2980results about "Additive manufacturing with liquids" patented technology

A variety of support structures and build styles for use in Rapid Prototyping and Manufacturing systems are described wherein particular emphasis is given to Thermal Stereolithography, Fused Deposition Modeling, and Selective Deposition Modeling systems, and wherein a 3D modeling system is presented which uses multijet dispensing and a single material for both object and support formation.

A system and methods for solid freeform fabrication of an object is disclosed. The system comprises a solid freeform fabrication apparatus having a plurality of dispensing heads, a building material supply apparatus configured to supply a plurality of building materials to the fabrication apparatus, and a control unit configured for controlling the fabrication apparatus and the supply apparatus based on an operation mode selected from a plurality of predetermined operation modes.

Methods, devices and systems for efficient 3D printing that address conventional inefficiencies while utilizing a single compact device are set forth. Some embodiments utilize a circular-shaped build area revolving symmetrically around a single center point utilizing a continuous helical printing process. In one embodiment a liquid photopolymer for solidification is deposited on a build platform to form the physical object The Build platform is continuously rotated and simultaneously raised in a gradual programmed manner. Focused from below the platform produces a single continuous “layer” of material deposited and bonded in a helical fashion.

A pseudo composite material, may include, inter alia, a first phase and a second phase, wherein each phase may include, inter alia, an organic compound, wherein each phase comprising a multiplicity of construction layers, wherein the layers were deposited by ink-jet printing, wherein the pseudo composite material exhibits non-homogeneous three-dimensional structure. A method is disclosed for the preparation of a pseudo composite material. An apparatus is disclosed for printing a pseudo composite material. Furthermore, there is disclosed a method for printing a three-dimensional object using various suitable materials.

An extrusion-based freeform fabrication method for making a three-dimensional object from a design created on a computer, including (a) providing a support member; (b) operating a dispensing head having at least one dispensing nozzle with a discharge orifice for dispensing continuous strands of a material composition in a fluent state at a first temperature onto the support member, the material composition including a reactive prepolymer with a melting point above 23° C. and the first temperature being greater than the prepolymer melting point; (c) operating material treatment devices for causing the dispensed strands of material composition to rapidly achieve a rigid state in which the material composition is substantially solidified to build up the 3-D object, the material treatment devices also working to convert the reactive prepolymer to a higher molecular weight thermoplastic resin; and (d) operating control devices for generating control signals in response to coordinates of the object design to control the movement of the dispensing nozzle relative to the support member and for controlling the strand dispensing of the material composition to construct the 3-D object.

The present invention is a method for performing a calibration routine of a deposition device in a three-dimensional modeling machine that deposits a material to build up three-dimensional objects as directed by a controller on a substrate mounted on a platform. The method comprises generating a material build profile, which represents a three-dimensional structure at defined locations. A relative position of the material build profile is then determined. An expected build profile is identified and then compared to the determined relative position of the material build profile to identify any difference which represents an offset. The modeling system then positions the deposition device based upon the offset.

An apparatus which extrudes flowable material from a liquifier includes a system for loading filament supplied in a cassette. The cassette is loaded into a loading bay of the apparatus. A strand of filament from the cassette is engaged and advanced along a path to the liquifier using a drive wheel or roller pair. A conduit having an entrance in the loading bay guides the filament as it is advanced. The filament loading system of the present invention provides a convenient manner of loading and unloading filament in a three-dimensional modeling machine, and can be implemented in a manner that protects the filament from environmental moisture.

A deposition modeling system incorporates a drive mechanism to feed a strand of filament to create a model. The drive mechanism comprises a pivot block that is rotatably connected to a fixed block and a motor that rotates a drive shaft. A drive roller is connected to the drive shaft and an idler roller is connected to an idler axle that extends from the pivot block in a substantially perpendicular direction to the direction of rotation of the pivot block with respect to the fixed block and in a substantially parallel direction to the drive shaft.

A deposition modeling system incorporates a drive mechanism to feed a strand of filament to create a model. The drive mechanism comprises a pivot block that is rotatably connected to a fixed block and a motor that rotates a drive shaft. A drive roller is connected to the drive shaft and an idler roller is connected to an idler axle that extends from the pivot block in a substantially perpendicular direction to the direction of rotation of the pivot block with respect to the fixed block and in a substantially parallel direction to the drive shaft.

The present invention relates to an article fabrication system having a plurality of material deposition tools containing one or more materials useful in fabricating the article, and a material deposition device having a tool interface for receiving one of the material deposition tools. A system controller is operably connected to the material deposition device to control operation of the material deposition device. Also disclosed is a method of fabricating an article using the system of the invention and a method of fabricating edible foodstuffs.

A direct write or freeform fabrication apparatus and process for making a device or a three-dimensional object. By way of example the method comprises: (a) providing a target surface on an object-supporting platform; (b) operating a material deposition sub-system comprising a liquid deposition device for dispensing at least a liquid composition and a solid powder-dispensing device for dispensing solid powder particles to selected locations on the target surface; (c) operating a directed energy source for supplying energy to the dispensed liquid composition and the dispensed powder particles to induce a chemical reaction or physical transition thereof at the selected locations; and (d) moving the deposition sub-system and the object-supporting platform relative to one another in a plane defined by first and second directions to form the dispensed liquid composition and the dispensed powder particles into the device or object. An apparatus is also provided for carrying out this process.

A process of, and apparatus for, three-dimensional printing of an object (200) from modeling material (220) including a printing tray (170) having a surface coating (202), a carpet (210), a support material (215), a support pedestal (210), a barrier layer (230) and a temperature control unit (204).

