Method and apparatus for the computer-controlled manufacture of three-dimensional objects from computer data

• US 6,175,422 B1
• Filed: 07/31/1992
• Issued: 01/16/2001
• Est. Priority Date: 01/31/1991
• Status: Expired due to Term

• Current Assignee: Texas Instruments, Inc.
• Original Assignee: Texas Instruments, Inc.
• Inventors: Penn, Steven M., Jones, David N., Embree, Michael E.
• Primary Examiner(s): Popovici, Dov
• Application Number:
  US07/923,278
• Time in Patent Office: 3,091 Days
• Field of Search: 395/101, 395/119, 395/120, 395/125, 364/468, 364/474.05, 364/479, 364/476, 364/468-1-4, 364/479-1-4, 364/476.01, 264/129, 264/131, 264/132
• US Class Current: 358/1.1
• CPC Class Codes: B29C 2793/00 Shaping techniques involving a cutting or machining operation
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2995/0021 Multi-coloured
• 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 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 40/20 Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G05B 2219/49016 Desktop manufacturing [DTM]; Solid freeform machining [SFM]; Solid freeform fabrication [SFF]
• CPC Class Codes: H05K 2203/0126 Dispenser, e.g. for solder paste, for supplying conductive paste for screen printing or for filling holes
• CPC Class Codes: H05K 2203/013 Inkjet printing, e.g. for printing insulating material or resist
• CPC Class Codes: H05K 3/125 by ink-jet printing
• CPC Class Codes: H05K 3/4664 Adding a circuit layer by thick film methods, e.g. printing techniques or by other techniques for making conductive patterns by using pastes, inks or powders H05K3/4647 takes precedence
• CPC Class Codes: Y02P 80/40 Minimising material used in manufacturing processes
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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.

Claims

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.

2. The apparatus of claim 1, wherein said planing apparatus further comprises:

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.

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.

4. The apparatus of claim 1, wherein said target surface comprises a water soluble platform.

5. The apparatus of claim 1, wherein said layer of said first material are of a plurality of colors.

6. The apparatus of claim 1, wherein selected portions of a single layer of said first material are of a plurality of colors.

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.

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.

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.

10. An apparatus for producing a three dimensional object from a computer database, comprising:

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.

11. The apparatus of claim 10, wherein said planning apparatus further comprises:

means for removing a portion of said second material to expose said hardened first material thereunder.

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.

13. The apparatus of claim 10, wherein said second material is water soluble.

14. A system for manufacturing three-dimensional objects from computer data comprising:

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.

15. The system of claim 14, wherein said target surface comprises a water soluble platform.

16. The system of claim 14, wherein said controlled dispensing device is controllable in such a manner that it is turned on and off according to a two dimensional data map stored in a microprocessor.

17. The system of claim 14, wherein said controlled dispensing device is for dispensing a plurality of materials of the same composition but having different colors.

18. The system of claim 14, wherein said controlled dispensing device is for dispensing a plurality of materials of different composition and different color.

19. The system of claim 14, wherein said controlled dispensing device is for dispensing a plurality of materials of different composition but the same color.