Method and apparatus for the computer-controlled manufacture of three-dimensional objects from computer data
First Claim
1. A computer-controlled apparatus for manufacturing of three-dimensional objects, comprising:
- a first dispenser operable to dispense a layer of a first material on a target surface and for dispensing said layer of said first material at only selected locations of said target surface, said selected locations corresponding to a cross-section of a three-dimensional object, wherein said first material is dispensed in liquid form and hardens once so dispensed to form a hardened first material;
a second dispenser for dispensing a second material over said layer of said hardened first material to encapsulate said hardened first material to form an encapsulating second material;
a planing apparatus for planing the surface of said encapsulating second material, of said hardened first material wherein said first dispenser dispenses another layer of said first material onto said planned uppermost surface at selected locations corresponding to another cross-section of said three-dimensional object.
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Accused Products
Abstract
A method and process for computer-controlled manufacture of three-dimensional objects involves dispensing a layer of a first material, such as a liquid, insoluble material onto a platform at predetermined locations corresponding to a cross-section of the object, which then hardens. A second medium, preferably water soluble, is then sprayed onto this layer to thereby encapsulate the hardened insoluble media. The uppermost surface of this encapsulant is planned, thus removing a portion of the encapsulant to expose the underlying insoluble material for new pattern deposition. After the resulting planing residue is removed, another layer of liquid, insoluble media is dispensed onto the planned surface. The insoluble media can be of any color and may vary from layer to layer, and from location within a layer to location with a layer. These steps are repeated, until the desired three-dimensional object, surrounded by a mold, is completed. At this point, the object is either heated or immersed in solvent, thereby dissolving the mold and leaving the three-dimensional object intact. Other system methods, and processes are also disclosed.
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Citations
19 Claims
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1. A computer-controlled apparatus for manufacturing of three-dimensional objects, comprising:
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a first dispenser operable to dispense a layer of a first material on a target surface and for dispensing said layer of said first material at only selected locations of said target surface, said selected locations corresponding to a cross-section of a three-dimensional object, wherein said first material is dispensed in liquid form and hardens once so dispensed to form a hardened first material;
a second dispenser for dispensing a second material over said layer of said hardened first material to encapsulate said hardened first material to form an encapsulating second material;
a planing apparatus for planing the surface of said encapsulating second material, of said hardened first material wherein said first dispenser dispenses another layer of said first material onto said planned uppermost surface at selected locations corresponding to another cross-section of said three-dimensional object. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
means for removing a portion of the second material; and
means for exposing the underlying first material so that the subsequently dispensed portions of said first material thereover will bond thereto.
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3. The apparatus of claim 1, wherein said apparatus further comprises a control system to receive, store and process data describing the dimensions of said three-dimensional object, by determining said selected locations corresponding to cross section of the three-dimensional object.
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4. The apparatus of claim 1, wherein said target surface comprises a water soluble platform.
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5. The apparatus of claim 1, wherein said layer of said first material are of a plurality of colors.
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6. The apparatus of claim 1, wherein selected portions of a single layer of said first material are of a plurality of colors.
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7. The apparatus of claim 1, wherein said apparatus further comprises a microprocessor control system to receive, store and process data describing a desired color of said three-dimension object to establish said selected location.
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8. The apparatus of claim 1, wherein said apparatus further comprises a microprocessor control system to receive, store and process data describing a desired composition of said three-dimensional object by establishing a selected location.
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9. The apparatus of claim 1, further comprises a microprocessor control system to receive, store and process data describing a desired texture of said three-dimensional object to establish said selected location.
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10. An apparatus for producing a three dimensional object from a computer database, comprising:
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a controller for loading first slice data corresponding to a first slice of said object and for loading next slice data corresponding to a second slice of said object;
a platform having a target surface;
a first dispenser operable for dispensing a layer of a first material onto said target surface and for dispensing said layer of said first material onto said target surface at only locations established according to said loaded first slice data, and controlled by said controller, wherein said first material hardens once so dispensed;
a second dispenser for spraying a second material to encapsulate said layer of hardened first material to form an encapsulated layer of said hardened first material;
said controller loading data corresponding to said next slice of said object;
a planing apparatus for planing the uppermost surface of said encapsulated layer of said hardened first material, wherein said first dispenser dispenses another layer of said first material onto said planed surface of said encapsulated layer at locations established according to said loaded next slice data. - View Dependent Claims (11, 12, 13)
means for removing a portion of said second material to expose said hardened first material thereunder.
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12. The apparatus of claim 10, wherein said slice data comprises sufficient data to simulate an image generated by an object scan and image capture device, including dimensions, color, texture or composition.
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13. The apparatus of claim 10, wherein said second material is water soluble.
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14. A system for manufacturing three-dimensional objects from computer data comprising:
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a substantially planar target surface;
a controlled dispensing device operable for dispensing a layer of a first material onto said target surface and for repeated dispensing of said first material in a liquid state onto said target surface at only selected locations corresponding to a cross-section of an object to be manufactured;
a dispensing device for repeated spraying of soluble material to encapsulate said first material to form an encapsulated first material; and
a cutting device for planarizing said encapsulated first material in preparation for receiving additional dispensing of said first material. - View Dependent Claims (15, 16, 17, 18, 19)
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Specification