The present invention relates to 3D printer inputs including filaments comprising separated layers or sections. These inputs particularly including filaments may be prepared by coextrusion, microlayer coextrusion or multicomponent / fractal coextrusion. These inputs and specifically filaments enable layering or combining different materials simultaneously through one or more nozzles during the so-called 3D printing process. These techniques facilitate smaller layer sizes (milli, micro, and nano) different layer configurations as well as the potential to incorporate materials that would otherwise not be usable in standard 3D printer methods.

A fused filament fabrication printer has a fixed extrusion module having multiple printheads having print tips. The fixed arrangement of the printing heads allows the close spacing of multiple print tips in a printhead unit, and the simple routing of multiple plastic or metal filaments to the individual printing heads. The closely spaced print tips in the printhead unit share common components. An exemplary printhead unit has four printing heads which share a common heating block and heating block temperature sensor. The heating block incorporates a group of four print tips evenly spaced along a line. Each printing head has a separate filament which is controlled and driven by its own stepper motor through the heating block to one of the print tips. Printing of a part is by control of individual stepper motors which drive filaments through the heating block and through one of the printing tips.

A patient-specific porous metal prosthesis and a method for manufacturing the same are provided. The orthopaedic prosthesis may be metallic to provide adequate strength and stability. Also, the orthopaedic prosthesis may be porous to promote bone ingrowth.

Disclosed is a method for making a prototype plastic injection molded part from a mold tool (10) built by fused deposition modeling. The mold tool (10) is built by depositing roads of a molten thermoplastic resin in layers in a predetermined pattern defined by computer file data representing the inverse of the desired prototype molded part, and is used in an injection molding machine without the addition of any reinforcement fill material or layers to create the prototype part. The disclosed method provides prototype plastic injection molded parts within a twenty-four hour time period.

Automatic process control of additive manufacturing. The system includes an additive manufacturing device for making an object and a local network computer controlling the device. At least one camera is provided with a view of a manufacturing volume of the device to generate network accessible images of the object. The computer is programmed to stop the manufacturing process when the object is defective based en the images of the object.

A control mechanism for maneuvering an end effector is provided. The control mechanism comprises multiple actuator assemblies, multiple arm assemblies, and the end effector. Each of the multiple arm assemblies connect the end effector and the multiple actuator assemblies respectively. Each multiple actuator assemblies controls the movement of the multiple arm assemblies independently. One of the arm is rotated by a tool actuator where the rotating motion of the rotating arm drives a tool attached at the end effector. The control mechanism positions the tool actuator away from the end effector, thereby operating the tool at a remote location away from the end effector.

The disclosed embodiments relate to portions of an article of footwear formed from an extruded member. In certain embodiments, a sole or portion of a sole can be formed from one or more extruded members. In certain embodiments, the extruded member can be a single, continuous piece of solid material. In certain embodiments, a sole for an article of footwear can be fashioned from an extruded member formed in a controlled geometric pattern. In certain embodiments, the sole can include one or more layers.

Systems and methods for using a three dimensional fabrication device, like a 3D Printer, for novel automation and additive manufacturing techniques in manufacturing medical devices such as orthotics, customized for a particular person. The systems and methods may use a plurality of work surfaces on the three dimensional fabrication device. The systems and methods may use a plurality of materials or a plurality of fabrication tools and processes to manufacture the customized product.

A 3-D printer system moves a printed tool over a print surface with a mechanism controlling a rotational angle of an arm holding the print tool and a revolutionary angle of axis of rotation of the printable area to eliminate the disadvantages of conventionally used linear motion mechanisms

A coated print bed for a 3D printer having a permanent print-surface coating permanently secured to a print bed substrate plate, having a smooth, planar surface that provides an adhesive interface layer between a first layer of an applied plastic print material and the coated print bed. The coating contains a matrix-forming compound, such as a solvent- or water-based epoxy resin, an adhesive material, and optionally a filler. The user can print a series of print object directly onto the permanent print surface coating of the coated print bed, without having to refresh or refurbish the print surface, such as by applying to the print bed surface a temporary coating such as painter's tape, or a liquid adhesive.

An apparatus and method for making a three-dimensional object from a solidifiable material using a linear solidification device is shown and described. In certain examples, the linear solidification device includes a laser diode that projects light onto a scanning device, such as a rotating polygonal mirror or a linear scanning micromirror, which then deflects the light onto a photohardenable resin. As a result, the linear solidification device scans a line of solidification energy in a direction that is substantially orthogonal to the direction of travel of the laser diode. In other examples, the linear solidification device is a laser device array or light emitting diode array that extends in a direction substantially orthogonal to the direction of travel of the array.

A method of forming a three-dimensional object is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid, the polymerizable liquid including a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from the first component; (c) irradiating the build region with light through the optically transparent member to form a solid polymer scaffold from the first component and also advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, and containing the second solidifiable component carried in the scaffold in unsolidified and / or uncured form; and (d) concurrently with or subsequent to the irradiating step, solidifying and / or curing the second solidifiable component in the three-dimensional intermediate to form the three-dimensional object.

Several examples of additive manufacturing machines and methods for depositing a bead of composite polymer material having continuous fiber reinforcement are disclosed. A length of fiber reinforcement is provided to a nozzle. The fiber reinforcement is embedded into a stream of a base polymer material at the nozzle and deposited as a bead of composite polymer material having fiber reinforcement. The fiber reinforcement may be dry or pre-impregnated with a reinforcing polymer. The additional strength of the composite polymer material having fiber reinforcement allows for true, three-dimensional printing of articles having unsupported regions.

Disclosed are interfacially modified particulate and polymer composite material for use in injection molding processes, such as metal injection molding and additive process such as 3D printing. The composite material is uniquely adapted for powder metallurgy processes. Improved products are provided under process conditions through surface modified powders that are produced by extrusion, injection molding, additive processes such as 3D printing, Press and Sinter, or rapid prototyping.