3-D model making

• US 5,740,051 A
• Filed: 11/08/1995
• Issued: 04/14/1998
• Est. Priority Date: 01/25/1991
• Status: Expired due to Term

• Current Assignee: Solidscape, Inc. (Groupe Gorgé SA)
• Original Assignee: Sanders Prototypes Incorporated
• Inventors: Forsyth, John L., Philbrook, Kempton F., Sanders, Royden C. Jr.
• Primary Examiner(s): Elmore, Reba I.
• Assistant Examiner(s): Garland, Steven R.
• Application Number:
  US08/555,037
• Time in Patent Office: 888 Days
• Field of Search: 364/468, 364/474.24, 364/476, 364/477, 364/468.25-468.27, 364/475.01, 264/308, 264/309, 264/401, 264/460, 264/255, 264/317, 264/482, 264/40.1, 264/122, 156/379.6, 156/272.8, 156/273.3, 156/64, 156/58, 347/1, 347/23, 347/37, 164/46, 118/695, 425/375, 427/466
• US Class Current: 700/119
• CPC Class Codes: B29C 2791/002 Making articles of definite length, i.e. discrete articles B29C53/40 takes precedence
• CPC Class Codes: B29C 2793/009 after shaping
• 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 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/182 in parallel batches
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• 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 2995/0021 Multi-coloured
• CPC Class Codes: B29K 2995/0026 Transparent
• CPC Class Codes: B29L 2031/40 Test specimens ; Models, e.g. model cars mannequins B29L2031/7028; Probes
• CPC Class Codes: B41J 3/4073 Printing on three-dimensional objects not being in sheet or web form, e.g. spherical or cubic objects B41J3/283, B41J3/286 take precedence; building up a 3D object using individual droplets from jetting heads B29C64/112
• CPC Class Codes: G05B 2219/49031 Project particles, laser beam to point using two, more jets, beams, ballistic particle
• CPC Class Codes: Y02P 80/40 Minimising material used in manufacturing processes

Abstract

A method of and apparatus for producing a 3-D model by forming a continuous plurality of parallel layers of modeling material comprising a) producing a plurality of bead producing drops of the modeling material for deposition at desired locations b) controlling the locations and timing of deposition to produce vectors, in any and all directions required to produce an outer surface defining wall of said layer with a desired surface finish; c) adjusting the distance of the location of drop production to the location of drop deposition in preparation for the formation of a subsequent said layer; and d) repeating steps a), b), and c) as required to complete the model.

Claims

1. A method of producing a 3-D model by forming a contiguous plurality of parallel layers of modeling material on a platform comprising the steps of:

a) producing a plurality of bead producing drops of the modeling material for deposition from a drop on demand jet at desired locations to solidify into beads to form at least a portion of a layer of said parallel layers;

b) controlling the locations of deposition by simultaneously coordinating relative movement in the X-Y coordinates for a support arrangement of said jet to produce vectors, defined by overlapping pluralities of the beads, in any and all directions required to produce, by vector plotting, at least a desired outer surface defining wall;

c) timing the production of said plurality of beads, at least, when producing said desired outer surface defining wall to overlap previously deposited beads to a desired extent and to meld with previously deposited beads to produce said vectors, thereby forming said desired outer surface defining wall with a desired surface finish;

d) adjusting the distance of the location of drop production to the location of drop deposition following formation of said layer in preparation for the formation of a subsequent said layer; and

e) repeating steps a), b), c), and d) as required to complete the model.

2. The method according to claim 1, further comprising the step of machining, at select intervals, the last deposited layer to a uniform thickness along a plane defined by the layers before depositing a said next layer of the model.

3. The method according to claim 2, further comprising the step of machining each deposited layer along said plane before deposition of a said next layer of the model, thereby to form said desired outer surface defining wall with a desired surface finish.

4. The method according to claim 3, wherein the step of machining comprises removing at least about 25% of the thickness of each layer.

