Method of incremental layered object fabrication
First Claim
1. A method of forming an object from incremental layers of object material, the method comprising the steps of:
- providing x, y and z dimensions of the object in a machine-readable format;
forming a layer of mold material on a datum surface, the layer of mold material defining at least a portion of the x and y dimensions of the object;
a) forming a layer of the object material over the layer of mold material, wherein the layer of object material assumes the dimensions defined by the layer of mold material;
b) forming another layer of mold material on the first layers of mold and object material, said another layer of mold material defining further dimensions of the object; and
repeating steps a) and b) until the object is fully formed.
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Accused Products
Abstract
The dimensional boundaries of a part are determined in a computer CAD/CAM system, including x, y, and z dimensions. A reference surface is provided and a first incremental layer of mold material is formed on the reference surface. The first incremental layer of mold material is selectively interrupted to define at least one dimensional boundary of the object. A first incremental layer of object material is formed upon at least the reference surface and assumes the dimensions defined by the interruption in the layer of mold material. The steps of forming incremental layers of mold and object material are repeated until the object or part is fully fabricated and all dimensional boundaries are defined.
68 Citations
82 Claims
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1. A method of forming an object from incremental layers of object material, the method comprising the steps of:
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providing x, y and z dimensions of the object in a machine-readable format; forming a layer of mold material on a datum surface, the layer of mold material defining at least a portion of the x and y dimensions of the object; a) forming a layer of the object material over the layer of mold material, wherein the layer of object material assumes the dimensions defined by the layer of mold material; b) forming another layer of mold material on the first layers of mold and object material, said another layer of mold material defining further dimensions of the object; and repeating steps a) and b) until the object is fully formed. - 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)
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26. A method of forming an object from incremental layers of object material, the method comprising the steps of:
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providing x, y and z dimensions of the object in a machine-readable format in a computer system; depositing a layer of mold material on a datum surface, the layer of mold material defining at least a portion of the x and y dimensions of the object; electroforming a layer of object material over the layer of mold material, wherein the layer of object material assumes the dimensions of the object defined by the layer of mold material; depositing another layer of mold material on the first layers of mold and object material, said another layer of mold material defining further x and y dimensions of the object; continuing to deposit and electroforming layers of mold and object material until the object is fully formed; and at least partially removing the layers of mold material from the fully formed object. - View Dependent Claims (27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40)
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41. A method of forming an object from incremental layers of object material, the method comprising the steps of:
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providing x, y, and z dimensions of the object in a machine-readable format; forming a layer of mold material from an array of dispensing jets, wherein the layer of mold material defines at least x and y dimensions of the object; forming a layer of object material over and on the layer of mold material, wherein the layer of object material at least partially assumes the dimensions defined by the layer of mold material; and repeating the steps of forming layers of mold and object material until the object is fully formed of layers of object material. - View Dependent Claims (42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59)
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60. A method of forming an object from incremental layers of object material, the method comprising the steps of:
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providing x, y, and z dimensions of the object in a machine-readable format; utilizing the x, y, and z dimensions to control relative movement between a deposition apparatus and a platform; depositing mold material onto the platform from the deposition apparatus, wherein the mold material defines at least x and y dimensions of the object; forming a layer of object material over and on the mold material, wherein the layer of object material at least partially assumes the dimensions defined by the layer of mold material; repeating the steps of depositing mold material and forming object material until the object is fully formed of layers of object material; and at least partially removing the layers of mold material from the fully formed object. - View Dependent Claims (61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82)
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Specification