Method and apparatus for variably controlling the temperature in a selective deposition modeling environment

• US 6,162,378 A
• Filed: 02/25/1999
• Issued: 12/19/2000
• Est. Priority Date: 02/25/1999
• Status: Expired due to Term

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Vahidkhah, Andisheh, Stockwell, John, Bedal, Bryan J. L., Brown, Joe M.
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US09/257,360
• Time in Patent Office: 663 Days
• Field of Search: 264/40.1, 264/308, 425/143, 425/375, 700/119
• US Class Current: 264/40.1
• CPC Class Codes: B29C 2035/1658 using gas
• CPC Class Codes: B29C 2037/90 Measuring, controlling or regulating
• CPC Class Codes: B29C 35/045 using gas or flames
• CPC Class Codes: B29C 41/08 Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder spray-up of reinforcing fibres B29C70/305
• CPC Class Codes: B29C 41/12 Spreading-out the material on a substrate , e.g. on the surface of a liquid
• CPC Class Codes: B29C 41/52 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling

Abstract

A method, system and apparatus for variably controlling the temperature in a selective deposition modeling environment. The temperature of the formed portion of the three-dimensional object is detected. A gas is forced onto a surface of the formed portion of the three-dimensional object. The forced gas has a characteristic, such as temperature and quantity, that is variably controlled based on the detected temperature of the formed portion of the three-dimensional object.

Claims

1. A method of forming a three-dimensional object, comprising the steps of:

forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein a formed portion of the three-dimensional object has a temperature and a surface;

detecting the temperature of the formed portion of the three-dimensional object; and

forcing a gas onto the surface of the formed portion of the three-dimensional object, the forced gas having a characteristic, and wherein the characteristic of the forced gas is variably controlled based on the detected temperature of the formed portion of the three-dimensional object.

2. The method of claim 1, wherein the characteristic is a quantity of the forced gas.

3. The method of claim 1, wherein the characteristic is a temperature of the forced gas.

4. The method of claim 1, wherein the forced gas is a cooling gas.

5. The method of claim 1, wherein the step of forming the portion of the three-dimensional object further comprises forming the portion of the three-dimensional object by using a dispensing head which controllably dispenses a flowable material that solidifies upon being dispensed.

6. The method of claim 5, wherein the dispensing head has at least two sides, and wherein the step of forcing the gas further comprises forcing the gas from a position located at one side of the dispensing head.

7. The method of claim 5, wherein the step of forming a portion of the three-dimensional object further comprises forming a portion of the three-dimensional object by using a planarizer to planerize the solidified material.

8. The method of claim 7, wherein the step of forcing the gas further comprises forcing the gas from a position located in between the dispensing head and the planarizer.

9. The method of claim 7, wherein the step of forcing the gas further comprises forcing the gas after using both the dispensing head and the planarizer.

10. The method of claim 1, wherein the formed portion of the three-dimensional object has at least one region, and wherein the step of detecting the temperature further comprises detecting the temperature at each region of the formed portion of the three-dimensional object.

11. The method of claim 10, wherein the step of forcing the gas further comprises selectively forcing the gas onto each region of the formed portion of the three-dimensional object based on the detected temperature at each region of the formed portion of the three-dimensional object.

12. A method of forming a three-dimensional object, comprising the steps of:

forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein each of the formed portions of the three-dimensional object has a geometry and a surface; and

forcing a gas flow in a flow rate onto the surface of each formed portion of the three-dimensional object, the forced gas flow having a characteristic, and wherein the characteristic of the forced gas flow is variably controlled based on the geometry of each formed portion of the three-dimensional object.

13. The method of claim 12, wherein the characteristic is a quantity of the forced gas.

14. The method of claim 13, wherein the step of forcing the gas further comprises forcing the gas flow rate using at least one fan.

15. The method of claim 14, wherein the quantity of gas is variably controlled by changing the flow rate of gas being forced by each fan.

16. The method of claim 14, wherein the quantity of gas is variably controlled by changing a number of fans used to force the gas flow.

17. The method of claim 14, wherein the at least one fan comprises a first fan and a second fan, and wherein the step of forcing the gas flow further comprises forcing the gas using the first fan and the second fan, the first fan producing a nonzero quantity of gas flow and the second fan selectively producing a non-zero or zero quantity of gas flow.

18. The method of claim 12, wherein the characteristic is a temperature of the forced gas.

19. The method of claim 12, wherein the method further comprises the step of detecting the geometry of the formed portion of the three-dimensional object.

20. The method of claim 12, wherein the method further comprises the step of determining the geometry of the formed portion of the three-dimensional object using software.

21. The method of claim 12, wherein the step of forming at least one portion of the three-dimensional object further comprises forming a first portion of the three-dimensional object at a first time and forming a second portion of the three-dimensional object at a second time, wherein the geometry of the second portion is equal to the geometry of the first portion.

22. The method of claim 12, wherein the step of forming at least one portion of the three-dimensional object further comprises the steps of:

forming a portion of the three-dimensional object at a first time; and

identifying an unformed portion of the three-dimensional object, wherein the unformed portion will be formed at a second time, and wherein the geometry of the formed portion is equal to the geometry of the unformed portion.

23. A method of forming a three-dimensional object, comprising the steps of:

forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein a formed portion of the three-dimensional object has a surface; and

forcing the gas onto the surface of the formed portion of the three-dimensional object, wherein the gas has a quantity and a temperature, and wherein the quantity of gas is variably controlled based on a pre-determined quantity of gas value, and wherein the temperature of the gas is variably controlled based on a pre-determined temperature of gas value.