5. The method according to claim 2, further comprising the steps of:

depositing a wall of support material contiguous with the outer surface of at least said desired outer surface defining wall after shrinkage of the deposited modeling material, but before machining, to support the outer surface defining wall during machining, thereby to substantially prevent delamination, fraying, and chipping of said desired outer surface defining wall during machining and form said desired outer surface defining wall with a desired surface finish; and

subsequently removing the support material.

6. The method according to claim 1, further comprising the step of depositing at least one of a molten modeling material and a molten fill and support material to produce lattice walls, to at least one of i) support cantilever portions and other overhanging portions of the model during production and ii) provide a fill structure in interior spaces of the model.

7. The method according to claim 6, wherein the step of depositing molten material to produce lattice walls comprises, producing a plurality of unidirectional walls oriented and joined with the outer surface defining wall to provide desired reinforcement of hollow models.

8. The method according to claim 6, wherein the step of depositing molten material to produce lattice walls comprises producing a plurality of bi-directional walls oriented and joined with the outer surface defining wall(s) to provide desired reinforcement of hollow models.

9. The method according to claim 6, wherein the step of depositing molten material to produce lattice walls comprises producing an interconnecting inner wall structure, that is intimately connected to an outer wall structure formed during the formation of the same layer to provide desired reinforcement of hollow models.

10. The method according to claim 9, further comprising the step of closing off the top of the model with a single layer of modeling material by:

a) depositing beads of molten modeling material on a first half of a top surface of each outer and lattice wall of the modeling during a first pass;

b) depositing beads of molten modeling material on a second half of the top surface of each outer and lattice wall of the model during a second pass, such that the molten modeling material flows down the sides of the walls and, due to capillary action, surface cohesion and surface tension, contact and meld with adjacent beads, closing off the top of the model with a single layer of modeling material.

11. The method according to claim 10, further comprising the steps of:

before closing off the top of the model with a single layer of modeling material, machining the last deposited layer along plane defined by the layer; and

after closing off the top of the model with a single layer of modeling material, machining along a plane defined by the layer.

12. The method according to claim 1, further comprising the step of depositing a plurality of differently colored and transparent build materials in each layer to produce a transparent 3-D model, in which interior 3-D formations can be seen.

13. The method according to claim 12, wherein the step of depositing a plurality of differently colored and transparent build materials in each layer produces a biological model.

14. The method according to claim 12, depositing a plurality of differently colored and transparent build materials in each layer to form a 3-D model in which each layer accurately represents a corresponding slice produced by a medical imaging machine to produce an accurate at least partially transparent biological model.

15. The method according to claim 12, further comprising the step of forming at least the outer boundary defining layers of the differently colored build materials by vector plotting, to facilitate formation of distinct boundaries between the differently colored build materials.

16. The method according to claim 15, further comprising the step of depositing the modeling material, at least when forming the outer boundary defining layers, at an elevated temperature, such that the build material cools upon contact with the model to hold the desired pattern until the layer hardens.

17. The method according to claim 1, further comprising the step of filling interior spaces of the model with fill material by depositing a constant stream of fill material.

18. The method according to claim 1, further comprising the step of simultaneously producing pluralities of bead producing drops of modeling material, to simultaneously build a corresponding plurality of substantially identical models.

19. A method according to claim 1, further comprising the step of controlling rate of production of the plurality of beads, at least when forming said desired outer surface defining wall of the model, in response to vector plotting speed, acceleration and direction to provide a constant vector bead pitch regardless of speed, acceleration, angle or curvature of said vector, thereby to provide said outer surface defining wall of modeling material with a substantially constant width and with sides having a desired surface quality regardless of speed, acceleration, direction or curvature of said vector.

20. The method according to claim 1, wherein the 3-D model is a contour mold and said desired outer surface defines a portion of the interior of the mold, comprising the steps of:

f) filling the contour mold with a build material to produce a layer of a molded model, with at least a desired outer surface defining wall of the model, molded by said inner surface defining wall, having a desired surface finish;

g) adjusting the distance of the location of drop production to the location of drop deposition following formation of said layers in preparation for formation of a subsequent said layer;

h) repeating steps a), b), c), d), e), f) and g) as required to complete the contour mold and the molded model; and

i) removing the contour mold.

