REMOVE AND REFILL METHOD AND APPARATUS FOR LAMINATED OBJECT MANUFACTURING
First Claim
1. A method of forming an integral three-dimensional object from sheet laminations, comprising:
- providing a length of film;
providing forming means for defining the shape of consecutive layers of the three dimensional object by dividing the film into regions that constitute the layers of the object and the surrounding regions intended for removal;
providing connecting means for maintaining physical connection between separate regions constituting the formed layers prior to their attachment to each other, so that the unconnected portions of the layers remain in registration to one another after the material surrounding them has been removed;
providing removing means for removing waste portions the film that do not belong to the layers of the three-dimensional object;
providing stacking means for stacking the formed layers to each other;
providing alignment means for alignment the layers in precise registration to each other while they are being stacked;
providing bonding means for bonding the stacked layers to each other;
applying forming means to the consecutive layers of the three-dimensional object distributed both along the film material and across it, while maintaining the connection between separate regions of the formed layers by the connecting means;
applying removing means for removing portions of the film surrounding the formed layers of the object;
adding one or several formed layers to the stack by applying the stacking means, the alignment means and the bonding means; and
chemically dissolving or mechanically removing the connecting means after one or several layers have been attached to the stack.
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Accused Products
Abstract
An apparatus and method of manufacture for an integral three-dimensional object of unlimited complexity formed from individually contoured laminations (layers) produced from thin sheet materials that are stabilized on a removable carrier and formed both along and across the sheet material prior to stacking the contoured laminations in precise registration to one another. The waste material surrounding the laminations and the carrier is separated from the desired object. An optional method includes refilling the space surrounding the layers with another material and leveling the upper surface of the laminations. The process of forming the contoured laminations, separating the waste material, bonding, and stacking is continued until the construction of the desired three-dimensional object is complete.
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Citations
32 Claims
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1. A method of forming an integral three-dimensional object from sheet laminations, comprising:
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providing a length of film; providing forming means for defining the shape of consecutive layers of the three dimensional object by dividing the film into regions that constitute the layers of the object and the surrounding regions intended for removal; providing connecting means for maintaining physical connection between separate regions constituting the formed layers prior to their attachment to each other, so that the unconnected portions of the layers remain in registration to one another after the material surrounding them has been removed; providing removing means for removing waste portions the film that do not belong to the layers of the three-dimensional object; providing stacking means for stacking the formed layers to each other; providing alignment means for alignment the layers in precise registration to each other while they are being stacked; providing bonding means for bonding the stacked layers to each other; applying forming means to the consecutive layers of the three-dimensional object distributed both along the film material and across it, while maintaining the connection between separate regions of the formed layers by the connecting means; applying removing means for removing portions of the film surrounding the formed layers of the object; adding one or several formed layers to the stack by applying the stacking means, the alignment means and the bonding means; and chemically dissolving or mechanically removing the connecting means after one or several layers have been attached to the stack. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. An apparatus for forming an integral three-dimensional object from sheet laminations, comprising:
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means for moving a length of film stabilized on a conveyor or a removable carrier; means for forming an array of layers of the three-dimensional object out of the film distributed both along the film and across the film; means for removing individual layers from the carrier or the conveyor, means for stacking and bonding the layers in precise registration to one another; and means for insuring that the stacked laminations are in precise alignment with one another. - View Dependent Claims (26, 27, 28, 29, 30, 31)
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32. An apparatus for forming an integral object from sheet laminations, comprising:
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a layer-forming station that forms individual layers of a three-dimensional in an array distributed along and across a film removably attached to a carrier ribbon or carried by a conveyor; and a stacking station where the individual layers are assembled in precise registration to one another.
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Specification