Method and apparatus for precisely fitting, reproducing, and creating 3-dimensional objects from digitized and/or parametric data inputs using computer aided design and manufacturing technology

• US 7,225,050 B2
• Filed: 01/04/2002
• Issued: 05/29/2007
• Est. Priority Date: 01/04/2001
• Status: Expired due to Fees

• Current Assignee: Daniel P. Sutula Jr
• Original Assignee: Daniel P. Sutula Jr
• Inventors: Sutula, Daniel P. Jr.
• Primary Examiner(s): Picard; Leo
• Assistant Examiner(s): KASENGE, CHARLES R
• Application Number:
  US10/039,821
• Publication Number:
  US 20020114537A1
• Time in Patent Office: 1,971 Days
• Field of Search: 700/182, 700/180, 700/118, 700/119, 700/159, 700/161, 700/166, 700/169, 700/95, 700/98, 700/117, 700/120, 264/401, 382/285
• US Class Current: 700/182
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 19/4207 in which a model is traced or scanned and corresponding data recorded
• CPC Class Codes: G05B 2219/49008 Making 3-D object with model in computer memory
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A high-technology method for creating, reproducing, and or precisely fitting custom appendages to topographically complex structures. The method comprises a combination of novel measurement techniques in conjunction with computerized modeling and machining processes applied to achieve a virtually perfect tailored fit with mating structures. The method does not require the physical presence of the mating structure so the modeling and machining operations may be conducted at a separate location based solely on parametric dimensional and/or graphical data inputs and a customized data form. Said data may be transmitted conventionally or electronically as by fax or the internet. The invention includes a printed virtual protractor tool (16) for accurately measuring angles. A means for direct digitization of the required topological data input is also provided. The novel aspects of this invention can be combined with conventional fitting equipment and processes. The scope of this invention is exceedingly broad with a variety of potential applications cited. Two examples are presented to illustrate utility in the context of complex operations routinely encounter by gunsmiths in fitting recoil pads (9) to gunstocks (23) and fitting sighting ribs (37) to gun barrels (42).

Claims

1. A method enabling the precise creation, fitting, and reproduction of objects, comprising the steps of:

1) defining a single 2-dimensional profile representation of an object;

2) measuring values from the object and defining a sufficient number of parametric values, comprising angular dimensions and/or linear dimensions and/or point coordinates, wherein the sufficient number of parametric values are derived from the measured values and characterize how the object changes in cross-section in 3-dimensional space with respect to the 2-dimensional profile of step 1;

3) converting the profile and parametric values into an electronic format suitable for input to computer aided design and manufacturing (CAD/CAM) programs;

4) creating a virtual CAD model from the profile and parametric values;

5) calculating Numerical Control (NC) motion commands from the CAD model using CAM technology;

6) processing an object using Computer Numerical Controlled (CNC) machine; and

,

7) transmitting data throughout the process, enabling theses steps to be conducted at any combination of geographic locations.

2. The method of claim 1, wherein step 1 comprises a tracing technique to define the 2-dimensional profile.

3. The method of claim 1, wherein step 1 comprises a digitizing device to define the 2-dimensional profile.

4. The method of claim 1, wherein step 1 comprises an optical scanning process to define the 2-dimensional profile.

5. The method of claim 1, wherein step 1 comprises exposure to a reactive chemical media, to define the 2-dimensional profile.

6. The method of claim 1, wherein step 1 and step 2 comprise a digitizing device to define the 2-dimensional profile and 3-dimensional parametric values.

7. The method of claim 1, wherein step 2 is facilitated by means of printed measuring utensils that may be used to provide accurate measurement of parametric values in the absence of conventional measuring equipment.

8. The method of claim 1, wherein step 1 and step 2 are facilitated by means of an integrated instruction and data acquisition form on which the profile and parametric values are defined and recorded.

9. The method of claim 1, wherein step 3 comprises converting the profile and parametric values by means of optical scanning technology.

10. The method of claim 1, wherein step 6 comprises processing by cutting, grinding, and/or sanding by means of a CNC controlled machine with a rotating tool.

11. The method of claim 1, wherein step 6 comprises processing by cutting or otherwise removing material by means of a CNC controlled machine with a water and/or abrasive media cutting jet.

12. The method of claim 1, wherein step 6 comprises processing by cutting by means of a CNC controlled machine with a cutting wire.

13. The method of claim 1, wherein step 6 comprises processing by cutting by means of a CNC controlled machine with a cutting laser.

14. The method of claim 1, wherein step 6 comprises processing by means of an additive material deposition process enabled by a CNC controlled Rapid Prototyping machine capable of directly producing a part.

15. The method of claim 1, wherein step 7 comprises data transmitted electronically.

16. The method of claim 1, wherein step 7 comprises data transmitted over the Internet.

17. The method of claim 1, wherein any combination of steps 1-7 may be combined consolidated and/or automated.

18. An apparatus enabling the precise creation, fitting, and reproduction of objects, comprising:

1) a means of defining a 2-dimensional profile representation of an object'"'"'s edges;

2) a means of measuring values from the object and defining a sufficient number of parametric values, comprising angular dimensions and/or linear dimensions and/or point coordinates, wherein the sufficient number of parametric values are derived from the measured values and characterize how the object changes in cross-section in 3-dimensional space with respect to the 2-dimensional profile of step 1;

3) a means of converting the profile and parametric values into an electronic format suitable for input to computer aided design and manufacturing (CAD/CAM) programs;

4) a means of creating a virtual CAD model from the profile and parametric values;

5) a means of calculating Numerical Control (NC) motion commands from the CAD model using CAM technology;

6) a means of processing an object using Computer Numerical Controlled (CNC) machine; and

,

7) a means of transmitting data throughout the process, enabling theses steps to be conducted at any combination of geographic locations.