21. A method according to claim 20, further comprising the step of machining each completed layer to remove any build material accidentally deposited on the contour mold to expose the contour mold before deposition of the next layer of the contour mold.

22. The method according to claim 21, comprising the steps of:

depositing one of a U.V. curable, catalytically curable and thermosetting build material to fill the contour mold;

causing each layer to solidify before machining; and

removing the contour mold by one of melting and dissolving the modeling material.

23. The method according to claim 20, comprising the steps of:

depositing a relatively low melting point, LMP, modeling material to form the contour mold and a relatively high melting point, HMP, build material, as compared to the LMP, to fill the contour mold;

machining each layer after that layer has cooled; and

removing the contour mold upon completion of the model by one of melting and dissolving the contour mold.

24. The method according to claim 23, wherein the LMP has a melting point from about 60°

to about 70°

C. and the HMP has a melting point of at least about 80°

C.

25. The method according to claim 23, further comprising the step of depositing HMP to form a support structure to support overhanging portions of the contour mold.

26. The method according to claim 25, further comprising the step of depositing webs of LMP to separate sections of the support structure and facilitate removal of the support structure upon completion of the model.

27. The method according to claim 20, further comprising the steps of:

depositing a plurality of differently colored and transparent build materials in each layer to produce a transparent 3-D model, in which interior 3-D formations can be seen.

28. The method according to claim 27, depositing the plurality of differently colored and transparent build materials to form a plurality layers that accurately represent corresponding slices produced by a medical imaging machine, thereby to produce an accurate partially transparent biological model.

29. The method according to claim 27, further comprising the step of forming the different colored and transparent build materials at least at an outer boundary defining layer by vector plotting, to facilitate formation of distinct boundaries between the differently colored build materials.

30. The method according to claim 29, further comprising the step of depositing the build material, at least when forming the outer boundary defining layers, at an elevated temperature, such that the build material cool upon contact with the model to hold the desired pattern until solidification of each layer.

31. A method according to claim 20, further comprising the step of controlling rate of production of the plurality of beads of modeling material, at least when forming said desired inner surface defining wall of the contour mold, in response to vector plotting speed, acceleration and direction to provide a constant vector bead pitch regardless of speed, acceleration, angle or curvature of said vector and thereby provide said desired portion of said inner surface defining wall of the contour mold with a substantially constant width and sides with a desired surface quality regardless of speed, acceleration, direction or curvature of said vector.

32. The method according to claim 20, comprising the steps of depositing the modeling material, at least when forming said inner surface defining wall of the contour mold by vector plotting and filling the contour mold with build material by raster scanning.

33. The method according to claim 20, comprising the step of filling the contour mold with build material by depositing a constant stream of build material.

34. A 3-D model maker for producing a 3-D model by sequentially forming layer upon layer, by plotting vectors of modeling material, one layer at a time comprising:

a) a support means defining a surface for supporting the 3-D model during production;

b) a drop on demand jet means for ejecting discrete bead producing drops of molten modeling material one drop at a time upon demand to meld with previously deposited beads, thereby to plot vectors of modeling material defining the layers;

c) mounting means mounting the jet means i) for simultaneous movement along at least two axes of an X, Y, Z axis coordinate system relative to said surface to move the jet means along any desired vector direction while said jet means plots said vectors of modeling material on said surface and ii) for movement of the jet means, when desired, along all three of the X, Y, Z axes of the system, relative to said surface; and

d) control means i) for providing vector plotting control of movement of the mounting means to move the jet means simultaneously along the at least two axes of the X, Y, Z axis coordinate system, and ii) for controlling the timing of the ejection of bead producing drops of molten modeling material by the jet means to overlap previously deposited beads to a desired extent and to meld with previously deposited beads to generate vectors of modeling material, defined by the beads, in any and all directions required to produce, layer by layer by vector plotting, at least a desired outer surface defining wall-of the model with a desired surface quality.

