Modeling apparatus for three-dimensional objects
First Claim
1. Apparatus for making three-dimensional physical objects of a predetermined shape by sequentially depositing multiple layers of solidifying material on a base member in a desired pattern, comprising:
- a moveable dispensing head having an elongated material passage therein connected to a dispensing outlet at one end thereof, and having an oppositely disposed material receiving end;
a supply of material comprising a continuous flexible strand which solidifies at a predetermined temperature, and a material advance mechanism positioned to advance the strand into the elongated material passage on the head;
a base member disposed in close, working proximity to said dispensing outlet of said dispensing head;
mechanical means for moving said dispensing head and said base member relative to each other in multiple dimensions in a predetermined sequence and pattern;
means for metering the discharge of said material in a fluid state from said dispensing outlet at a predetermined rate onto said base member to form a three-dimensional object as said dispensing head and base member are moved relative to each other;
heating means in heat exchange relation to said dispensing head for heating said strand material to a temperature above its solidification temperature in said material passage wherein said material is in a fluid state; and
a heat insulating seal ring positioned on said dispensing head in surrounding, sealing relation to the material receiving end of said material passage, said seal ring having an aperture therethrough in alignment with the material passage in the head, said aperture and said material passage being of a predetermined diameter to provide an annular clearance space around a strand of supply material directed therethrough by the material advance mechanism, whereby the seal ring will be at a lower temperature than the heated head, and fluid supply material flowing into the annual clearance space around the advancing strand of material will cool and solidify within the seal ring annular clearance space to form a fluid seal therein.
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Accused Products
Abstract
Apparatus incorporating a movable dispensing head provided with a supply of material which solidifies at a predetermined temperature, and a base member, which are moved relative to each other along multiple axes in a predetermined pattern to create three-dimensional objects by building up material discharged from the dispensing head onto the base member at a controlled rate. The apparatus is preferably computer driven in a process utilizing computer aided design (CAD) and computer-aided (CAM) software to generate drive signals for controlled movement of the dispensing head and base member as material is being dispensed.
Three-dimensional objects may be produced by depositing repeated layers of solidifying material until the shape is formed. Any material, such as self-hardening waxes, thermoplastic resins, molten metals, two-part epoxies, foaming plastics, and glass, which adheres to the previous layer with an adequate bond upon solidification, may be utilized. Each layer base is defined by the previous layer, and each layer thickness is defined and closely controlled by the height at which the tip of the dispensing head is positioned above the preceding layer.
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Citations
16 Claims
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1. Apparatus for making three-dimensional physical objects of a predetermined shape by sequentially depositing multiple layers of solidifying material on a base member in a desired pattern, comprising:
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a moveable dispensing head having an elongated material passage therein connected to a dispensing outlet at one end thereof, and having an oppositely disposed material receiving end; a supply of material comprising a continuous flexible strand which solidifies at a predetermined temperature, and a material advance mechanism positioned to advance the strand into the elongated material passage on the head; a base member disposed in close, working proximity to said dispensing outlet of said dispensing head; mechanical means for moving said dispensing head and said base member relative to each other in multiple dimensions in a predetermined sequence and pattern; means for metering the discharge of said material in a fluid state from said dispensing outlet at a predetermined rate onto said base member to form a three-dimensional object as said dispensing head and base member are moved relative to each other; heating means in heat exchange relation to said dispensing head for heating said strand material to a temperature above its solidification temperature in said material passage wherein said material is in a fluid state; and a heat insulating seal ring positioned on said dispensing head in surrounding, sealing relation to the material receiving end of said material passage, said seal ring having an aperture therethrough in alignment with the material passage in the head, said aperture and said material passage being of a predetermined diameter to provide an annular clearance space around a strand of supply material directed therethrough by the material advance mechanism, whereby the seal ring will be at a lower temperature than the heated head, and fluid supply material flowing into the annual clearance space around the advancing strand of material will cool and solidify within the seal ring annular clearance space to form a fluid seal therein. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. Apparatus for making three-dimensional physical objects of a predetermined shape by sequentially depositing multiple layers of solidifying material on a base member in a desired pattern, comprising:
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a moveable dispensing head having an elongated material passage therein connected to a dispensing outlet at one end thereof, and having an oppositely disposed material receiving end; a supply of material comprising a continuous flexible strand in the form of a hollow tube which solidifies at a predetermined temperature within 2°
C. of its melting point, and a material advance mechanism positioned to advance the strand into the elongated material passage on the head;a base member disposed in close, working proximity to said dispensing outlet of said dispensing head; mechanical means for moving said dispensing head and said base member relative to each other in multiple dimensions in a predetermined sequence and pattern; means for metering the discharge of said material in a fluid state from said dispensing outlet at a predetermined rate onto said base member to form a three-dimensional object as said dispensing head and base member are moved relative to each other; heating means in heat exchange relation to said dispensing head for heating said strand material to a temperature above its solidification temperature in said material passage wherein said material is in a fluid state. - View Dependent Claims (14, 15)
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16. Apparatus for making three-dimensional physical objects of a predetermined shape by sequentially depositing multiple layers of solidifying material on a base member in a desired pattern, comprising:
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a moveable dispensing head having an elongated material passage therein connected to a dispensing outlet at one end thereof, and having an oppositely disposed material receiving end; a supply of material comprising a continuous flexible strand which solidifies at a predetermined temperature, and a material advance mechanism positioned to advance the strand into the elongated material passage on the head; a base member disposed in close, working proximity to said dispensing outlet of said dispensing head; mechanical means for moving said dispensing head and said base member relative to each other in multiple dimensions in a predetermined sequence and pattern; means for metering the discharge of said material in a fluid state from said dispensing outlet at a predetermined rate onto said base member to form a three-dimensional object as said dispensing head and base member are moved relative to each other; heating means in heat exchange relation to said dispensing head for heating said strand material to a temperature above its solidification temperature in said material passage wherein said material is in a fluid state; and a substrate positioned on said base member to receive material in a fluid state from said dispensing outlet, said substrate comprising a foam plastic material of open cellular construction.
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Specification