Model generation system having closed-loop extrusion nozzle positioning
First Claim
1. A system for fabricating a three-dimensional object in accordance with a specification of the object in three dimensions, comprising:
- means for extruding a self-supporting material;
means for controllably positioning the extruding means in accordance with the specification of the object in three dimensions; and
means, having an output coupled to the positioning means, for generating a feedback signal that is indicative of at least one characteristic of a previously extruded portion of the self-supporting material, whereinsaid positioning means is responsive to the feedback signal or determining at least a deviation of a location of the previously extruded portion of the material from an expected location that is specified by the specification of the object in three dimensions and for modifying, if required, further positioning of the extruding means to compensate for the deviation.
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Accused Products
Abstract
Apparatus and method for fabricating a three-dimensional object in accordance with a CAD-generated specification of the object. A closed-loop extrusion system (10) includes a nozzle (12) for extruding a material, such as a hot melt adhesive; apparatus (14, 18, 46) for controllably positioning the nozzle in accordance with the specification; and a sensor (60) for generating a feedback signal that is indicative of at least one characteristic of a most recently extruded portion of the material. Visual and non-visual feedback sensors may be employed, including optical sensors, infrared emission sensors, and proximity detection sensors. The specification of the object is converted to a bit-mapped representation thereof to improve accuracy relative to vector-based representations. Methods for determining a need for supporting structures and anti-aliasing features and for integrating the structures and features into the object specification are also disclosed.
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Citations
40 Claims
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1. A system for fabricating a three-dimensional object in accordance with a specification of the object in three dimensions, comprising:
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means for extruding a self-supporting material; means for controllably positioning the extruding means in accordance with the specification of the object in three dimensions; and means, having an output coupled to the positioning means, for generating a feedback signal that is indicative of at least one characteristic of a previously extruded portion of the self-supporting material, wherein said positioning means is responsive to the feedback signal or determining at least a deviation of a location of the previously extruded portion of the material from an expected location that is specified by the specification of the object in three dimensions and for modifying, if required, further positioning of the extruding means to compensate for the deviation. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 28, 34)
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17. A method for fabricating a three-dimensional object in accordance with a computer-generated specification of the object in three dimensions, comprising the steps of:
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controllably positioning an extruding means for extruding a self-supporting material in accordance with the specification of the object in three dimensions; generating a feedback signal that is indicative of at least a location of a previously extruded portion of the material; and responsive to the feedback signal, modifying, if required, further positioning of the extruding means to compensate for a deviation of the location from a location specified by the specification of the object in three dimensions. - View Dependent Claims (18, 19, 20)
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21. Apparatus for fabricating a three-dimensional object in accordance with a computer generated specification of the object in three dimensions, comprising:
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means for slicing the computer generated specification of the object in three dimensions into a plurality of horizontal layers; means for extruding a self-supporting material; means or controllably positioning the extruding means, in accordance with the sliced specification of the object in three dimensions, to sequentially fabricate the object layer by layer; and means for generating a feedback signal that is indicative of at least a location of a previously extruded portion of the self-supporting material, the feedback signal being coupled to the positioning means;
whereinthe positioning means is responsive to the feedback signal for modifying, if required, further positioning of the extruding means to compensate of a deviation of the location from a location specified by the specification of the object in three dimensions. - View Dependent Claims (22)
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23. Apparatus for fabricating a three-dimensional object in accordance with a computer generated specification of the object, comprising:
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means for slicing the computer generated specification into a plurality of horizontal layers; means for extruding a self-supporting material; means or controllably positioning the extruding means to sequentially fabricate the object layer by layer; and means for generating a feedback signal that is indicative of at least a location of a previously extruded portion of the self-supporting material, the feedback signal being coupled to the positioning means;
whereinthe positioning means is responsive to the feedback signal for modifying, if required, further positioning of the extruding means to compensate for a deviation of the location from a location specified by the specification, and wherein the positioning means is operable for positioning the extruding means at a previously extruded layer for extruding additional material at the previously extruded layer. - View Dependent Claims (24)
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25. A system for fabricating a three-dimensional object in accordance with a specification of the object, comprising:
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means for extruding a material; means for controllably positioning the extruding means in accordance with the specification of the object; and means, having an output coupled to the positioning means, for generating a feedback signal that is indicative of at least one characteristic of a most recently extruded portion of the material, wherein the generating means comprises imaging means, wherein the feedback signal is indicative of at least a location of the most recently extruded portion of the material, and wherein the imaging means is comprised of a Cassegrain optical system disposed for relaying an image of at least the most recently extruded portion of the material. - View Dependent Claims (26, 27)
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29. A system for fabricating a three-dimensional object in accordance with a specification of the object, comprising:
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means for extruding a material; means for controllably positioning the extruding means in accordance with the specification of the object; and means, having an output coupled to the positioning means, for generating a feedback signal that is indicative of at least one characteristic of a most recently extruded portion of the material, wherein the generating means comprises imaging means, wherein the feedback signal is indicative of at least a location of the most recently extruded portion of the material, and wherein the imaging means is comprises of a confocal line camera system disposed for imaging at least the most recently extruded portion of the material. - View Dependent Claims (30, 31, 32)
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33. A system for fabricating a three-dimensional object in accordance with a specification of the object, comprising:
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means for extruding a material; means for controllably positioning the extruding means in accordance with the specification of he object; and means, having an output coupled to the positioning means, for generating a feedback signal that is indicative of at least one characteristic of a most recently extruded portion of the material, wherein the generating means comprises infrared emission imaging means, and wherein the feedback signal is indicative of a location of the most recently extruded portion of the material and also a temperature of the most recently extruded portion of the material. - View Dependent Claims (35, 36)
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37. A system for fabricating a three-dimensional object in accordance with a specification of the object in three dimensions, comprising:
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means having at least one orifice for extruding a self-supporting material; means for controllably positioning the extruding means in accordance with the specification of the object in three dimensions; and means, having an output coupled to the positioning means, for generating a feedback signal that is indicative of at least one characteristic of a previously extruded portion of the material, wherein the generating means comprises at least one source of electromagnetic radiation for illuminating a region in the vicinity of the at least one orifice, means for detecting a potion of the electromagnetic radiation that results from an illumination of a surface of the self-supporting material that has been extruded from the at least one orifice, and means, responsive to a signal output by said detecting means, for providing to said positioning means information that indicates a location of the self-supporting material that has been extruded rom the at least one orifice; and
whereinsaid positioning means is responsive to the information for modifying, if required, further positioning of the extruding means to compensate for a deviation of the location of the self-supporting material from an expected location that is specified by the specification of the object in three dimensions. - View Dependent Claims (38, 39, 40)
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Specification