35. A model maker according to claim 34, wherein said jet means also comprises a continuous stream jet means, for ejecting an elongate bead producing continuous stream of molten modeling material to meld with previously deposited elongate beads, thereby to plot vectors of modeling material defining the layers, such that said jet means is a combined drop on demand and continuous stream jet means, for selectively emitting one of i) discrete bead producing drops and ii) an elongate bead producing continuous stream of molten modeling material, as desired.

36. A 3-D model maker for producing a 3-D model by sequentially forming layer upon layer, by plotting vectors of modeling material, one layer at a time comprising:

a) a support means defining a surface for supporting the 3-D model during production;

b) a continuous stream jet means for ejecting an elongate bead producing continuous stream of molten modeling material to meld with previously deposited beads, thereby to plot vectors of modeling material defining the layers;

c) mounting means mounting the jet means i) for simultaneous movement along at least two axes of an X, Y, Z axis coordinate system relative to said surface to move the jet means along any desired vector direction while said jet means plots said vectors of modeling material on said surface and ii) for movement of the jet means, when desired, along all three of the X, Y, Z axes of the system, relative to said surface; and

d) control means i) for providing vector plotting control of movement of the mounting means to move the jet means simultaneously along the at least two axes of the X, Y, Z axis coordinate system, and ii) for controlling the volumetric rate of ejection of the bead producing stream of molten modeling material by the jet means to generate vectors of modeling material, defined by the beads, in any and all directions required to produce, layer by layer by vector plotting, at least a portion of at least the outer surface defining walls of the model with a substantially continuous thickness and thereby provide walls with a desired surface quality.

37. A model maker according to claim 36, wherein said jet means further includes a drop on demand jet means jet means, for ejecting discrete bead producing drops of molten modeling material, upon demand, to overlap previously deposited discrete beads to a desired extent and to meld with previously deposited discrete beads, thereby to plot vectors of modeling material defining the layers, such that said jet means is a combined drop on demand and continuous stream jet means for selectively ejecting one of i) a an elongate bead producing continuous stream and ii) discrete bead producing drops of modeling material, as desired.

38. A method of producing a 3-D model by forming a contiguous plurality of parallel layers of modeling material comprising the steps of:

a) producing a plurality of bead producing drops of the modeling material for deposition at desired locations to solidify into beads to format least a portion of a layer of said parallel layers;

b) controlling the locations of deposition to produce vectors, defined by overlapping pluralities of the beads, in any and all directions required to produce, by vector plotting, at least a desired outer surface defining wall;

c) timing the production of said plurality of beads, at least, when producing said desired outer surface defining wall to overlap previously deposited beads to a desired extent and to meld with previously deposited beads to produce said vectors, thereby forming said desired outer surface defining wall with a desired surface finish;

d) adjusting the distance of the location of drop production to the location of drop deposition following formation of said layer in preparation for the formation of a subsequent said layer; and

e) repeating steps a), b), c), and d) as required to complete the model.

39. A method of producing a 3-D model by forming a continuous plurality of parallel layers of modeling material comprising the steps of:

a) producing a plurality of bead producing drops of the modeling material for deposition at desired locations to solidify into beads to format least a portion of a layer of said parallel layers;

b) controlling the locations of deposition to produce vectors, defined by overlapping pluralities of the beads, in any and all directions required to produce, by vector plotting, at least a desired outer surface defining wall;

c) timing the production of said plurality of beads, at least, when producing said desired outer surface defining wall to overlap previously deposited beads to a desired extent and to meld with previously deposited beads to produce said vectors, thereby forming said desired outer surface defining wall with a desired surface finish;

d) adjusting the distance of the location of drop production to the location of drop deposition following formation of said layer in preparation for the formation of a subsequent said layer;

e) machining, at select intervals, the last deposited layer to a uniform thickness along a plane defined by the layers before depositing a said next layer of the model,

wherein the step of machining comprises milling a coarse cut that removes a top, of the last deposited layer substantially to the plane during a first pass and milling a fine climb cut that removes the remainder of the deposited layer down to the plane during a return pass; and

f) repeating steps a), b), c), d), and e) as required to complete the model.

