Rapid prototyping apparatus

• US 7,500,846 B2
• Filed: 05/02/2004
• Issued: 03/10/2009
• Est. Priority Date: 05/01/2003
• Status: Active Grant

• Current Assignee: Objet Geometries
• Original Assignee: Objet Geometries
• Inventors: Zeytoun, Igal, Eshed, David, Levi, Moshe, Danai, Dror, Kritchman, Eliahu M., Gothait, Hanan
• Primary Examiner(s): Gupta; Yogendra
• Assistant Examiner(s): Ewald; Maria Veronica D
• Application Number:
  US10/555,087
• Publication Number:
  US 20070179656A1
• Time in Patent Office: 1,773 Days
• Field of Search: 425/174.4, 425/375, 425/185, 264/308, 264/401, 264/497, 264/113, 700/119
• US Class Current: 425/375
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/321 Feeding
• CPC Class Codes: B29C 64/343 Metering
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• 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 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: G05B 19/048 Monitoring; Safety
• CPC Class Codes: G05B 2219/49023 3-D printing, layer of powder, add drops of binder in layer, new powder
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]

Abstract

Apparatus for producing an object by sequentially forming thin layers of a construction material one on top of the other responsive to data defining the object, the apparatus comprising: a plurality of printing heads each having a surface formed with a plurality of output orifices and controllable to dispense the construction material through each orifice independently of the other orifices; a shuttle to which the printing heads are mounted; a support surface; and a controller adapted to control the shuttle to move back and forth over the support surface and as the shuttle moves to control the printing heads to dispense the construction material through each of their respective orifices responsive to the data to form a first layer on the support surface and thereafter, sequentially the other layers; wherein each printing head is dismountable from the shuttle and replaceable independently of the other printing heads.

Claims

1. Apparatus for producing an object by sequentially forming thin layers of a construction material one on top of the other responsive to data defining the object, the apparatus comprising:

a plurality of printing heads each having a surface formed with a plurality of output orifices and controllable to dispense the construction material through each orifice independently of the other orifices;

a shuttle to which the printing heads are mounted;

a support surface; and

a controller adapted to control the shuttle to move back and forth over the support surface and as the shuttle moves to control the printing heads to dispense the construction material through each of their respective orifices responsive to the data to form a first layer on the support surface and thereafter, sequentially the other layers;

wherein

each printing head is dismountable from the shuttle and replaceable independently of the other printing heads; and

wherein

each printing head comprises at least one registration structure that matches a registration structure in the shuttle when the printing head is mounted to the shuttle, wherein the shuttle registration structure is different for some printing head mounting positions such that the orifices in the such mounted printing heads are offset relative to orifices of at least some other printing heads in the cross-printing direction by less than a distance between two neighboring orifices on one printing head, wherein the cross-printing direction is a direction parallel to the support surface and perpendicular to a printing direction.

2. Apparatus according to claim 1 wherein each printing head comprises at least one registration structure that matches a registration structure comprised in the shuttle and when a printing head is mounted to the shuttle its at least one registration structure contacts the corresponding shuttle registration structure and positions each orifice of a printing head at a same distance in a printing direction from the shuttle registration structure.

3. Apparatus according to claim 2 wherein the orifices in each printing head are equally spaced in a linear array having a first orifice located at a first end of the array.

4. Apparatus according to claim 3 wherein the at least one registration structure comprised in each printing head and its corresponding shuttle registration structure position the printing heads so that their respective lines of orifices are parallel.

5. Apparatus according to claim 1 wherein the at least one registration structure comprised in each printing head and its corresponding shuttle registration structure, position the printing heads so that the first orifice in each printing head is accurately positioned relative to the first orifices of the other printing heads.

6. Apparatus according to claim 1 wherein distances of the first orifices from a same plane perpendicular to the lines of orifices are located at distances from the plane in accordance with an expression of the form y(n)=C+n(d_y/N), where y is the distance from the plane, C is a constant, N is a number of printing heads, d_y is a distance between adjacent orifices in a same printing head and for each of the printing heads, n is a different integer satisfying 0≦

n≦

(N−

1).

7. Apparatus according to claim 6 wherein the controller controls the shuttle to move along a direction perpendicular to the lines of orifices when construction material is dispensed from orifices in the printing heads during formation of a layer.

8. Apparatus according to claim 7 wherein the distances y(n) are such that a printing head deposits droplets on a given line in the layer parallel to the lines of orifices at locations such that the droplets are substantially not contiguous with any droplets of material deposited previously on the given line by other of the N printing heads.

9. Apparatus according to claim 8 wherein each droplet deposited between two closest, previously deposited droplets on the given line, is equidistant from the two previously deposited droplets.

10. Apparatus according to claim 3 wherein the at least one registration structure in each printing head comprises at least one registration pin that protrudes from the printing head and has an end accurately positioned relative to the line of orifices.

11. Apparatus according to claim 10 wherein the corresponding shuttle registration structure is a surface and wherein the registration pin and registration surface are positioned so that when the printing head is mounted to the shuttle the tip of the pin butts up against the surface.

12. Apparatus according to claim 10 wherein the at least one registration pin comprises three registration pins.

13. Apparatus according to claim 12 wherein the tip of a third registration pin is displaced parallel to the line of orifices and away from all the orifices by an accurate distance relative to the first orifice.

14. Apparatus according to claim 1 wherein each printing head is associated with a memory.

15. Apparatus according to claim 14 wherein the memory is comprised in the printing head.

16. Apparatus according to claim 14 wherein the memory comprises profile data that specifies operating characteristics peculiar to the printing head that the controller uses to control the printing head.

