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Layer-additive method and apparatus for freeform fabrication of 3-D objects

  • US 6,471,800 B2
  • Filed: 11/29/2000
  • Issued: 10/29/2002
  • Est. Priority Date: 11/29/2000
  • Status: Expired due to Fees
First Claim
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1. A method for fabricating a three-dimensional object from individual porous solid preform layers and at least a pore-filling material, said method comprising:

  • (a) providing a work surface lying substantially parallel to an X-Y plane of an X-Y-Z Cartesian coordinate system defined by three mutually perpendicular X-, Y- and Z-axes;

    (b) feeding a first porous solid preform layer to said work surface;

    (c) using dispensing means to dispense a first pore-filling material onto predetermined areas of said first porous preform layer to at least partially fill in the pores in said predetermined areas for the purpose of hardening said areas and forming the first section of said 3-D object;

    (d) feeding a second porous preform layer onto said first layer, dispensing a second pore-filling material onto predetermined areas of said second layer for hardening said areas and forming the second section of said 3-D object;

    (e) repeating the operations from (b) to (d) to stack up and build successive preform layers along the Z-direction of said X-Y-Z coordinate system for forming multiple layers of said object with the remaining un-hardened areas of individual layers staying as a support structure;

    (f) providing means to sequentially or simultaneously affix successive layers together to form a unitary body; and

    (g) removing said support structure by exposing said un-hardened areas of said unitary body to a support-collapsing environment, causing said 3-D object to appear.

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