Method and apparatus for solid prototyping
First Claim
1. Apparatus for making a three-dimensional physical object by sequentially depositing, in a pattern, multiple layers of a solidifiable material on a support member, said apparatus comprising:
- nozzle means for providing an extruded material;
pump means having an input and an output, said output in fluid communication with said nozzle means and providing a pressurized flow of said solidifiable material in a fluid state to said nozzle means;
motive means coupled to said pump means for enabling said pump means to provide a variable level of pressurization and rate of flow of said solidifiable material to said nozzle means; and
a pressurization stage having an outlet coupled to said inlet of said pump means, for providing to said inlet said solidifiable material in a fluid state and at a determined pressure which assures, for all operational levels of pressurization and rates of flow in said pump means, that a continuous quantity of said solidifiable material is available at said inlet for continuous operation of said pump means, assuring an uninterrupted flow of said solidifiable material to and through said nozzle means, said solidifiable material supplied to said pressurization stage as a solid, said pressurization stage including;
a conduit for receiving said solid and for applying heat thereto to convert said solid to a fluid state of said solidifiable material; and
drive means for physically impelling said solid into said conduit so as to pressurize said fluid state of said solidifiable material to said determined pressure.
1 Assignment
0 Petitions
Accused Products
Abstract
An improved extrusion-based manufacturing system includes one or more extruders, with each extruder containing at least two stages of increasing pressurization. In a preferred embodiment, a first stage of pressurization is created by the motion of a solid wafer of thermoplastic through an orifice into a heater chamber. In another preferred embodiment, the wafers are stored in removable, electronically tagged, cassettes and are removed therefrom by a stapler mechanism which feeds the wafers from the cassette to a tractor feed mechanism on demand. In each embodiment, a second stage of pressurization is provided by a pump, with the first stage pressurization maintaining a flow of thermoplastic to the pump under all expected pump rates.
-
Citations
16 Claims
-
1. Apparatus for making a three-dimensional physical object by sequentially depositing, in a pattern, multiple layers of a solidifiable material on a support member, said apparatus comprising:
-
nozzle means for providing an extruded material; pump means having an input and an output, said output in fluid communication with said nozzle means and providing a pressurized flow of said solidifiable material in a fluid state to said nozzle means; motive means coupled to said pump means for enabling said pump means to provide a variable level of pressurization and rate of flow of said solidifiable material to said nozzle means; and a pressurization stage having an outlet coupled to said inlet of said pump means, for providing to said inlet said solidifiable material in a fluid state and at a determined pressure which assures, for all operational levels of pressurization and rates of flow in said pump means, that a continuous quantity of said solidifiable material is available at said inlet for continuous operation of said pump means, assuring an uninterrupted flow of said solidifiable material to and through said nozzle means, said solidifiable material supplied to said pressurization stage as a solid, said pressurization stage including; a conduit for receiving said solid and for applying heat thereto to convert said solid to a fluid state of said solidifiable material; and drive means for physically impelling said solid into said conduit so as to pressurize said fluid state of said solidifiable material to said determined pressure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
-
-
12. An apparatus for providing wafers of solidifiable material to an extruder, comprising:
-
removable cassette means for holding a plurality of said wafers; a holder for receiving a cassette means; and means for removing individual wafers from said cassette means and for causing said wafers to pass to said extruder. - View Dependent Claims (13, 14, 15)
-
-
16. A method for making a three-dimensional physical object by sequentially depositing, in a pattern, multiple layers of a solidifiable material on a support member, said method employing apparatus which includes a nozzle means for providing an extruded material, pump means having an input and an output, said output in fluid communication with said nozzle means and providing a pressurized flow of said solidifiable material in a fluid state to said nozzle means, motive means for enabling said pump means to provide a variable level of pressurization and rate of flow of said solidifiable material to said nozzle means and a pressurization stage having an outlet coupled to said inlet of said pump means, for providing to said inlet said solidifiable material in a fluid state, said method comprising the steps of:
-
controlling said motive means to cause said pump means to provide a continuous flow of said solidifiable material to said nozzle means; and feeding a solid form of said solidifiable material to said pressurization stage at a rate and with an amount of force which assures that a determined pressure is created in said pressurization means which further assures, for all operational levels of pressurization and rates of flow created by operation of said pump means, that a continuous quantity of said solidifiable material is available at said inlet for continuous operation of said pump means, thereby assuring an uninterrupted flow of said solidifiable material to and through said nozzle means.
-
Specification