Rapid prototyping

• US 6,153,034 A
• Filed: 08/03/1998
• Issued: 11/28/2000
• Est. Priority Date: 08/03/1997
• Status: Expired due to Fees

• Current Assignee: Micromod RP Limited
• Original Assignee: Micromod RP Limited
• Inventors: Lipsker, Daniel
• Primary Examiner(s): SELLS, JAMES D
• Application Number:
  US09/128,100
• Time in Patent Office: 848 Days
• Field of Search: 156/73.1, 156/73.2, 156/250, 156/256, 156/510, 156/580.1, 156/580.2, 156/166, 156/167
• US Class Current: 156/73.1
• CPC Class Codes: B29C 41/36 Feeding the material on to the mould, core or other substrate
• CPC Class Codes: B29C 64/141 using only solid materials
• CPC Class Codes: B29C 64/147 using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29K 2105/0097 Glues or adhesives, e.g. hot melts or thermofusible adhesives
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: Y10T 156/12 Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing

Abstract

Rapid prototype apparatus including an adhesive dispenser for dispensing an adhesive and an actuator which moves the adhesive dispenser in at least one of six degrees of freedom (preferably in at least four degrees of freedom, and most preferably in six degrees of freedom) in accordance with a geometry of an object. The adhesive dispenser then dispenses the adhesive in accordance with the geometry of the object, applying successive layers of adhesive one on top of the previous layer. The adhesive layers cure and bond to each other, thus forming a prototype of the object.

Claims

1. A method for producing a prototype of an object, comprising:

dispensing layers of a wire in at least four degrees of freedom in accordance with a geometry of the object; and

bonding a previously dispensed portion of the wire to a presently dispensed portion of the wire with adhesive, said adhesive being formed of a material which is different and distinct from said wire.

2. A method according to claim 1 and comprising curing the adhesive so that the layers of the wire form a prototype of the object.

3. A method according to claim 2 wherein the adhesive at least partially covers a perimeter of the wire.

4. A method according to claim 1 wherein the adhesive is selected from the group consisting of:

quick curing adhesives, cyanoacrylates, ultraviolet curable adhesives, thermocurable adhesives, epoxies, animal glues, vegetable glues, lacquers, polymers, monomers, self-adhesive materials, double-sided adhesives, single side adhesives, and hot glues.

5. A method according to claim 1 wherein said bonding further comprises ultrasonic welding.

6. A method according to claim 1 wherein the wire is selected from the group consisting of:

metals, plastics, thermoplastics, vegetable fibers, animal fibers, synthetic fibers, composite materials, putty, elastomers, adhesives and extrudable food products.

7. Apparatus for producing a prototype of an object, comprising:

a wire dispenser for dispensing a wire;

an adhesive dispenser for dispensing an adhesive, which is formed of a material which is different and distinct from said wire; and

an actuator which moves the wire dispenser and the adhesive dispenser in at least four degrees of freedom in accordance with a geometry of said object.

8. Apparatus according to claim 7 wherein the adhesive dispenser and the wire dispenser are fixedly attached to each other.

9. Apparatus according to claim 7 wherein the adhesive dispenser dispenses the adhesive as the wire is dispensed by the wire dispenser.

10. Apparatus according to claim 7 wherein the adhesive dispenser dispenses the adhesive into the wire dispenser such that the wire is dispensed from the wire dispenser pre-coated with the adhesive.

11. Apparatus according to claim 7 and comprising a cutter for cutting the wire after being dispensed by the wire dispenser.