic waves generated by the electromagnetic wave source to constituent material that is extruded through the nozzle.

9. The additive manufacturing apparatus of claim 7, wherein the subassembly further comprises optics for focusing electromagnetic waves generated by the electromagnetic wave source onto constituent material that is extruded through the nozzle.

10. The additive manufacturing apparatus of claim 2, wherein the at least one subassembly is at least two subassemblies.

11. The additive manufacturing apparatus of claim 10, wherein:

the at least two subassemblies are disposed about the perimeter of the nozzle; and

each of the at least two subassemblies is configured to begin the manipulation of the material properties in the same manner on different respective portions of constituent material that is extruded through the nozzle.

12. The additive manufacturing apparatus of claim 10, wherein each of the subassemblies is configured to begin the manipulation of the material properties on constituent material that is extruded through the nozzle in a manner differently than the other respective subassembly.

13. The additive manufacturing apparatus of claim 1, wherein:

the nozzle is configured to accommodate the extrusion of a constituent material that comprises at least two component materials; and

the subassembly is configured to begin the manipulation of the material properties of at least some portion of the constituent material by manipulating the composition of the cross-section of the constituent material as it is extruded through the nozzle.

14. The additive manufacturing apparatus of claim 13, wherein the subassembly is configured to manipulate the spatial positioning of a first component material relative to a second component material within a given cross-section of the constituent material as it is deposited on a surface.

15. The additive manufacturing apparatus of claim 14, wherein the subassembly comprises a channel that is configured to transmit the first component material for aggregation with the second component material to form the constituent material.

16. The additive manufacturing apparatus of claim 15, wherein the subassembly is configured to cause the aggregation of the first component material and the second component material prior to, or at the time of, the extrusion of the constituent material through the nozzle.

17. The additive manufacturing apparatus of claim 15, further comprising a spatial orienting mechanism configured to spatially orient the channel to thereby control the aggregation of the first component material and the second component material.

18. The additive manufacturing apparatus of claim 15, further comprising at least a second channel disposed proximate the first channel and configured to transmit the second component material, and a rotating mechanism for translating the first channel and second channel in a circular path such that the respective component materials that outflow from the respective channels can be controllably intertwined to thereby form the constituent material.

19. The additive manufacturing apparatus of claim 1, wherein the subassembly comprises a shutter assembly configured to control the dimensions of the cross-section of constituent material that is extruded through the nozzle.

20. A method of fabricating an object comprising:

progressively depositing constituent material onto a surface to form the shape of the object to be fabricated in accordance with an additive manufacturing process; and

manipulating the material properties of at least some portion of the constituent material that is deposited onto a surface such that at least some portion of the deposited constituent material possesses different material properties than at least some other portion of the deposited constituent material;

wherein manipulating the material properties of the at least some portion of the constituent material begins prior to, or concurrently with, its deposition onto a surface.

21. The method of claim 20 wherein:

progressively depositing the constituent material onto a surface comprises extruding the constituent material through a nozzle; and

manipulating the material properties of the at least some portion of the constituent material begins after the at least some portion of the constituent material is extruded through the nozzle.

22. The method of claim 21, wherein manipulating the material properties of the at least some portion of the constituent material comprises one of:

subjecting the at least some portion of the constituent material to electromagnetic waves;

magnetizing the at least some portion of the constituent material;

subjecting the at least some portion of the constituent material to a gas;

vibrating the at least some portion of the constituent material; and

heating the at least some portion of the constituent material.

23. The method of claim 22, wherein manipulating the material properties of the at least some portion of the constituent material comprises subjecting the at least some portion of the constituent material to electromagnetic waves.

24. The method of claim 23, wherein subjecting the at least some portion of the constituent material to electromagnetic waves comprises using fiber optic cables to transmit the electromagnetic waves from a wave source to the at least some portion of the constituent material.

25. The method of claim 23, wherein subjecting the at least some portion of the constituent material to electromagnetic waves comprises using optics to focus the electromagnetic waves onto the at least some portion of the constituent material.

26. The method of claim 20, further comprising manipulating the material properties of at least some portion of the constituent material that is deposited onto a surface in at least another way.

27. The method of claim 20, wherein:

the constituent material comprises at least two component materials; and

manipulating the material properties of the at least some portion of the constituent material comprises manipulating the composition of the cross-section of the constituent material that is deposited onto a surface.

28. The method of claim 27, wherein:

manipulating the composition of the cross-section of the constituent material that is deposited onto a surface comprises varying the aggregation of a first component material and at least a second component material.

29. The method of claim 28, wherein varying the aggregation of a first component material and at least a second component material comprises intertwining the first component material and at least the second component material as the constituent material is being deposited onto a surface.

30. The method of claim 20, wherein manipulating the material properties of the at least some portion of the constituent material comprises varying the cross-section of the constituent material that is deposited.