Three-dimensional fabrication with cavity filling

• US 9,475,233 B2
• Filed: 10/29/2013
• Issued: 10/25/2016
• Est. Priority Date: 10/29/2012
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: MakerBot Industries, LLC (Ultimaker BV)
• Inventors: Schmehl, Peter Joseph
• Primary Examiner(s): SCHIFFMAN, BENJAMIN A
• Application Number:
  US14/065,449
• Publication Number:
  US 20140121813A1
• Time in Patent Office: 1,092 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B29C 2948/9258 Velocity
• CPC Class Codes: B29C 2948/92704 Temperature
• CPC Class Codes: B29C 48/02 Small extruding apparatus, e.g. handheld, toy or laboratory extruders
• CPC Class Codes: B29C 48/154 Coating solid articles, i.e. non-hollow articles
• CPC Class Codes: B29C 48/265 Support structures or bases for apparatus, e.g. frames
• CPC Class Codes: B29C 48/266 Means for allowing relative movements between the apparatus parts, e.g. for twisting the extruded article or for moving the die along a surface to be coated
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/205 Means for applying layers
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• 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: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29K 2105/0067 Melt
• 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: 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: B33Y 80/00 : Products made by additive manufacturing

Abstract

A three-dimensional printer is configured to fill interior cavities of a fabricated object with functional or aesthetic materials during fabrication. In general, a number of layers can be fabricated with an infill pattern that leaves void space within an exterior surface of the object. These void spaces can receive a second material such as an epoxy or adhesive that spans multiple layers of the object to increase structural integrity. Similarly, aesthetic materials may be used to add color, opacity or other desired properties to a fabricated object. The void spaces can also or instead form molds that are filled with a build material to provide a fabricated object.

Claims

1. A method comprising:

fabricating a number of layers of an object with a three-dimensional printer using a first material to provide an object having a number of layers including an exterior surface and an infill within the exterior surface;

depositing a second material within a void space defined by the infill within the exterior surface; and

fabricating at least one additional layer above the number of layers to enclose the second material within the void space.

2. The method of claim 1 wherein the void space forms a mold for a three-dimensional object and the second material includes a build material for the three-dimensional object.

3. The method of claim 1 wherein the infill is formed of a regular geometry.

4. The method of claim 1 wherein the first material is a build material selected from a group consisting of acrylonitride butadiene styrene (ABS), high-density polyethylene (HDPL), and polylactic acid (PLA).

5. The method of claim 1 wherein the second material is a structural filler.

6. The method of claim 5 wherein the structural filler is one or more of a foam, a resin, an adhesive, an epoxy, and a glue.

7. The method of claim 5 wherein the structural filler is a curable adhesive.

8. The method of claim 1 wherein the second material is an aesthetic filler.

9. The method of claim 8 wherein the aesthetic filler is a colored filler.

10. The method of claim 8 wherein the aesthetic filler is an opaque filler.

11. The method of claim 8 wherein the aesthetic filler is a liquid.

12. The method of claim 11 wherein the void space includes a prism extending through the number of layers.

13. The method of claim 12 wherein the prism includes a rectangular prism or a cylinder.

14. The method of claim 12 wherein the prism is perpendicular to the number of layers.

15. The method of claim 12 wherein the prism passes diagonally through the number of layers.

16. The method of claim 12 wherein the void space includes a plurality of prisms extending through the number of layers.

17. The method of claim 16 wherein each one of the plurality of prisms has a top and a bottom each at a different layer height than another one of the plurality of prisms.

18. The method of claim 1 wherein the void space is defined by a closed shape within each of the number of layers, where the closed shape in one of the number of layers has edges offset from at least one other closed shape in an adjacent one of the number of layers.

19. The method of claim 18 wherein the closed shape in each one of the number of layers is offset relative to an adjacent closed shape in an adjacent one of the number of layers.

20. The method of claim 19 wherein a number of offsets for a number of closed shapes in a number of layers are arranged in a regular vertical pattern.

21. The method of claim 20 wherein the regular vertical pattern includes a sinusoid or a vertical V.