Method for manufacturing a three-dimensional model by variable deposition and apparatus used therein
First Claim
1. A method for manufacturing a three-dimensional model by depositing a material in accordance with shape data of the three-dimensional model using a variable deposition manufacturing apparatus that comprises a material feeder, an electrical melting device, a variable nozzle moved by a three-dimensional moving mechanism and a turntable adapted for rotating the three-dimensional model, the method comprising the steps of:
- (a) designing the three-dimensional model and collecting shape data of the three-dimensional model;
(b) slicing the three-dimensional model into several layers in height;
(c) dividing each of the layers into several sublayers, each of said sublayers having an exterior shape so that one layer can be formed at once by depositing the sublayers using the variable nozzle;
(d) determining whether any of the sublayers requires a support, and positioning the support and adding shape data of the support to said shape data of the three-dimensional model when a sublayer requires the support;
(e) depositing a material in accordance with shape data in relation to a sublayer divided from one layer of the three-dimensional model by adjusting a width, thickness and slope of the material ejected from the variable nozzle;
(f) determining whether said one layer of the three-dimensional model has been completed;
(g) if said one layer of the three-dimensional model has not been completed as determined in step (f), repeating steps (d) through (f) for another sublayer divided from said one layer of the three-dimensional model;
(h) if said one layer of the three-dimensional model has been completed as determined in step (f), determining whether the three-dimensional model has been completed; and
(i) if the three-dimensional model has not been completed as determined in step (h), repeating steps (c) through (h) for another layer sliced from the three-dimensional model.
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Abstract
To enhance accuracy of the size and the shape of manufactures, and to shorten the time of operation, there is provided a method for manufacturing a 3D model comprising steps of designing the 3D model and collecting shape data of the 3D model slicing the 3D model into several layers in height, dividing each of the layers into several sublayers so that a sublayer is formed by depositing a material at once, depositing a material in accordance with shape data in relation to a sublayer divided from one layer of the 3D model, and deciding whether the one layer of the 3D model has been completed. The method is conducted using computer-aided design and computer aided manufacturing system including a variable deposition manufacturing apparatus. The apparatus comprises a material feeder 11, an electrical melting device 13 connected to the material feeder 11 through a conduit 12, a variable nozzle 15 connected to the variable nozzle 15 through a flow controller 14, a three-dimensional moving mechanism for moving the variable nozzle is in relation to the 3D model and a turntable adapted for rotating the 3D model.
75 Citations
15 Claims
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1. A method for manufacturing a three-dimensional model by depositing a material in accordance with shape data of the three-dimensional model using a variable deposition manufacturing apparatus that comprises a material feeder, an electrical melting device, a variable nozzle moved by a three-dimensional moving mechanism and a turntable adapted for rotating the three-dimensional model, the method comprising the steps of:
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(a) designing the three-dimensional model and collecting shape data of the three-dimensional model;
(b) slicing the three-dimensional model into several layers in height;
(c) dividing each of the layers into several sublayers, each of said sublayers having an exterior shape so that one layer can be formed at once by depositing the sublayers using the variable nozzle;
(d) determining whether any of the sublayers requires a support, and positioning the support and adding shape data of the support to said shape data of the three-dimensional model when a sublayer requires the support;
(e) depositing a material in accordance with shape data in relation to a sublayer divided from one layer of the three-dimensional model by adjusting a width, thickness and slope of the material ejected from the variable nozzle;
(f) determining whether said one layer of the three-dimensional model has been completed;
(g) if said one layer of the three-dimensional model has not been completed as determined in step (f), repeating steps (d) through (f) for another sublayer divided from said one layer of the three-dimensional model;
(h) if said one layer of the three-dimensional model has been completed as determined in step (f), determining whether the three-dimensional model has been completed; and
(i) if the three-dimensional model has not been completed as determined in step (h), repeating steps (c) through (h) for another layer sliced from the three-dimensional model.
