United States Patent [191
`Masters
`
`I 111111111111111111111111111111111111 IIIII IIIII IIIII IIIII IIIIII Ill lllll Ill!
`US005134569A
`5,134,569
`[11] Patent Number:
`
`[45] Date of Patent:
`
`Jul. 28, 1992
`
`[54] SYSTEM AND METHOD FOR COMPUTER
`AUTOMATED MANUFACTURING USING
`FLUENT MATERIAL
`
`[76]
`
`Inventor: William E. Masters, 313 Dogwood
`La., Easley, S.C. 29640
`
`[21] Appl. No.: 371,084
`
`[51]
`
`Jun. 26, 1989
`[22] Filed:
`Int. Cl.5 .•.................•... G06F 15/46; B28B 17/00;
`B28B 1/14; B27G 11/02
`[52] U.S. Cl ............................. 364/474.24; 156/379.6;
`156/59; 156/272.8; 264/308;425/162;425/174
`[58] Field of Search ................... 364/474.24, 469, 473,
`364/477; 156/379.6, 59, 272.8, 244.11; 264/22,
`308,309,211.13, 211.12, 219; 219/121.73;
`425/162, 174, 174.4; 365/119, 111
`
`[56]
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`4,078,229 3/1978 Swanson et al. .................... 365/111
`4,238,840 12/1980 Swainson ............................ 365/119
`4,247,508 1/1981 Housholder ......................... 264/308
`4,333, I 65 6/1982 Swainson et al. ................... 365/119
`4,575,330 3/1986 Hull ..................................... 364/473
`4,665,492 5/1987 Masters .......................... 364/474.24
`4,710,253 12/1987 Soszek .............................. 156/272.8
`4,749,347 6/1988 Valavaara ........................... 264/219
`4,752,352 6/1988 Feygin ............................ 219/121.73
`4,915,757 4/1990 Rando ................................... 156/59
`
`4,943,928 7/1990 Campbell et al. ................... 364/477
`4,961,154 10/1990 Pomerantz et al. .............. 425/174.4
`4,961,886 10/1990 Eckstein et al. ................. 425/174.4
`
`Primary Examiner-Jerry Smith
`Assistant Examiner-Jim Trammell
`Attorney, Agent, or Firm-Cort Flint
`
`[57]
`
`ABSTRACT
`A system and method for constructing a three-dimen­
`sional object (10) from a design created on a CAD
`machine (14) is disclosed which includes a support (B)
`which may be indexed along two coordinate axes (X, Y)
`and a movable dispensing head (A) which indexes along
`a Z-axis. A fluent material (54) is dispensed or extruded
`from head (A) and as it is dispensed, the fluent material
`is subjected to a treatment by treatment sources (D)
`which cause the fluent material to transform into a fixed
`solidified state in the form of a three-dimensional object.
`Fluent material (54) may be a polymeric material which
`is solidified by an energy beam of ultraviolet light (56)
`upon dispensing. A shield (E) is provided to shield the
`dispensing head (A) and strand of material (54) so that
`the material is treated at the proper time and location to
`cause it to solidify properly to form the three-dimen­
`sional object. In accordance with the method, indexing
`takes place in desired steps so a dimensionally accurate
`object is formed.
`
`47 Claims, 3 Drawing Sheets
`
`Page 1 of 9
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`U.S. Patent
`
`July 28, 1992
`
`Sheet 1 of 3
`
`5,134,569
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`22
`
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`U.S. Patent
`
`July 28, 1992
`
`Sheet 2 of 3
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`5,134,569
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`Page 3 of 9
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`U.S. Patent
`
`July 28, 1992
`
`Sheet 3 of 3
`
`5,134,569
`
`B
`
`y
`
`E
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`\
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`A
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`58
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`58b
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`SYSTEM AND METHOD FOR COMPUTER
`AUTOMATED MANUFACTURING USING
`FLUENT MATERIAL
`
`10
`
`BACKGROUND-OF THE INVENTION
`The invention relates to the automated manufactur(cid:173)
`ing of a three-dimensional object whose design has been
`created with a computer aided design (CAD) machine.
`Modern day manufacturing technology continues to
`grow in complexity and sophistication. The result is a
`great need for flexibility in the manufacturing process.
`Several systems and methods for manufacturing three(cid:173)
`dimensional objects which have been designed on a 15
`computer have been proposed. However, turning a
`computer aided design into a solid three-dimensional
`object quickly and inexpensively remains a problem to
`which considerable attention need be given.