24. The method of claim 23, wherein the gas is a cooling gas.

25. The method of claim 23, wherein the step of forming the portion of the three-dimensional object further comprises the steps of:

forming the portion of the three-dimensional object by using a dispensing head which controllably dispenses a flowable material that solidifies upon being dispensed, and passing the dispensing head over the formed portion after the flowable material solidifies.

26. The method of claim 25, wherein the step of detecting further comprises detecting the gas temperature before the step of passing the dispensing head over the formed portion.

27. The method of claim 25, wherein the step of detecting further comprises detecting the gas temperature after the step of passing the dispensing head over the formed portion.

28. A method of forming a three-dimensional object, comprising the steps of:

forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein a portion of the three-dimensional object is formed in a build environment that has a temperature;

detecting the temperature of the build environment; and

forcing a gas through the build environment, the forced gas having a characteristic, and wherein the characteristic of the forced gas is related to the detected temperature of the build environment.

29. A method of forming a three-dimensional object, comprising the steps of:

forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein the three-dimensional object has a temperature, and wherein the portion of the three-dimensional object is formed in a build environment that has a temperature;

detecting the temperature of the build environment;

detecting the temperature of a formed portion of the three-dimensional object; and

forcing a gas through the build environment, the forced gas having a characteristic, and wherein the characteristic of the forced gas is related to the detected temperature of the build environment and the formed portion of the three-dimensional object.

30. A method of forming a three-dimensional object, comprising the steps of:

forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein selective deposition modeling involves using a dispensing head which controllably dispenses a flowable material that solidifies upon being dispensed, and wherein the dispensing head has a dispensing rate;

detecting the temperature of a build environment, wherein the build environment houses the formed portion of the three-dimensional object; and

modifying the dispensing rate using a minimum layer per second (MLS) technique, wherein the MLS technique incorporates the detected temperature of the build environment.

31. A method of forming a three-dimensional object, comprising the steps of:

forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein selective deposition modeling involves using a dispensing head which controllably dispenses a flowable material that solidifies upon being dispensed, and wherein a formed portion of the three-dimensional object has a surface;

forcing a quantity of gas onto the surface of the formed portion of the three-dimensional object; and

selecting a thickness and a vertical accumulation rate of the flowable material, wherein the thickness is based on the forced quantity of gas, and wherein the vertical accumulation rate is greater than 1.5 mils/15 seconds.

32. An apparatus for forming a three-dimensional object, comprising:

means for forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein a formed portion of the three-dimensional object has a temperature and a surface;

means for detecting the temperature of the formed portion of the three-dimensional object; and

means for forcing a gas onto the surface of the formed portion of the three-dimensional object, the forced gas having a characteristic, and wherein the characteristic of the forced gas is variably controlled based on the detected temperature of the formed portion of the three-dimensional object.

33. An apparatus for forming a three-dimensional object, comprising:

means for forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein each of the formed portions of the three-dimensional object has a geometry and a surface; and

means for forcing a gas onto the surface of each formed portion of the three-dimensional object, the forced gas having a characteristic, and wherein the characteristic of the forced gas is variably controlled based on the geometry of each formed portion of the three-dimensional object.

34. An apparatus for forming a three-dimensional object, comprising:

means for forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein a formed portion of the three-dimensional object has a surface; and

means for forcing the gas onto the surface of the formed portion of the three-dimensional object, wherein the gas has a quantity and a temperature, and wherein the quantity of gas is variably controlled based on a pre-determined quantity of gas value, and wherein the temperature of the gas is variably controlled based on a pre-determined temperature of gas value.

35. An apparatus for forming a three-dimensional object, comprising:

means for forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein a portion of the three-dimensional object is formed in a build environment that has a temperature;

means for detecting the temperature of the build environment; and

means for forcing a gas through the build environment, the forced gas having a characteristic, and wherein the characteristic of the forced gas is related to the detected temperature of the build environment.

36. An apparatus for forming a three-dimensional object, comprising:

means for forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein the three-dimensional object has a temperature, and wherein a portion of the three-dimensional object is formed in a build environment that has a temperature;

means for detecting the temperature of the formed portion of the three-dimensional object; and

means for forcing a gas through the build environment, the forced gas having a characteristic, and wherein the characteristic of the forced gas is related to the detected temperature of the formed portion of the three-dimensional object.

37. An apparatus for forming a three-dimensional object, comprising:

means for forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein selective deposition modeling involves using a dispensing head which controllably dispenses a flowable material that solidifies upon being dispensed, and wherein the dispensing head has a dispensing rate;

means for detecting the temperature of a build environment, wherein the build environment houses the formed portion of the three-dimensional object; and

means for modifying the dispensing rate using a minimum layer per second (MLS) technique, wherein the MLS technique incorporates the detected temperature of the build environment.

38. An apparatus for forming a three-dimensional object, comprising:

means for forming the three-dimensional object in layer-by-layer portions using selective deposition modeling, wherein selective deposition modeling involves using a dispensing head which controllably dispenses a flowable material that solidifies upon being dispensed, and wherein the formed portion of the three-dimensional object has a surface;

means for forcing a quantity of gas onto the surface of the formed portion of a three-dimensional object; and

means for selecting a thickness and a vertical accumulation rate of the flowable material, wherein the thickness is based on the forced quantity of gas, and wherein the vertical accumulation rate is greater than 1.5 mils/15 seconds.