Method for building a three dimensional object

• US 7,685,694 B2
• Filed: 04/03/2008
• Issued: 03/30/2010
• Est. Priority Date: 03/21/2001
• Status: Expired due to Term

• Current Assignee: Stratasys Incorporated
• Original Assignee: Objet Geometries
• Inventors: Gothait, Hanan, Zagagi, Zvi, Miller, Gershon
• Primary Examiner(s): Cozart; Jermie E
• Application Number:
  US12/062,094
• Publication Number:
  US 20080211124A1
• Time in Patent Office: 726 Days
• Field of Search: 294/58, 295/271, 295/272, 295/275, 295/276, 295/30, 295/57, 700/118, 700/119, 700/182, 264/494, 264/308
• US Class Current: 29/458
• CPC Class Codes: B29C 35/04 using liquids, gas or steam
• CPC Class Codes: B29C 35/08 by wave energy or particle radiation B29C64/00, B29C71/04 take precedence
• CPC Class Codes: B29C 37/0067 Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other separating agents B29C33/60
• 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 70/68 by incorporating or moulding on preformed parts, e.g. inserts or layers , e.g. foam blocks mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70
• 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 40/20 Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: Y10T 29/49885 with coating before or during assembling
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material
• CPC Class Codes: Y10T 29/49982 Coating
• CPC Class Codes: Y10T 29/49993 Filling of opening

Abstract

A method for building a three-dimensional (3-D) object is provided. The method may include dispensing an interface material to form a lower part of the three dimensional object, inserting an insert into a recess present in the lower part and dispensing the interface material on the lower part to form the three dimensional object.

Claims

1. A method for building a three-dimensional object, the method comprising:

dispensing, layer by layer, an interface material from nozzles of a print head to form a lower part of the three-dimensional object, the lower part having a recess;

curing the interface material;

inserting an insert into the recess; and

dispensing additional interface material, layer by layer, on the lower part and the insert to form an upper part of the three-dimensional object.

2. The method of claim 1, wherein said interface material comprises a building material.

3. The method of claim 1, wherein said interface material comprises a building material and a support material.

4. The method of claim 1 comprising:

removing remnants of uncured interface material prior to inserting the insert into the recess.

5. The method of claim 1, wherein the recess is larger than the insert and further comprising:

after inserting the insert into the recess, dispensing interface material onto the recess to fill gaps between cured material and the insert.

6. The method of claim 1 comprising:

dispensing a support material to form at least a portion of a support structure for supporting the three-dimensional object.

7. The method of claim 1, wherein the insert is rigid, semi-rigid or flexible.

8. The method of claim 1, wherein the insert is made of an insert material different than the interface material.

9. The method of claim 8, wherein the insert material is more rigid than the interface material after the interface material is cured.

10. The method of claim 1, wherein the insert includes plastic.

11. The method of claim 1, wherein the insert includes metal.

12. The method of claim 1, wherein the insert includes wood.

13. The method of claim 1, wherein the insert is a plate shaped member.

14. The method of claim 1, wherein the insert is a skewed member.

15. The method of claim 1, wherein the insert includes threads.

16. A method for building a three-dimensional object, the method comprising:

dispensing, layer by layer, an interface material from nozzles of a print head to form a lower part of the three-dimensional object, the lower part having a recess;

inserting an insert into the recess; and

dispensing additional interface material, layer by layer, on the lower part and the insert to form an upper part of the three-dimensional object;

dispensing a support material to form at least a portion of a support structure for supporting the three-dimensional object, the support structure comprises at least one pillar of building material surrounded by the support material.