`Technology, commonly referred to as direct cad 20
`manufacturing (DCM), has been rapidly developing. In
`desk top manufacturing, a three-dimensional object is
`created on a computer screen using a CAD program.
`Any physical product that is designed, shaped, or proto(cid:173)
`typed prior to production could benefit from DCM. 25
`Industries that may use DCM include automotive, aero(cid:173)
`space, appliance, toy manufacturers, and any process
`that involves the design, redesign, prototyping, and
`production of three-dimensional models, molds, pat(cid:173)
`terns, or short production runs. Designs that once re- 30
`quired weeks or months to be turned into actual models
`or prototypes can become objects in a matter of hours
`or days using DCM. Using DCM, a design can be re(cid:173)
`called from a library and the object manufactured in
`just a short period of time, thus eliminating the need for 35
`large inventories. Basically, there are five identifiable
`desk top manufacturing systems and methods.
`First is ballistics particle manufacturing as disclosed
`in U.S. Pat. No. 4,665,492. In this system, the coordi(cid:173)
`nates of a three-dimensional design are stored in a com- 40
`puter data base. Particles are directed to specific loca(cid:173)
`tions and built up and deposited to construct the desired
`object. Second, in photochemical machining, shapes are
`formed by the polymerization of a monomer, or by
`sculpting a solid block of plastic, for example, see U.S. 45
`Pat. Nos. 4,078,229; 4,238,840; and 4,571,377. In poly(cid:173)
`merization, one laser may pump a photo initiator or
`photosynthesizer, while a second laser pumps energy.
`Polymerization takes place where the two beams inter(cid:173)
`sect. When using the other sculpting technique, a block 50
`of rigid plastic is carved by degrading material at the
`intersection of the two beams. Third is laminated object
`manufacturing where objects are constructed by the
`successive definition of thin layers of powdered plastics
`or metals, thin layers of powder are deposited, then 55
`compressed with a heated press platform or by roller
`compression. Pulses from a single laser then sinter or
`melt the powder in the desired cross-sectional shape and
`to the required depth. An example of this type system
`can be seen in U.S. Pat. No. 4,752,352. Fourth is selec- 60
`tive laser sintering where objects may be fabricated by ·
`the successive deposition and sintering of thin layers of
`powdered material, either plastic or metal. The powder
`layers are spread by a feeding mechanism, but are not
`compressed. Sintering energy can come from a laser or 65
`other suitable direct beam of energy. Fifth, stereolithog(cid:173)
`raphy is a form of stereolithographic printing wherein a
`single laser beam cures successive thin layers of liquid
`
`1
`
`5,134,569
`
`2
`monomer by a series of controlled photopolymerization
`reactions such as shown in U.S. Pat. No. 4,575,330.
`Further, U.S. Pat. No. 4,749,347 discloses a topology
`fabrication apparatus in which a three-dimension solid
`5 body having a predetermined topography is automati(cid:173)
`cally manufactured using an extrusion process. Thin
`sections of the solid body are extruded and successively
`built up next to each other to form the topographical
`form such as a topology model made from topographi(cid:173)
`cal map information. This system requires a fairly so-
`phisticated apparatus and control for forming what is a
`relatively simple form. The types of objects which can
`be made with such an apparatus and control are rela(cid:173)
`tively limited.
`Accordingly, it can be seen that the field of desk top
`manufacturing or computer aided manufacturing is one
`in which considerable activity and attention need to be
`given. While the above systems and methods are all
`candidates for a practical system, a need for the devel(cid:173)
`opment of more reliable and practical systems and
`methods still exists.
`Accordingly, an important object of the present in(cid:173)
`vention is to provide a method and system for the com(cid:173)
`puter aided manufacture of three-dimensional objects
`which is reliable and practical.
`Another object of the present invention is to provide
`a system and method for automatically manufacturing
`three-dimensional objects whose design has been cre(cid:173)
`ated on a CAD machine using practical hardware and
`methods.
`Another object of the present invention is to provide
`a system and method for automatically manufacturing a
`three-dimensional object whose design has been created
`on a CAD machine wherein the object may be accu(cid:173)
`rately formed in a simple and reliable manner under
`ordinary manufacturing.