40. The method according to claim 39, wherein the step of milling a coarse cut comprises removing a layer of material sufficiently thick that a layer less than approximately 0.01 mm thick is removed during the fine climb cut.

41. A method of producing a 3-D model by forming a contiguous plurality of parallel layers of modeling material comprising the steps of:

a) producing a plurality of bead producing drops of the modeling material for deposition at desired locations to solidify into beads to format least a portion of a layer of said parallel layers;

b) controlling the locations of deposition to produce vectors, defined by overlapping pluralities of the beads, in any and all directions required to produce, by vector plotting, at least a desired outer surface defining wall;

c) timing the production of said plurality of beads, at least, when producing said desired outer surface defining wall to overlap previously deposited beads to a desired extent and to meld with previously deposited beads to produce said vectors, thereby forming said desired outer surface defining wall with a desired surface finish;

d) adjusting the distance of the location of drop production to the location of drop deposition following formation of said layer in preparation for the formation of a subsequent said layer;

e) when an inter-layer build angle of an outer surface defining wall is less than a predetermined critical angle from vertical;

i) forming the outer surface defining wall by depositing at least two contiguous layers of beads of modeling material to produce said desired outer surface defining wall; and

ii) filling interior spaces of the model by depositing a single layer of support material formed by drops that are substantially twice as large as said bead producing drops of modeling material, thereby to decrease the time required to fill said interior spaces; and

f) repeating steps a), b), c), d), and e) as required to complete the model.

42. The method according to claim 41, further comprising the steps of, at least when the inter-layer build angle exceeds the critical angle from vertical:

depositing a support material at least, contiguous with, said outer surface defining wall during formation of each layer, to support beads of said outer surface defining wall in the next layer formed.

43. The method according to claim 42, wherein the critical angle is approximately 30 degrees from vertical.

44. A method of producing a 3-D model by forming a contiguous plurality of parallel layers of modeling material comprising the steps of:

a) producing a plurality of bead producing drops of the modeling material for deposition at desired locations to solidify into beads to format least a portion of a layer of said parallel layers;

b) controlling the locations of deposition to produce vectors, defined by overlapping pluralities of the beads, in any and all directions required to produce, by vector plotting, at least a desired outer surface defining wall;

c) timing the production of said plurality of beads, at least, when producing said desired outer surface defining wall to overlap previously deposited beads to a desired extent and to meld with previously deposited beads to produce said vectors, thereby forming said desired outer surface defining wall with a desired surface finish;

d) adjusting the distance of the location of drop production to the location of drop deposition following formation of said layer in preparation for the formation of a subsequent said layer;

e) depositing at least one of a molten modeling material and a molten fill and support material to produce lattice walls, to at least one of i) and ii), wherein,

i) support cantilever portions and other overhanging portions of the model during production, and

ii) provide a fill structure in interior spaces of the model,

and wherein depositing molten material to produce lattice walls comprises producing an interconnecting inner wall structure, that is intimately connected to an outer wall structure formed during the formation of the same layer to provide desired reinforcement of hollow models,

and further wherein the step of producing said interconnecting inner wall structure that is intimately connected to said outer wall comprises the steps of;

1) forming the outer wall structure of the model;

2) filling interior spaces in the model by forming the interconnecting inner wall structure, leaving a gap between the interconnecting wall structure and the outer wall structure; and

3) after shrinkage of the interconnecting inner wall structure, closing the gap to join the interconnecting wall structure with the outer wall structure; and

f) repeating steps a), b), c), d), and e) as required to complete the model.

45. The method according to claim 44, wherein the gap has a width approximately equal to one half of the width of the outer wall structure.

