Method and apparatus for continuous composite three-dimensional printing
DCFirst Claim
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1. A method of manufacturing a three-dimensional object comprising:
- extruding through one or more openings at least one path comprising at least one primary material and at least one secondary material;
wherein the at least one primary material comprises a liquid material,wherein the at least one secondary material comprises at least one strand, andwherein the at least one primary material and the at least one secondary material are extruded contemporaneously;
encasing at least a portion of the at least one secondary material in the at least one primary material;
coupling a portion of the at least one path to an anchor point;
pulling the at least one path through the one or more openings by at least one of moving the one or more openings and moving the anchor point;
adjusting orientation of the at least one path relative to the one or more openings to adjust the shape of the at least one path;
hardening at least a portion of the at least one primary material; and
forming at least a portion of the three-dimensional object from the at least one path as the at least one path is extruded.
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Abstract
A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.
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Citations
41 Claims
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1. A method of manufacturing a three-dimensional object comprising:
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extruding through one or more openings at least one path comprising at least one primary material and at least one secondary material; wherein the at least one primary material comprises a liquid material, wherein the at least one secondary material comprises at least one strand, and wherein the at least one primary material and the at least one secondary material are extruded contemporaneously; encasing at least a portion of the at least one secondary material in the at least one primary material; coupling a portion of the at least one path to an anchor point; pulling the at least one path through the one or more openings by at least one of moving the one or more openings and moving the anchor point; adjusting orientation of the at least one path relative to the one or more openings to adjust the shape of the at least one path; hardening at least a portion of the at least one primary material; and forming at least a portion of the three-dimensional object from the at least one path as the at least one path is extruded. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. An automated method of manufacturing a three-dimensional object comprising:
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receiving a specification related to the three-dimensional object; extruding at least one path through an extruder comprising one or more openings based on the specification, wherein the at least one path comprises at least one primary material and at least one secondary material, wherein the at least one primary material comprises a liquid material, wherein the at least one secondary material comprises at least one strand, wherein the at least one primary material and the at least one secondary material are extruded contemporaneously, and wherein the at least one primary material at least partially encases the at least one secondary material; coupling a portion of the at least one path to an anchor point; pulling the at least one path through the extruder by at least one of moving the extruder and moving the anchor point; and forming at least a portion of the three-dimensional object from the at least one path as the at least one path is extruded. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29)
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30. A method of manufacturing a three-dimensional object comprising:
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extruding at least first and second paths through an extruder, each path comprising at least one primary material and at least one secondary material, wherein the at least one primary material comprises at least one liquid material, wherein the at least one secondary material comprises at least one strand, wherein the at least one primary material and the at least one secondary material are extruded contemporaneously, and wherein at least a portion of the at least one secondary material is encased in the at least one primary material; coupling a portion of the at least first and second paths to one or more anchor points; pulling the first and second paths through the extruder by at least one of moving the extruder and moving the one or more anchor points; hardening at least a portion of the at least one primary material of the first path; manipulating the first and second paths so that the hardened portion of the first path and a non-hardened portion of the second path overlap; hardening the at least one primary material of the second path while the first and second paths are overlapping; and forming at least a portion of a three-dimensional object from the paths as the paths are extruded. - View Dependent Claims (31, 32, 33, 34, 35, 36, 37)
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38. A method of manufacturing a three-dimensional object comprising:
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extruding through one or more openings at least one path comprising at least one primary material and at least one secondary material, wherein the at least one primary material comprises a liquid material, and wherein the at least one secondary material comprises at least one strand, encasing at least a portion of the at least one secondary material in the at least one primary material; coupling a portion of the at least one path to an anchor point; pulling the at least one path through the one or more openings by at least one of moving the one or more openings and moving the anchor point; hardening at least a portion of the at least one primary material as the at least one path is extruded from the one or more openings; and forming at least a portion of the three-dimensional object from the at least one path as the at least one path is extruded. - View Dependent Claims (39, 40, 41)
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Specification