`SUMMARY OF THE INVENTION
`The above objectives are accomplished in accor(cid:173)
`dance with the present invention by providing a com(cid:173)
`puter machine which creates a design for a three-dimen(cid:173)
`sional object and a data file of the corresponding three(cid:173)
`dimensional coordinates. The data file is used to control
`servos which index and position a dispensing head
`which extrudes a generally continuous strand of fluent
`material on a base which is indexed in the remaining
`coordinate directions. As the dispensing head and sup(cid:173)
`port are indexed, material is extruded through an orifice
`having a desired cross-sectional profile and is treated
`upon being dispensed to solidify to construct the three(cid:173)
`dimensional object. In a preferred embodiment, a poly(cid:173)
`meric material is extruded in a fluent state and is sub(cid:173)
`jected to a radiation beam for transition into the solid
`three-dimensional obj~ct. A shield is provided about the
`dispensing head so that the dispensed material is con(cid:173)
`tacted by the radiation beam at the proper time of loca(cid:173)
`tion for tram.ition. The sources of radiation are disposed
`relative to the dispensing head so that a prescribed time
`period is established between the time the material
`leaves the tip of the dispensing head and the time at
`which the radiation beam contacts it. By making this
`time constant, a dimensionally accurate object is pro(cid:173)
`duced. Controlling the indexing steps of the movement
`of the servo and control of the cross-sectional profile of
`the strand dispensed, the result is increased dimensional
`accuracy of the object.
`
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`5,134,569
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`3
`DESCRIPTION OF THE DRAWINGS
`The construction designed to carry out the invention
`will hereinafter be described, together with other fea(cid:173)
`tures thereof. The invention will be more readily under- 5
`stood from a reading of the following specification and
`by reference to the accompanying drawings forming a
`part thereof, wherein an example of the invention is
`shown and wherein:
`FIG. 1 is an isometric view of a system and method 10
`for automatically manufacturing a three-dimensional
`object from a design created on a CAD machine in
`accordance with the present invention;
`FIG. 2 is a perspective view of a system and method
`for automatically manufacturing a three-dimensional 15
`object from a design created on a CAD machine in
`accordance with the present invention;
`FIG. 3 is a close up perspective view illustrating a
`system and method for automatically manufacturing a
`three-dimensional object from a design created on a 20
`CAD machine in accordance with the present inven(cid:173)
`tion; and
`FIG. 4 is an enlarged isometric view illustrating a
`system and method according to the present invention
`for automatically manufacturing a three-dimensional 25
`object in accordance with the invention.
`DESCRIPTION OF A PREFERRED
`EMBODIMENT
`The invention relates to the automatic manufacture of 30
`a three-dimensional object whose design has been cre(cid:173)
`ated on a CAD machine.
`Referring now in more details to the drawings, an
`object 10 in the form of a cup is illustrated which has
`been designed by a computer system 12 which includes 35
`a computer machine 14 which designs the object 10 by
`instructions from a draftsman or designer. Computer
`machine 14 may be any suitable machine such as a CAD
`machine. In a conventional CAD machine, a designer
`uses a natural dialogue to talk to the computer machine 40
`by way of a data tablet and/or keyboard. He instructs
`the machine to create, scale, rotate, modify, and/or
`label various elements of the design or drawing. The
`CAD machine answers by interpreting the instructions,
`accomplishing what it was directed to do, displaying 45
`the results on the terminal CRT screen, and compiling a
`data file corresponding to the design produced and
`displayed. When the drafting and design effort is com(cid:173)
`plete, the data file containing coordinate information of
`the three-dimensional design may be stored on a hard 50
`disk or other computer storage medium for archival
`purposes.
`In accordance with the invention, the data file, which
`may be in the form of coded binary information, is
`transferred to a machine controller 16 which forms part 55
`of the computer system 12. Any suitable computer soft(cid:173)
`ware may be utilized to transfer this coded binary infor(cid:173)
`mation into machine control information for input into
`the machine controller 16. The machine controller 16
`sends signals to a pair of servo means 20 and 22 to posi- 60
`tion the material dispensing means A and a movable
`support means B, respectively. The control of the servo
`means may be had as is conventional in those type of
`devices commonly referred to as computer aided manu(cid:173)
`facturing machines. Computer machine 14 which de- 65
`signs the part and the computer machine 16 which con(cid:173)
`trols the servo mechanism in response to the data file of
`three-dimensional coordinates may be any suitable
`
`4
`CAD and CAM machines. Alternately, computer sys(cid:173)
`tem 12 may include an integrated computer machine
`which incorporates the functions of both the CAD and
`CAM controller. Servo means 20 controls material
`dispensing means A which may be any suitable working
`head for dispensing fluent materials such as an extrusion
`nozzle. While it is conceivable that droplets or segments
`of fluent material may be dispensed, it is contemplated
`that a continuous strand of fluent material will be ex(cid:173)
`truded from the head. Servo means 20 moves material
`dispensing means A in opposing directions along a Z(cid:173)
`axis. Support means B may be any suitable base or sup(cid:173)
`port upon which a three-dimensional object is con(cid:173)
`structed according to the design created on the CAD
`machine. Servo means 22 moves support means B in
`orthogonal directions in the XY plane.
