System and method for producing a tangible object

• US 9,205,599 B2
• Filed: 07/06/2007
• Issued: 12/08/2015
• Est. Priority Date: 07/07/2006
• Status: Active Grant

• Current Assignee: Nederlandse Organisatie Voor Toegepast-Natuurwetenschappelijk Onderzoek Tno
• Original Assignee: Nederlandse Organisatie Voor Toegepast-Natuurwetenschappelijk Onderzoek Tno
• Inventors: Maalderink, Herman Hendrikus, Michels, Jasper Joost, Boot, Ronaldus Jacobus Johannes
• Primary Examiner(s): Sanders, James
• Assistant Examiner(s): LE, NINH V
• Application Number:
  US12/306,235
• Publication Number:
  US 20090289384A1
• Time in Patent Office: 3,077 Days
• Field of Search: 425/174.4, 425/375, 425/149, 425/150, 425/170, 264/113, 264/308, 264/401, 264/497, 264/40.7, 700118-120, 700/163, 700/195
• US Class Current: 1/1
• CPC Class Codes: B23Q 17/20 for indicating or measuring workpiece characteristics, e.g. contour, dimension, hardness
• CPC Class Codes: B29C 45/76 Measuring, controlling or regulating measuring in general G01; controlling or regulating in general G05
• CPC Class Codes: B29C 45/766 the setting or resetting of moulding conditions, e.g. before starting a cycle
• CPC Class Codes: B29C 45/80 of relative position of mould parts
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: G05B 19/19 characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
• CPC Class Codes: G05B 19/235 with force or acceleration feedback only
• CPC Class Codes: G05B 19/237 with a combination of feedback covered by G05B19/232 - G05B19/235
• CPC Class Codes: G05B 19/404 characterised by control arrangements for compensation, e.g. for backlash, overshoot, tool offset, tool wear, temperature, machine construction errors, load, inertia G05B19/19, G05B19/41 take precedence
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing

Abstract

A system for producing a tangible object. The system has a space which can be filled with a fluid. A reference platform at least partially defines at least one side of the space. The system further has a phase-transformer which can form a layer of the object by selectively transforming the fluid into a solid in a predetermined area of the space. An actuator can separate the layer from the reference platform by moving the layer relative to the reference platform or vice versa. The system has a controller connected with an actuator control output to the actuator and/or with a transformer control output to the phase transformer. The controller can control the production of the object based on a determined value of the force exerted on the reference platform or the solid or of a parameter related to the force.

Claims

1. A system for producing a tangible object, including:

a space of predetermined thickness which can be filled with a fluid;

a reference platform which at least partially defines at least one side of the space;

a phase-transformer, for forming each of a first layer and a second layer of said object by selectively transforming the fluid into a solid in a predetermined area of said space, the forming of each of said layer including performing a first action with respect to said layer, said first action being selected from a group consisting of (a) initiating a step of separating said solid from said platform, (b) separating said solid from said platform, (c) finishing the step of separating said solid from said platform, (d) starting a step of providing the space of a predetermined thickness, and (e) completing the step of providing the space of predetermined thickness;

the forming of each said layer further including determining a value of (a) a relative force exerted between the reference platform and the solid for separating said solid from said reference platform or (b) a parameter which is predictive of said relative force;

an actuator for separating each of said layers from said reference platform by moving the reference platform relative to another side of the space or vice versa; and

a controller connected with an actuator control output to said actuator and/or with a transformer control output to said phase transformer, said controller being configured and effective (a) to control a period of time or a moment in time for the first action with respect to the first layer based on the determined value for the first layer and (b) to control a period of time or a moment in time for the first action with respect to the second layer based on the determined value for the second layer, wherein the determined value for the first layer is different from the determined value of the second layer, whereby a time to produce the tangible object is reduced.

2. A system according to claim 1, further including:

a sensor for sensing said relative force or the parameter which is predictive of said relative force, and

wherein said controller is connected with a control input to said sensor, for receiving said determined value.

3. A system according to claim 2, wherein said sensor includes a force sensor for measuring a force parallel or opposite to a direction of movement of the first layer, the second layer or the reference platform.

4. A system according to claim 2, wherein said sensor includes a three-point force measurement system.

5. A system according to claim 1, wherein said controller is configured and effective to determine from the relative force value the period of time for the first action.

