System and method for computer automated manufacture with reduced object shape distortion

• US 5,216,616 A
• Filed: 12/01/1989
• Issued: 06/01/1993
• Est. Priority Date: 06/26/1989
• Status: Expired due to Term

• Current Assignee: Kristina King
• Original Assignee: BPM Technology, Inc.
• Inventors: Masters, William E.
• Primary Examiner(s): Smith, Jerry
• Assistant Examiner(s): TRAMMELL, JAMES P
• Application Number:
  US07/444,529
• Time in Patent Office: 1,278 Days
• Field of Search: 364/474.24, 364/468-469, 364/473, 364/477, 156/379.6, 156/59, 156/272.8, 156/244.11, 264/22, 264/308, 264/309, 264/211.13, 264/211.12, 264/219, 219/121.73, 425/162, 425/174, 425/174.4, 365/119, 365/111
• US Class Current: 264/401
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 35/08 by wave energy or particle radiation B29C64/00, B29C71/04 take precedence
• CPC Class Codes: B29C 39/42 Casting under special conditions, e.g. vacuum
• CPC Class Codes: B29C 41/36 Feeding the material on to the mould, core or other substrate
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2105/0002 monomers or prepolymers
• CPC Class Codes: B29L 2031/40 Test specimens ; Models, e.g. model cars mannequins B29L2031/7028; Probes
• CPC Class Codes: B29L 2031/757 Moulds, cores, dies
• CPC Class Codes: B33Y 40/20 Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/49015 Wire, strang laying, deposit fluid, welding, adhesive, hardening, solidification, fuse
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A system and method for producing a three-dimensional object (10, 70) from coordinates generated on a computer machine (12) is disclosed wherein the object has improved dimensional accuracy. Control signals (20b) are generated for controlling a servo (20) that controls a reaction or interaction of material (20a) at the coordinate points to form the object while a second servo (22) serves to build up a three-dimensional support system (42) in response to support control signals (22b). Support control signals (22b) are generated at the same time the coordinate points of the design are generated to specify strategic points of the object at which a support environment need be placed in order to insure the dimensional accuracy of the object avoiding warpage or other dimensional distortion. As a support environment, a series of webs (50, 52, 54) or columns (76), or encapsulation (44, 92) may be provided for providing a support environment for the object.

Claims

1. A method of producing a three-dimensional object from a three-dimensional design generated on a computer machine wherein said object is dimensionally accurate, said object having at least a portion which includes a hollow interior, said method comprising the steps of:

generating control signals specifying coordinate points of said there-dimensional object in a prescribed coordinate system;

providing an object material from which said object is formed;

providing a support material;

controlling a reaction of said object material at said coordinate points in response to said control signals to form said object in said coordinate system;

dispensing said support material at least within said hollow interior;

simultaneously forming a three-dimensional structural support environment from said support material which physically supports said object in situ as said object is being formed; and

wherein one of said object material and said support material is dispensed as mass particles while the other is dispensed as a fluent strand.

2. The method of claim 1 including forming said support environment by encapsulating said object with said support material as said object is being formed.

3. The method of claim 2 including forming said object in a chamber, and forming said support environment with said chamber by surrounding said object with said support material in said chamber.

4. The method of claim 1 including forming said support environment by surrounding an exterior of said object with said support material while filling said interior of said object with said support material.

5. The method of claim 1 including forming said support environment by forming thin support webs which contact said object at spaced support points.

6. The method of claim 1 including forming said support environment by forming separate columns which support said object at said support points.

7. The method of claim 1 including forming said support environment by supporting said object with a web extending between plural support points on said objects.

8. The method of claim 1 including:

generating support control signals specifying coordinate support points which correspond to coordinate points for physically supporting said object while it is being formed to reduce warpage and the like of said object; and

forming said three-dimensional support environment in response to said support control signals for physically supporting said object at said support points while forming said object.

9. The method of claim 1 including forming said support environment by the steps of:

generating support coordinate points at which it is desired to support said object;

controlling a working head for directing movement of mass particles of said support material to said support coordinate points;

controlling said working head in response to said support control signals for directing said mass particles to said support points; and

joining said mass particles with one another at said coordinate points to form said support environment.

10. The method of claim 1 including:

generating support coordinate points at which it is desired to support said object as it is formed for accurate formation;

forming said support environment at said support coordinate points by dispensing a fluent material in a fluent state in response to said support control signals and treating said fluent material after dispensing in controlled relation to said dispensing of said material which set said fluent material in a fixed physical state to support said object during formation.