`As can best be seen in FIGS. 2-4, a preferred embodi(cid:173)
`ment of the invention is illustrated wherein material
`dispensing means A includes a global dispensing head
`28 carried by a carriage 30 which moves vertically
`along the Z-axis within a standard 32 which may be
`suitably journaled to slidably carry the housing in recip(cid:173)
`rocating vertical movements. A post 34 serves as a
`carrier for dispensing means A which may be clamped
`to the post by any suitable means such as clamp 36.
`Support means B includes a first platform 40 movable
`along the X-axis and a second platform 42 which moves
`along the Y-axis. Platform 42 may include a key, not
`shown, which slides in a keyway 44 in platform 40.
`Platform 40 may slide by means of any suitable mecha(cid:173)
`nism on base housing 46 which may also carry standard
`32 fixably. Servo apparatus C may be any suitable ma(cid:173)
`chine such as that manufactured by Roland, Inc., and
`sold under the designation of Model No. CADD 3.
`A source 50 of fluent material is provided which is
`connected to dispensing head A by means of a conduit
`52. Source 50 is pressurized with compressed air to
`dispense or extrude a material through conduits 52 and
`head 28. Fluent material 50 may be any suitable chemi(cid:173)
`cal composition which may be transformed from a flu(cid:173)
`ent state to a fixed state in order to solidify the material
`in the form of the three-dimensional object. One suit(cid:173)
`able material is a resin manufactured under the designa(cid:173)
`tion Litetak 375 which is commercially available from
`the Locklite Corporation of Newington, Conn. This is a
`polymer material which can be hardened or solidified
`with an energy beam of ultraviolet light.
`Material treatment means, designated generally as D,
`is provided for treating fluent material 54 as it is dis(cid:173)
`pensed from dispensing means A to cause the material
`to undergo a transition from its fluent state to its fixed
`state in which it solidifies to form the three-dimensional
`object being designed. As can best be seen in FIGS. 3
`and 4, material treatment means D includes a plurality
`of ultraviolet light beams 56 emitted from a plurality of
`light tubes 58 which, preferably, are equally angularly
`spaced around dispensing means A. Light tubes 58 are
`carried by suitable bracket means 60 which are attached
`to a T-arm 62 of post 34. Ultraviolet light coming from
`a radiation source 65 are directed by light tubes 58.
`Radiation source 65 may be any suitable source of ultra-
`. violet radiation or light such as a model ZETA 7000
`manufactured by Locklite Corporation of Newington,
`Conn. Material treatment means D may be any suitable
`means for causing the material to solidify and form a
`three-dimensional object, and depending upon the type
`of material being used. For example, material treatment
`means D may include a chemical composition in which
`
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`5,134,569
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`5
`two or more chemicals are mixed internally in the fluent
`material so that upon dispensing, fluent material 54
`solidifies. Alternately, the treatment means may be a
`second chemical composition which is mixed with a
`first chemical composition dispensed by dispensing 5
`means A after it is dispensed. The material treatment
`means may be a concentrated energy beam of heat, laser
`energy, or other radiation energy, all of which depend
`on the fluent material utilized.
`A shield means E for shielding dispensing head 28 is 10
`provided. Shield means E shields dispensing head 28
`and dispensed material 54 so that the material is sub(cid:173)
`jected to the treatment of material treatment means D at
`the proper time and position to cause effective transfor(cid:173)
`mation and solidification. This is particularly important 15
`when material 54 is laid and built up as a continuous
`strand in layers. Solidification of the layers at the proper
`position and time is important for the accurate and
`reliable construction of the three-dimensional object.
