Process of and apparatus for making a three-dimensional article
First Claim
1. An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising:
- a base;
processor means for defining a mold skin for producing a mold for the three-dimensional article based upon the article defining data;
build material dispensing means for dispensing build material responsive to said processor means to construct the mold skin extending outwardly from said base and defining at least one cavity;
said base comprising penetrable surface defining means for being penetrated to introduce a solidifiable fill material into the at least one cavity;
filling means for penetrating said penetrable surface defining means of said base and introducing solidifiable fill material into the at least one cavity to form solid mold portions;
separating means for separating the solid mold portions from the mold skin; and
molding means for using the solid mold portions to form the three-dimensional article.
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Accused Products
Abstract
An apparatus for making a three-dimensional article based upon article defining data may be used to make a mold for the article and molding the article from the mold. Alternately, the apparatus may be used to make articles having filled or solid portions. The apparatus preferably includes a base, a processor for defining a mold skin for producing a mold for the three-dimensional article, and a build material dispenser for dispensing build material responsive to the processor to construct the mold skin extending outwardly from the base and defining at least one cavity. Solidifiable fill material is introduced into the cavity to form solid mold portions. The solid mold portions may be separated from the mold skin, and injection molding, for example, used to mold the three-dimensional article. The base preferably includes a thin plastic layer which is penetrable to permit introduction of the solidifiable fill material into the cavity.
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Citations
70 Claims
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1. An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising:
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a base; processor means for defining a mold skin for producing a mold for the three-dimensional article based upon the article defining data; build material dispensing means for dispensing build material responsive to said processor means to construct the mold skin extending outwardly from said base and defining at least one cavity; said base comprising penetrable surface defining means for being penetrated to introduce a solidifiable fill material into the at least one cavity; filling means for penetrating said penetrable surface defining means of said base and introducing solidifiable fill material into the at least one cavity to form solid mold portions; separating means for separating the solid mold portions from the mold skin; and molding means for using the solid mold portions to form the three-dimensional article. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising:
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a base; build material dispensing means for dispensing build material based upon the article defining data to construct wall portions extending outwardly from said base and defining at least one cavity; said base comprising penetrable surface defining means for being penetrated to introduce fill material into the at least one cavity; and filling means for introducing solidifiable fill material into the at least one cavity so that solidified fill material defines at least a portion of the three-dimensional article or defines at least one mold portion for facilitating molding of the three-dimensional article. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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26. An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising:
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a base; build material dispensing means for dispensing build material based upon the article defining data to construct a mold skin extending outwardly from said base and defining at least one cavity; filling means for introducing solidifiable fill material into the at least one cavity to form solid mold portions; and molding means for using the solid mold portions to form the three-dimensional article. - View Dependent Claims (27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37)
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38. An apparatus for making a mold comprising:
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a base; build material dispensing means for dispensing build material to construct a mold skin extending outwardly from said base and defining at least one cavity; filling means for introducing solidifiable fill material into the at least one cavity to form solid mold portions; and separating means for separating the solid mold portions from the mold skin. - View Dependent Claims (39, 40, 41, 42, 43, 44, 45, 46, 47)
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48. A method for making a three-dimensional article based upon article defining data, the method comprising the steps of:
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providing a base having a penetrable surface; dispensing build material based upon the article defining data to construct wall portions extending outwardly from the base and defining at least one cavity; and penetrating the penetrable surface of the base and introducing fill material therethrough and into the at least one cavity so that the fill material defines at least a portion of the three-dimensional article or defines at least one mold portion for facilitating molding of the three-dimensional article. - View Dependent Claims (49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59)
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60. A method for making a three-dimensional article based upon article defining data, the method comprising the steps of:
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providing a base; dispensing build material based upon article defining data to construct a mold skin extending outwardly from the base and defining at least one cavity; introducing solidifiable fill material into the at least one cavity to form solid mold portions; and molding the three-dimensional article using the solid mold portions. - View Dependent Claims (61, 62, 63, 64, 65, 66, 67, 68, 69, 70)
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Specification