Rapid prototyping apparatus

• US 8,038,427 B2
• Filed: 02/18/2009
• Issued: 10/18/2011
• Est. Priority Date: 05/01/2003
• Status: Active Grant

• Current Assignee: Objet Geometries
• Original Assignee: Objet Geometries
• Inventors: Levi, Moshe, Kritchman, Eliahu M.
• Primary Examiner(s): Ewald; Maria Veronica
• Application Number:
  US12/372,747
• Publication Number:
  US 20090148621A1
• Time in Patent Office: 972 Days
• Field of Search: 425/375, 425/174.4, 264/113, 264/308, 264/401, 700/119
• US Class Current: 425/174.4
• 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. An apparatus for producing an object by sequentially forming thin layers of a material one on top of the other responsive to data defining the object, the apparatus comprising:

at least one printing head controllable to dispense a material in liquid form;

a lamp controllable to provide radiation to irradiate the material; and

a controller operative to control the printing head to dispense the material and sequentially form the layers and the lamp to irradiate the dispensed material;

wherein the lamp comprises an array of LEDs controllable to provide the radiation and wherein the controller is operative to operate at any time during production of the object, a first portion of the LEDs of the array at a higher radiation intensity than a second portion of the LEDs of the array.

2. The apparatus according to claim 1 wherein the controller is operative to switch the LEDs in the array on and off during irradiation of the material.

3. The apparatus according to claim 1, wherein the controller is operative to selectively turn off a portion of the LEDs of the array.

4. The apparatus according to claim 1 wherein the controller is operative to control intensities of some of the LEDs in the array independently of intensities of other LEDs in the array.

5. The apparatus according to claim 4, wherein the controller is operative to control intensities of UV light irradiated by the LEDs.

6. The apparatus according to claim 1, wherein the LEDs in the array irradiate at a selected wavelength.

7. The apparatus according to claim 1 wherein the controller is operative to control a current or voltage supplied to the LEDs.

8. The apparatus according to claim 1 wherein the controller is operative to control a duty cycle of pulses of current or voltage supplied to the LEDs.

9. The apparatus according to claim 1 comprising a micro-lens operative to configure light from the LED into a cone beam of radiation.

10. The apparatus according to claim 9 wherein the cone angle is 80°

or larger.

11. The apparatus according to claim 1 comprising radiation conductors operative to pipe radiation from a location of the LEDs to a location more proximal to a region of a layer to be irradiated.

12. The apparatus according to claim 1, wherein a substantial portion of radiation provided by the lamp is directed so that it is incident at a substantially non-normal angle on the layers.

13. The apparatus according to claim 1, wherein the LEDs are in a form of a semiconductor die.

14. The apparatus according to claim 13, wherein the LEDs are arrayed at a pitch of 2 mm or less.

15. The apparatus according to claim 13, wherein the LEDs are arrayed at a pitch of 1 mm or less.

16. The apparatus according to claim 1, wherein the material is a photopolymer material.

17. A method for producing an object by sequentially forming thin layers of material one on top of the other responsive to data defining the object, the method comprising:

dispensing a material in liquid form with at least one printing head;

irradiating the material with an array of LEDs;

controlling the irradiation of the array of LEDs during the producing; and

controlling the dispensing to sequentially form the layers, wherein controlling the irradiation of the array of LEDs includes operating at any time during the production a first portion of the LEDs of the array at a higher radiation intensity than a second portion of the LEDs of the array.

18. The method according to claim 17 wherein controlling the irradiation of the array of LEDs includes on/off switching of the LEDs in the array, during the production.

19. The method according to claim 17, wherein controlling the irradiation of the array of LEDs includes selectively turning off a portion of the LEDs of the array.

20. The method according to claim 17, wherein controlling the irradiation of the array of LEDs includes controlling intensities of some LEDs in the array independently of intensities of other LEDs in the array.

21. The method according to claim 20, wherein controlling the irradiation of the array of LEDs includes controlling intensities of UV light irradiated by the LEDs.

22. The method according to claim 17, wherein the LEDs in the array irradiate at a selected wavelength.

23. The method according to claim 17 wherein the second portion of the LEDs is directed at a non-printed region of a layer.

24. The method according to claim 17 comprising turning off the second portion of the LEDs.

25. The method according to claim 17 comprising controlling a current or voltage supplied to the LEDs.

26. The method according to claim 17 comprising controlling a duty cycle of pulses of current or voltage supplied to the LEDs.

27. The method according to claim 17 comprising configuring light from the LED into a cone beam of radiation.

28. The method according to claim 27 wherein the cone angle is 80°

or larger.

29. The method according to claim 17 comprising directing radiation from the LEDs to a location proximal to a region of a layer to be irradiated.

30. The method according to claim 17, wherein a substantial portion of radiation provided by the LEDs is directed so that it is incident at a substantially non-normal angle on the layers.

31. The method according to claim 17, wherein the LEDs are arrayed at a pitch of 2 mm or less.

32. The method according to claim 17, wherein the LEDs are arrayed at a pitch of 1 mm or less.

33. The method according to claim 17, wherein the material is a photopolymer material.

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

at least one printing head controllable to dispense a material in liquid form;

a lamp controllable to provide radiation to irradiate the material; and

a controller operative to control the printing head to dispense the material and sequentially form the layers and the lamp to irradiate the dispensed material;

wherein the lamp comprises an array of LEDs controllable to provide the radiation and wherein the controller is operative to alter operation of at least a portion of the LEDs during production of the object so that a first portion of the LEDs of the array is radiated at a higher radiation intensity than a second portion of the LEDs of the array.

35. The apparatus according to claim 34, wherein the controller is operative to selectively turn off a portion of the LEDs of the array.

36. The apparatus according to claim 34 wherein the controller is operative to control intensities of some of the LEDs in the array independently of intensities of other LEDs in the array.

37. A method for producing an object by sequentially forming thin layers of material one on top of the other responsive to data defining the object, the method comprising:

dispensing a material in liquid form with at least one printing head;

irradiating the material with an array of LEDs;

controlling the irradiation of the array of LEDs during the producing; and

controlling the dispensing to sequentially form the layers, wherein controlling the irradiation of the array of LEDs includes altering operation of at least a portion of the LEDs during the production of the object so that a first portion of the LEDs of the array is radiated at a higher radiation intensity than a second portion of the LEDs of the array.

38. The method according to claim 37, wherein controlling the irradiation of the array of LEDs includes selectively turning off a portion of the LEDs of the array.

39. The method according to claim 37, wherein controlling the irradiation of the array of LEDs includes controlling intensities of some LEDs in the array independently of intensities of other LEDs in the array.

40. The method according to claim 37, wherein the second portion of the LEDs is directed at a non-printed region of a layer.