46. A method of producing a 3-D model by forming a continuous plurality of parallel layers of modeling material comprising the steps of:

a) producing a plurality of bead producing drops of the modeling material for deposition at desired locations to solidify into beads to format least a portion of a layer of said parallel layers;

b) controlling the locations of deposition to produce vectors, defined by overlapping pluralities of the beads, in any and all directions required to produce, by vector plotting, at least a desired outer surface defining wall;

c) timing the production of said plurality of beads, at least, when producing said desired outer surface defining wall to overlap previously deposited beads to a desired extent and to meld with previously deposited beads to produce said vectors, thereby forming said desired outer surface defining wall with a desired surface finish;

d) adjusting the distance of the location of drop production to the location of drop deposition following formation of said layer in preparation for the formation of a subsequent said layer;

e) depositing a plurality of differently colored and transparent build materials in each layer to form a 3-D model in which each layer accurately represents a corresponding slice produced by a medical imaging machine to produce an accurate at least partially transparent biological model;

f) interpolating data between slices produced by the imaging machine and forming layers in the 3-D model that are thinner than the slices produced by the imaging machine, thereby to enhance the resolution of the model; and

g) repeating steps a), b), c), d), e), and f) as required to complete the model.

47. A method of producing a 3-D model by forming a contiguous plurality of parallel layers of modeling material comprising the steps of:

a) producing a plurality of bead producing drops of the modeling material for deposition at desired locations to solidify into beads to format least a portion of a layer of said parallel layers;

b) controlling the locations of deposition to produce vectors, defined by overlapping pluralities of the beads, in any and all directions required to produce, by vector plotting, at least a desired outer surface defining wall;

c) timing the production of said plurality of beads, at least, when producing said desired outer surface defining wall to overlap previously deposited beads to a desired extent and to meld with previously deposited beads to produce said vectors, thereby forming said desired outer surface defining wall with a desired surface finish only in portions of the model where said desired surface finish is required;

d) adjusting the distance of the location of drop production to the location of drop deposition following formation of said layer in preparation for the formation of a subsequent said layer;

e) depositing molten modeling material using raster scanning to produce a lattice model structure to be deposited layer upon layer to quickly produce a near net shape model, leaving the lattice model structure exposed, except where closed off by said outer surface defining wall; and

f) repeating steps a), b), c), d), and e) as required to complete the model.

48. The method according to claim 47, further comprising the step of depositing support material to form a lattice support structure having an identical lattice as the lattice model structure, to support overhanging portions of the lattice model structure.

49. The method according to claim 47, further comprising the step of sealing the exposed lattice model structure by one of dipping, spraying, brushing and coating a sealing material onto the exposed lattice model structure to one of seal, enclose and fill open spaces in the exposed lattice structure, to produce a near net shape model.

50. The method according to claim 49, further comprising the step of using the near net shape model to form a near net shape mold for casting a near net shape article.

51. The method according to claim 49, comprising forming the near net shape model as a mold for casting a near net shape article.

52. A method of producing a contour mold by forming a contiguous plurality of parallel layers of modeling material comprising the steps of:

a) producing a plurality of bead producing drops of the modeling material for deposition at desired locations to solidify into beads to format least a portion of a layer of said parallel layers;

b) controlling the locations of deposition to produce vectors, defined by overlapping pluralities of the beads, in any and all directions required to produce, by vector plotting, at least a desired outer surface defining wall thereby to define a portion of the interior of the contour mold;

c) timing the production of said plurality of beads, at least, when producing said desired outer surface defining wall to overlap previously deposited beads to a desired extent and to meld with previously deposited beads to produce said vectors, thereby forming said desired outer surface defining wall with a desired surface finish;

d) filling the contour mold with a build material to produce a layer of a molded model, with at least a desired outer surface defining wall of the model, molded by said inner surface defining wall, having a desired surface finish;

e) adjusting the distance of the location of drop production to the location of drop deposition following formation of said layers in preparation for formation of a subsequent said layer;

f) depositing a plurality of differently colored and transparent build materials to form a plurality layers that accurately represent corresponding slices produced by a medical imaging machine, thereby to produce an accurate partially transparent biological model;

g) interpolating data between slices produced by the imaging machine and forming layers in the biological model that are thinner than the slices produced by the imaging machine, thereby to enhance the resolution of the biological model; and

h) repeating steps a), b), c), d), e), f), and g) as required to complete the contour model and the molded model.