Solid freeform fabrication methods
First Claim
Patent Images
1. A process for making a three-dimensional article, comprising the steps of:
- providing a mixture of a particulate composition dispersed in a binder;
feeding said mixture to a dispensing apparatus;
dispensing said mixture from said dispensing apparatus onto a build platform;
during said dispensing step, moving said dispensing apparatus and said build platform relative to one another in a plane defined by first and second directions and in a third direction orthogonal to said plane to form said mixture into a three-dimensional article; and
removing at least a portion of said binder from said article.
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Abstract
A fused deposition process is used to form three-dimensional solid objects from a mixture including a particulate composition dispersed in a binder. The article is formed by depositing the mixture in repeated layers of predefined thickness, with each layer solidifying before the next adjacent layer is dispensed. Following formation and a binder removal step, the article may be at least partially densified to achieve preselected properties. The process permits three-dimensional articles to be formed relatively quickly and inexpensively, without the need for molds or other tooling.
376 Citations
33 Claims
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1. A process for making a three-dimensional article, comprising the steps of:
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providing a mixture of a particulate composition dispersed in a binder; feeding said mixture to a dispensing apparatus; dispensing said mixture from said dispensing apparatus onto a build platform; during said dispensing step, moving said dispensing apparatus and said build platform relative to one another in a plane defined by first and second directions and in a third direction orthogonal to said plane to form said mixture into a three-dimensional article; and removing at least a portion of said binder from said article. - 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, 25, 26)
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27. A process for making a three-dimensional article, comprising in the steps of:
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creating an image of said three-dimensional article on a computer, said image including a plurality of segments defining said article; generating program signals corresponding to each of said segments in a predetermined sequence; providing a mixture of a particulate composition dispersed in a binder; feeding said mixture to a dispensing apparatus; dispensing said mixture in a flowable fluid state from said dispensing apparatus onto a build platform; during said dispensing step, moving said dispensing apparatus and said build platform in response to said programmed signals relative to one another in a plane defined by first and second directions and in a third direction orthogonal to said plane in a predetermined sequence of movements such that said mixture is dispensed in free space as a plurality of segments sequentially formed so that the last dispensed segment overlies at least a portion of the preceding segment in contact therewith to thereby form said three-dimensional article; and removing at least a portion of said binder from said article. - View Dependent Claims (28)
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29. A process for making a three-dimensional article, comprising the steps of:
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providing a mixture of a particulate composition dispersed in a binder; feeding said mixture to a dispensing apparatus; dispensing said mixture from said dispensing apparatus onto a build platform; during said dispensing step, moving said dispensing apparatus and said build platform relative to one another in a plane defined by first and second directions and in a third direction orthogonal to said plane to form said mixture into a three-dimensional article; removing at least a portion of said binder from said article by heating said article to a first temperature according to a predetermined heating cycle; and heating said article to a second temperature greater than said first temperature to at least partially bond said particulate composition together.
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30. A process for making a three-dimensional article, comprising of steps of:
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providing a first mixture of one particulate composition dispersed in a binder; providing a second mixture of another particulate composition dispersed in a binder, said second mixture being different than said first mixture; feeding said first and second mixtures to a least one dispensing apparatus; dispensing said first and second mixtures from said at least one dispensing apparatus onto a build platform; during said dispensing step, moving said at least one dispensing apparatus and said build platform relative to one another in a plane defined by first and second directions and in a third direction orthogonal to said plane to form said first and second mixtures into a three-dimensional article, wherein said first and second mixtures are dispensed in preselected regions of said article; and removing at least a portion of said binder from said article. - View Dependent Claims (31, 32, 33)
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Specification