`As illustrated, shield means Eis a cylindrical shield. It is 20
`contemplated that the shield may be shaped and con(cid:173)
`toured in accordance with the application and object
`being made for optimum shielding and accurate forma(cid:173)
`tion. For example, it has been found that the round
`shield may create an elliptical shadow under certain 25
`lighting conditions (2 light tubes at 180 degrees on XY
`plane). When dispensing head 28 travels through the
`Jong axis of the ellipse, the tip to light time is longer
`than when it travels through the short axis. This may
`cause a nonuniform tip to light time. The tip to light 30
`time is the time period between the resin leaving the tip
`of dispensing head 28 until the ultraviolet light 56
`contacts it. This tip to light time needs to be constant in
`order to achieve a dimensionally accurate object. It is
`contemplated that by reshaping the round shield to an 35
`ellipse, and mounting the shield so that the long axis of
`the shield is parallel to the light beams, the shadow will
`be more circular which will give a more constant tip to
`light time. Of course, other shapes, contours, and shield(cid:173)
`ing techniques may be had in order to achieve the de- 40
`sired result of dimensionally accurate object construc(cid:173)
`tion.
`Dimensionally accurate objects may also be a func(cid:173)
`tion of the arrangement of the material treatment means
`D. For example, when utilizing concentrated radiation 45
`such as ultraviolet light 58a, 58b, and 58c, it has been
`found that spacing these equal angularly, i.e. 180 de(cid:173)
`grees apart, with respect to cylindrical shield E results
`in a fairly accurate object formation. When utilizing
`ultraviolet light, it is preferred that base means B have 50
`a blackened surface which absorbs radiation so that
`reflected radiation does not result in adverse effects on
`solidification of material 54.
`Servo means 20 which moves platforms 40 and 42,
`and servo means 20 which moves platform 30, must be 55
`controlled in their indexing time and steps in order to
`achieve dimensionally accurate object formation. This
`is particular true of indexing and the direction in which
`layers 54a of material 54 are formed. In this same re(cid:173)
`spect, an orifice 28a of dispensing head 28 may be se- 60
`lected so that strand 54 has a prescribed cross-section
`depending upon the application and object being made.
`The dimensions anq shape of the cross-sectional profile
`of strand 54 produced by the orifice will be a variable in
`the function of the step size of indexing, particularly in 65
`the Z-direction as shown. By controlling the step size,
`cross-sectional profile, tip to light time, and other vari(cid:173)
`ables, a dimensionally accurate object may be had in
`
`6
`accordance with the invention. The smoothness of the
`object can be controlled in accordance with the inven(cid:173)
`tion by these variables, as well as the gap between the
`layers.
`The following examples will be illustrative of the
`invention:
`
`EXAMPLE 1
`Object shape-a cylinder with a 15.0 mm diameter and
`8.0 mm height.
`Shield E-i inch cylindrical height.
`Dispensing head 28-16 gauge needle.
`Material 54-Litetak 375.
`Material treatment-2 ultraviolet light tubes approxi(cid:173)
`mately 10 degrees from the vertical, 480 degrees
`apart at the XY plane at 40 degrees from the Z-axis.
`Distance from bottom of shield and dispensing head
`tip-1.0 mm; speed-12.0 mm per second.
`Air pressure on material source 50-30 psi.
`Indexing step in the Z direction-(approximately equal
`to the diameter of the strand).
`
`EXAMPLE2
`Object shape-cone (30.0 mm base X 47.0 mm top).
`Shield E-i inch elliptical.
`Dispensing head 28-16 gauge needle.
`Material 54-Litetak 375.
`Material treatment-2 ultraviolet light tubes approxi(cid:173)
`mately 180 degrees apart from the XY axis and 10
`degrees from the vertical axis.
`Distance between tip of dispensing head and shield
`-3.0mm.
`Air pressure-35 psi.
`Bottom indexing-LO mm.
`Wall indexing-out 1.0 mm; up 1.0 mm.
`Speed-12.0 mm/second.
`Base-black.
`
`EXAMPLE 3
`Object 10 T-cup-(30.0 mm base; 16.0 mm outward
`taper; 15.0 mm step up; and 47.0 mm top).
`Shield E-7/16 circular.
`Dispensing head 28-16 gauge needle.
`Material 54-Litetak 375.
`Material treatment-3 ultraviolet light tubes 58a, 58b,
`58c with 58c 10 degrees from vertical, 58b 15 degrees
`from vertical, and 58a 5 degrees from vertical; lights
`58b and 58a in the XY plane approximately 120 de(cid:173)
`grees apart.
`Air pressure-33 psi.
`Base-black.
