High temperature modeling apparatus

• US 6,722,872 B1
• Filed: 12/13/2001
• Issued: 04/20/2004
• Est. Priority Date: 06/23/1999
• Status: Expired due to Term

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Skubic, Robert L., LaBossiere, Joseph E., Karwoski, Peter J., Leavitt, Paul J., Swanson, William J., Turley, Patrick W.
• Primary Examiner(s): Davis, Robert B.
• Application Number:
  US10/018,673
• Time in Patent Office: 859 Days
• Field of Search: 425/225, 425/226, 425/375
• US Class Current: 425/225
• CPC Class Codes: B29C 2071/022 Annealing
• CPC Class Codes: B29C 2791/005 Using a particular environment, e.g. sterile fluids other than air
• CPC Class Codes: B29C 41/36 Feeding the material on to the mould, core or other substrate
• 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: B29C 71/02 Thermal after-treatment B29C71/0063 and B29C71/0072 take precedence
• 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 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: G05B 2219/49019 Machine 3-D slices, to build 3-D model, stratified object manufacturing SOM
• CPC Class Codes: Y10S 264/57 Processes of forming layered products

Abstract

Disclosed is a three-dimensional modeling apparatus (10) that builds up three-dimensional objects in a heated build chamber (24) by dispensing modeling material from a dispensing head (14) onto a base (16) in a pattern determined by control signals from a controller (140). The motion control components (18, 20) of the apparatus (10) are external to and thermally isolated from the build chamber (24). A deformable thermal insulator (132) forms a ceiling of the building chamber, allowing motion control of the dispensing head (14) in an x, y plane by an x-y gantry (18) located outside of and insulated from the build chamber (24). In the preferred embodiment, a material dispensing outlet (66) of the dispensing head is inside the chamber. Thermal isolation of the motion control components from the build chamber allows the chamber to be maintained at a high temperature.

Claims

1. A three-dimensional modeling apparatus comprising a heated build chamber in which three-dimensional objects are built, a base located in the build chamber, a dispensing head for dispensing modeling material onto the base, the dispensing head having a modeling material dispensing outlet inside of the build chamber, and an x-y-z gantry coupled to the dispensing head and to the base for generating relative movement in three-dimensions between the dispensing head and the base, characterized in that:

the x-y-z gantry is located external to the build chamber and is separated from the chamber by a deformable thermal insulator.

2. The apparatus of claim 1, wherein the deformable thermal insulator forms a portion of the build chamber through which the x-y-z gantry moves the dispensing head.

3. The apparatus of claim 2, wherein the x-y-z gantry comprises:

an x-y gantry coupled to the dispensing head to effect movement of the dispensing head in an x, y plane; and

a z-lift coupled to the base to effect movement of the base along a z-axis.

4. The apparatus of claim 3, wherein the z-lift is coupled to the base through sealed slits in walls of the build chamber.

5. The apparatus of claim 1, wherein the deformable thermal insulator forms a portion of the build chamber through which the x-y-z gantry is coupled to the base.

6. The apparatus of claim 1, wherein the dispensing head has a modeling material receiving inlet external to the build chamber.

7. The apparatus of claim 1, and further comprising:

a frame on which the x-y-z gantry and the build chamber are mounted.

8. The apparatus of claim 1, wherein the build chamber is heated to a temperature greater than 150°

C.

9. The apparatus of claim 1, wherein the x-y-z gantry effects movement of the dispensing head and the base in three non-orthogonal degrees of freedom.

10. A three-dimensional modeling apparatus comprising:

a heated build chamber;

a movable base located in the build chamber;

a movable dispensing head having an outlet for controllably dispensing modeling material, the outlet being located in the build chamber; and

an x-y-z gantry coupled to the dispensing head and to the base for moving the dispensing head and the base in three-dimensions with respect to one another in synchrony with the dispensing of modeling material so as to build up a three-dimensional object of predetermined shape, the x-y-z gantry being located external to and in thermal isolation from the build chamber.

11. The modeling apparatus of claim 10, wherein the build chamber has a ceiling formed of a deformable thermal insulator through which the x-y-z gantry moves the dispensing head.

12. The modeling apparatus of claim 11, wherein the x-y-z gantry comprises:

an x-y gantry coupled to the dispensing head to effect movement of the dispensing head in an x, y plane; and

a z-lift coupled to the base to effect a movement of the base along a z-axis.

13. The modeling apparatus of claim 12, wherein the dispensing head has a modeling material receiving inlet located outside of the build chamber.

14. The modeling apparatus of claim 10, and further comprising:

a frame external to the build chamber on which the x-y-z gantry and the build chamber are mounted.

15. The modeling apparatus of claim 10, wherein the build chamber is heated by convection such that an air flow pattern is created in the build chamber, and further comprising:

a means mounted to the dispensing head for deflecting air in the flow pattern towards the dispensing head outlet.

16. The modeling apparatus of claim 10, and further comprising:

a means for removing a buildup of modeling material from the dispensing head outlet.

17. The modeling apparatus of claim 10, wherein the build chamber is heated to a temperature greater than 150°

C.

18. A three-dimensional modeling apparatus comprising a heated build chamber in which three-dimensional objects are built, a base located in the build chamber, an dispensing head for dispensing modeling material onto the base, the dispensing head having a material dispensing outlet in the build chamber, and an x-y gantry coupled to the dispensing head for translating the dispensing head in an x, y plane, characterized in that:

the x-y gantry is located external to and in thermal isolation from the build chamber; and

a deformable thermal insulator forms a portion of the build chamber through which the x-y gantry moves the dispensing head.

19. The apparatus of claim 18, wherein the dispensing head has a material receiving inlet outside of the build chamber.

20. The modeling apparatus of claim 18, wherein the build chamber is heated by convection such that an air flow pattern is created in the build chamber, and further comprising:

a means mounted to the dispensing head for deflecting air in the flow pattern towards the dispensing head outlet.

21. The modeling apparatus of claim 18, and further comprising:

a means for removing a buildup of modeling material from the dispensing head outlet.

22. The apparatus of claim 18, and further comprising:

a z-lift located external to and in thermal isolation from the build chamber, the z-lift being coupled to the base through sealed slits in walls of the build chamber.