6. A system according to claim 1, wherein said controller includes a timer, for controlling the actuator based on the determined value as a function of time.

7. A system according to claim 1, wherein said controller includes a comparator connected to a controller input of the controller and to a memory in which a force threshold is stored, for limiting the moving or velocity of the moving in case said determined value exceeds the force threshold.

8. A system according to claim 7, wherein said force threshold is stored as a function of time.

9. A system according to claim 1, wherein said reference platform can be pivoted relative to each of said layers, for at least partially separating the reference platform and the respective layer and/or the respective layer can be moved in a direction away from the reference platform, for providing a space between the reference platform and the respective layer in which a following layer of the object can be produced.

10. A system according to claim 1, further including

a memory in which a model of forces acting on one or more of the layers or the reference platform is stored and wherein the controller includes a control input for receiving data suitable to be inputted in the model to determine said force.

11. A system according to claim 1, further including:

a carrier platform which defines a side of the space opposite to the side defined by said reference platform, to which one or more of said layers may be suspended from said carrier platform for moving the layer relative to the reference platform; and

wherein said actuator can move said carrier platform relative to the reference platform, for separating the layer suspended to the carrier platform from the reference platform.

12. A system according to claim 11, wherein said carrier platform provides a top side of the space and said reference platform defines a bottom side of the space, and said carrier platform is moved upwards and/or said reference platform is moved downwards to separate the layer from the reference platform.

13. A system according to claim 1, wherein the reference platform includes an anti-stick layer which forms a wall of the space.

14. A system according to claim 1, wherein said fluid can be transformed into a solid by energy and the phase-transformer includes a source of energy which can selectively provide the energy to the predetermined area.

15. A system according to claim 14, wherein:

said source of energy includes a source of electro-magnetic radiation;

the reference platform includes a window which is transparent to said radiation; and

said system further includes a projection unit for projecting the electromagnetic radiation through the window onto the predetermined area.

16. A system according to claim 1, wherein the phase-transformer can initiate a chemical reaction of a component in the fluid which results in a solid reaction product.

17. A system according to claim 5, wherein said first action is for separating one of the layers from the reference platform and/or for transforming the fluid into a solid and/or for a cycle of forming a following layer of said tangible object.

18. A system according to claim 16, wherein the chemical reaction results in a solid reaction product via curing a liquid resin by electro-magnetic radiation.

19. A method according to claim 1, wherein, when the determined value for the first layer is different from the determined value of the second layer, the period of time or the moment in time is changed.

23. A controller configured and adapted for a system according to claim 1.

24. A computer program, including program code portions provided on a data carrier, configured and effective to perform the function of a controller according to claim 23 when run on a programmable apparatus.

20. A method for producing a tangible object, including forming a first layer having a first predetermined shape and a second layer having a second predetermined shape, said forming of each layer including:

providing a liquid filled space of predetermined thickness of which at least one side is at least partially defined by a platform;

transforming said liquid into a solid in a predetermined area of the space corresponding to the respective predetermined shape;

separating said solid from said platform by moving the platform relative to another side of the space or vice versa;

said forming of each layer further including determining a value of (a) a relative force exerted between the platform and the solid for said separating said solid from said platform or (b) a parameter which is predictive of said relative force;

the forming of each layer including performing a first action with respect to said layer, said first action being selected from a group consisting of (a) initiating a step of separating said solid from said platform, (b) separating said solid from said platform, (c) finishing the step of separating said solid from said platform, (d) starting a step of providing the space of a predetermined thickness, and (e) completing the step of providing the space of predetermined thickness;

the method including controlling a period of time or a moment in time for the first action with respect to the first layer based on the determined value for the first layer and controlling a period of time or a moment in time for the first action with respect to the second layer based on the determined value for the second layer, wherein the determined value for the first layer is different from the determined value for the second layer, whereby a time to produce the tangible object is reduced.

21. A method according to claim 20, further including forming a following third layer with a predetermined shape by providing a space between said separated solid and said platform, filling said space between said separated solid and said platform with a liquid and repeating said transforming and separating.

22. A method according to claim 20, wherein said forming of said first layer includes determining the value of the relative force exerted between the platform and the solid for said separating said solid from said platform.