17. Apparatus according to claim 16 wherein the profile data becomes accessible to the controller automatically when the printing head is mounted to the shuttle.

18. Apparatus according to claim 16 wherein each orifice is associated with its own actuator controllable to control dispensing of the construction material from the orifice and wherein the profile data comprises data useable to control the actuator.

19. Apparatus according to claim 16 and comprising a temperature monitor that generates signals responsive to temperature of the printing head.

20. Apparatus according to claim 19 wherein the memory comprises calibration data that correlates a characteristic of the signals with temperature of the printing head.

21. Apparatus according to claim 16 wherein the printing head comprises a heat source controllable to maintain the printing head at a desired temperature and wherein the memory comprises data useable to control the heat source.

22. Apparatus according to claim 16 wherein the memory comprises data useable to determine the position of the orifices relative to the orifices of other printing heads mounted to the shuttle.

23. Apparatus according to claim 1 wherein the construction material comprises a photopolymer.

24. Apparatus according to claim 23 and comprising a lamp that provides radiation to polymerize the photopolymer.

25. Apparatus according to claim 24 wherein the lamp provides a substantial portion of the radiation so that it is incident on the layers at substantially non-normal angles to their planes.

26. Apparatus according to claim 1 wherein at least some of the shuttle registrations structures have different lengths and wherein the different lengths provide the offset.

27. Apparatus according to claim 14 wherein the memory comprises data useable to determine the position of the orifices relative to the orifices of other printing heads mounted to the shuttle.

28. Apparatus for producing an object by sequentially forming thin layers of a construction material one on top of the other responsive to data defining the object, the apparatus comprising:

a plurality of printing heads each having a surface formed with a plurality of output orifices and controllable to dispense the construction material through each orifice independently of the other orifices;

a shuttle to which the printing heads are mounted;

a support surface; and

a controller adapted to control the shuffle to move back and forth over the support surface and as the shuttle moves to control the printing heads to dispense the construction material through each of their respective orifices responsive to the data to form a first layer on the support surface and thereafter, sequentially the other layers;

wherein

each printing head is dismountable from the shuttle and replaceable independently of the other printing heads;

wherein

each printing head comprises at least one registration structure that matches a registration structure comprised in the shuttle and when a printing head is mounted to the shuttle its at least one registration structure contacts the corresponding shuttle registration structure and positions the printing head accurately in the shuttle;

wherein

the orifices in each printing head are equally spaced in a linear array having a first orifice located at a first end of the array;

wherein

the at least one registration structure comprised in each printing head and its corresponding shuttle registration structure position the printing heads so that their respective lines of orifices are parallel;

wherein

the at least one registration structure comprised in each printing head and its corresponding shuttle registration structure, position the printing heads so that the first orifice in each printing head is accurately positioned relative to the first orifices of the other printing heads; and

wherein

distances of the first orifices from a same plane perpendicular to the lines of orifices are located at distances from the plane in accordance with an expression of the form y(n) =C +n(d_y/N), where y is the distance from the plane, C is a constant, N is a number of printing heads, d_y is a distance between adjacent orifices in a same printing head and for each of the printing heads, n is a different integer satisfying 0 ≦

n≦

(N−

1).

29. Apparatus according to claim 28 wherein the controller controls the shuttle to move along a direction perpendicular to the lines of orifices when construction material is dispensed from orifices in the printing heads during formation of a layer.

30. Apparatus according to claim 29 wherein the distances y(n) are such that a printing head deposits droplets on a given line in the layer parallel to the lines of orifices at locations such that the droplets are substantially not contiguous with any droplets of material deposited previously on the given line by other of the N printing heads.

31. Apparatus according to claim 30 wherein each droplet deposited between two closest, previously deposited droplets on the given line, is equidistant from the two previously deposited droplets.

32. Apparatus according to claim 28 wherein the at least one registration structure in each printing head comprises at least one registration pin that protrudes from the printing, head and has an end accurately positioned relative to the line of orifices;

wherein

the corresponding shuttle registration structure is a surface and wherein the registration pin and registration surface are positioned so that when the printing head is mounted to the shuttle the tip of the pin butts up against the surface;

wherein

the at least one registration pin comprises three registration pins; and

wherein

the tip of a third registration pin is displaced parallel to the line of orifices and away from all the orifices by an accurate distance relative to the first orifice.

33. Apparatus according to claim 28 wherein each printing head is associated with a memory and wherein the memory is comprised in the printing head.

34. Apparatus according to claim 28 wherein each printing head is associated with a memory and wherein the memory comprises profile data that specifies operating characteristics peculiar to the printing head that the controller uses to control the printing head.

35. Apparatus according to claim 34 wherein the profile data becomes accessible to the controller automatically when the printing head is mounted to the shuttle.

36. Apparatus according to claim 34 wherein each orifice is associated with its own actuator controllable to control dispensing of the construction material from the orifice and wherein the profile data comprises data useable to control the actuator.

37. Apparatus according to claim 34 and comprising a temperature monitor that generates signals responsive to temperature of the printing head.

38. Apparatus according to claim 37 wherein the memory comprises calibration data that correlates a characteristic of the signals with temperature of the printing head.

39. Apparatus according to claim 34 wherein the printing head comprises a heat source controllable to maintain the printing head at a desired temperature and wherein the memory comprises data useable to control the heat source.

40. Apparatus according to claim 34 wherein the memory comprises data useable to determine the position of the orifices relative to the orifices of other printing heads mounted to the shuttle.