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2. A computer-aided design and computer aided manufacturing system used in manufacturing a three-dimensional model by depositing a material in accordance with shape data of the three-dimensional model using a variable deposition manufacturing apparatus that comprises a material feeder, an electrical melting device, a variable nozzle moved by a three-dimensional moving mechanism, and a turntable adapted for rotating the three-dimensional model, wherein the system comprises:
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a main processor for designing the three-dimensional model and collecting shape data of the three-dimensional model, slicing the three-dimensional model into several layers in height, and dividing each of the layers into several sublayers so that a sublayer is formed by depositing a material at once;
a material-feeding controller for controlling the material feeder to adjust the quantity of material fed to the electrical melting device;
a nozzle controller for controlling material ejection from the variable nozzle;
a model position controller for controlling operation of the three-dimensional moving mechanism; and
said main processor adapted for transmitting the shape data to said material-feeding controller, said nozzle controller and said model position controller so that these three controllers cooperate to form the three-dimensional model, wherein said three-dimensional moving mechanism comprises;
a first slider moved on a Y-directional rail, said first slider adapted to clamp said variable nozzle thereto;
a pair of sliders moved on a pair of X-directional rails, said pair of sliders moving said Y-directional rail in the X-direction; and
one or more sliders moved on one or more Z-directional rails, said one or more sliders moving said turntable in the Z-direction. - View Dependent Claims (3, 4, 5, 6, 7)
a thickness-adjusting panel adapted to be moved upward or downward to adjust the thickness of material ejected from said downstream part;
two width-adjusting panels adapted to be moved rightward or leftward to define right and left ends of an outlet of the downstream part of the variable nozzle; and
two slope-adjusting panels adapted for defining slopes of said right and left ends of said outlet of said downstream part.
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8. A variable deposition manufacturing apparatus used in manufacturing a three-dimensional model by depositing a material in accordance with shape data of the three-dimensional model, wherein the apparatus comprises:
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a material feeder for feeding a material used in forming the three-dimensional model;
an electrical melting device for melting the material, said electrical melting device connected to said material feeder through a conduit;
a variable nozzle adapted for depositing the melted material in accordance with shape data of the three-dimensional model, said variable nozzle connected to said variable nozzle through a flow controller;
a three-dimensional moving mechanism for moving said variable nozzle in relation to the three-dimensional model; and
a turntable adapted for rotating the three-dimensional model, wherein said three-dimensional moving mechanism comprises;
a first slider moved on a Y-directional rail, said first slider adapted to clamp said variable nozzle thereto;
a pair of sliders moved on a pair of X-directional rails, said pair of sliders moving said Y-directional rail in the X-direction; and
one or more sliders moved on one or more Z-directional rails, said one or more sliders moving said turntable in the Z-direction. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15)
a thickness-adjusting panel adapted to be moved upward or downward to adjust the thickness of material ejected from said downstream part;
two width-adjusting panels adapted to be moved rightward or leftward to define right and left ends of an outlet of the downstream part of the variable nozzle; and
two slope-adjusting panels adapted for defining slopes of said right and left ends of said outlet of said downstream part.
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13. The variable deposition manufacturing apparatus according to claim 8, wherein the apparatus further comprises a nozzle heater for preventing a melt in said variable nozzle from being solidified.
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14. The variable deposition manufacturing apparatus according to claim 8, wherein said variable nozzle is comprised of two parts connected by a pivot with each other, in which a downstream part of said two parts is adapted to swing around said pivot to adjust an angle in relation with a upstream part of said two parts, by which an ejection angle of said downstream part is adjusted.
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15. The variable deposition manufacturing apparatus according to claim 14, wherein said downstream part of said variable nozzle comprises:
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a thickness-adjusting panel adapted to be moved upward or downward to adjust the thickness of material ejected from said downstream part;
two width-adjusting panels adapted to be moved rightward or leftward to define right and left ends of an outlet of the downstream part of the variable nozzle; and
two slope-adjusting panels adapted for defining slopes of said right and left ends of said outlet of said downstream part.
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Specification