11. A system for producing a three-dimensional object from a three-dimensional design generated on a computer machine having improved dimensional accuracy, said object having at least a portion which includes a hollow interior, said system comprising:

means for generating control signals specifying coordinate points of said three-dimensional object;

a source of object material from which said object is formed;

control means receiving said control signals for controlling a reaction of said object material at said coordinate points to form said object in three dimensions form said object material in response to said first control signals;

a source of support material;

dispensing means disposed in spaced proximity relative to said object for depositing said support material from said dispensing means to said object being formed; and

support control means for controlling said dispensing means to form a three-dimensional structural support environment physically supporting said object including said hollow interior in situ as said object is being formed, said structural support environment including plural webs supporting said object at plural support points and wherein said webs include tapered edges contacting said object facilitating separation of said web and object.

12. A method for producing a three-dimensional object which ash been designed on a computer machine of the type which comprises generating control signals specifying three-dimensional coordinate points of said object in a prescribed coordinate system, said method comprising the steps of:

providing a source of object material from which said object is formed;

directing quantities of said object material to said three-dimensional coordinate points in response to said control signals to form said object by building said object material upon itself by dispensing a strand of object material in a fluent state in response to said control signals and treating said material after dispensing in controlled relation to said dispensing of said material and subjecting said material to a transition to a fixed physical state in which said material is set in a form of a three-dimensional object;

providing a source of support material, dispensing and directing said support material from above a plane in which said object is being formed toward said object, independently but in controlled relation to said object material; and

simultaneously forming a three-dimensional support structure from said support material which physically supports said object in situ during formation of said object.

13. A process for automatically manufacturing a three-dimensional object which has been designed on a computer machine comprising:

generating control signals specifying the coordinate points of said three dimensional design generated by said computer machine;

dispensing a strand of material in a fluent physical state in response to said control signals;

treating said strand of material generally simultaneously as it is dispensed in controlled relation to said dispensing of said fluid material to cause said material to undergo a transition to a fixed, physical state in which said material is set in a form of said three dimensional object; and

simultaneously forming a three-dimensional structural support environment which physically supports said object in situ during formation of said object to reduce warpage and dimensional distortion of said object.

14. The process of claim 13 dispensing said strand of material while supported on a base means;

and

indexing the relative positions of said dispensing means and base means so that strands are caused to build upon one another to construct said three dimensional object.

15. The process of claim 13 including dispensing said material by extruding a generally continuous strand of said material.

16. The process of claim 13 including treating said dispensed material by focusing a beam of radiation upon said fluid material after said material is dispensed to solidify said material.

17. The process of claim 16 including shielding said dispensing means from said energy beam in a controlled manner so that said energy beam acts upon said fluid material at a prescribed position, intensity, and time so as to cause said material to solidify and accurately construct said three dimensional object.

18. A system for producing a three-dimensional object from a three-dimensional design generated on a computer machine having improved dimensional accuracy comprising:

means for generating control signals specifying the three-dimensional coordinate points of said object in a prescribed coordinate system;

a source of object material from which said object is formed;

at least one working head for directing said object material from said working head to said coordinate points;

control means for controlling said working head to direct said object material to said three-dimensional coordinate points in response to said control signals to form said object;

a source of support material;

support material dispensing means disposed in spaced proximity above said object being formed for dispensing said support material about said object so as to form a three-dimensional structural support environment constructed about said object as said object is being formed for physically supporting said object during formation; and

wherein one of said working head and said support material dispensing means includes means for dispensing material as mass particles while the other of said working head and said support material dispensing means includes means for dispensing material as a fluent strand.

19. The system of claim 18 including a chamber in which said object is formed, a source of support material, and wherein said support environment includes said support material encapsulating said object in said chamber.

20. The system of claim 19 wherein said support environment includes said support material surrounding an exterior of said object and occupying at least a hollow interior of said object

21. The system of claim 18 wherein said support environment includes at least one web extending between spaced support points on said object.

22. The system of claim 18 wherein said support environment includes at least one column supporting said object at a support point.

23. The system of claim 18 wherein said support environment includes plural webs supporting said object at plural support points.

24. The system of claim 23 wherein said webs include tapered edges contacting said object facilitating separation of said web and object.

25. The system of claim 18 wherein said working head directs a plurality of mass particles to said coordinate points.

26. The system of claim 18 wherein said working head dispenses a continuous strand of fluent object material to form said object, and including treatment means for treating said fluid material as it is dispensed to set said material in the form of said object.