`Shield-approximately 2.0 mm above the needle tip.
`While a preferred embodiment of the invention has
`been described using specific terms, such description is
`for illustrative purposes only, and it is to be understood
`that changes and variations may be made without de(cid:173)
`parting from the spirit or scope of the following claims.
`What is claimed is:
`1. A system for constructing a three-dimensiorial
`object from a design created on a computer machine
`including:
`a) support means by which said object is supported
`while being constructed;
`b) material dispensing means for dispensing a strand
`of material in a fluent state;
`c) material treatment means disposed near said strand
`of material dispensing means for causing said mate(cid:173)
`rial to undergo a transition from said fluent state to
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`7
`a fixed state in which said material is solidified and
`built up in a form of said three-dimensional object;
`and
`d) control means for generating control signals in
`response to coordinates of said design of said three- 5
`dimensional object an.d controlling the position of
`said material dispensing means and said material
`treatment means relative to said support means in
`response to said control signals to control dispens(cid:173)
`ing and transition of said material to construct said
`object while supported with said support means.
`2. The system of claim 1 including a gaseous atmo(cid:173)
`sphere in which said support means is disposed.
`3. The system of claim 1 including servo means for
`indexing and positioning said support means.
`4. The system of claim 3 wherein said servo means
`and said support means are indexed in at least two di(cid:173)
`mensions.
`5. The system of claim 4 wherein said servo means
`positions and indexes said dispensing means in a third 20
`dimension.
`6. The system of claim 1 wherein said material dis(cid:173)
`pensing means includes an extrusion means which dis(cid:173)
`penses a generally continuous strand of said material.
`7. The system of claim 6 wherein said extrusion
`means includes a nozzle having an orifice through
`which said strand is dispensed and contoured to have a
`prescribed cross-sectional profile in accordance with
`the object being constructed.
`8. The system of claim 1 wherein said dispensing
`means includes profile control means through which
`said material is dispensed in a generally continuous
`strand and by which controlling a continuous strand
`profile of said stand is controlled according to the ob- 35
`ject being produced.
`9. The system of claim 8 wherein said profile control
`means includes an orifice through which said material
`passes.
`10. The system of claim 1 wherein said material treat- 40
`ment means includes radiation means for focusing a
`beam of radiation upon said fluid material after said
`material is dispensed to solidify said material.
`11. The system of claim 10 including shield means
`shielding said dispensing means from said radiation 45
`beam for controlling solidification of said material.
`12. The system of claim 10 wherein said radiation
`means includes a plurality of ultraviolet radiation
`sources disposed in prescribed positions about said dis(cid:173)
`pensing means.
`13. The system of claim 1 wherein said material treat(cid:173)
`ment means includes a chemical treatment means for
`subjecting said fluent material to a chemical treatment
`to fix said fluent material in a form of said three-dimen-
`sional object.
`14. The system of claim 13 wherein said chemical
`treatment means includes a chemical mixture within
`said fluent material which causes said fluent material to
`solidify in said form of said three-dimensional object
`after leaving said dispensing means.
`15. The system of claim 13 wherein said chemical
`treatment means includes means for mixing a chemical
`with said fluid material as it is dispensed from said dis(cid:173)
`pensing means to solidify said fluent material.
`16. The system of claim 10 wherein said material 65
`treatment means includes means for solidifying said
`fluent material in a form of said three-dimensional ob(cid:173)
`ject using photopolymers.
`
`8
`17. The system of claim 10 wherein said material
`treatment means includes treating said fluid material
`with a laser means for solidifying said fluent material
`after it is dispensed by said material dispensing means.
`18. The system of claim 10 wherein said radiation
`means includes a beam of heat energy generated by a
`heat source.
`19. The system of claim 18 wherein said control
`means includes signal generator means for generating
`10 said control signals in response to said data file.
`20. The system of claim 1 wherein said support means
`includes a base having a blackened support surface
`which absorbs radiation.
`21. The system of claim 1 wherein said control means
`15 includes a data file of said three dimensional coordinates
`corresponding to said three dimensional design created
`on said computer machine.
`22. The system of claim 1 including an assembly for
`carrying said material dispensing means and said mate(cid:173)
`rial treatment means together as a working unit, said
`assembly being operatively connected to said servo
`means so that said dispensing means and treatment
`means are indexed together as a unit.
`23. The system of claim 1 wherein said material dis(cid:173)
`pensing means dispenses said fluid material is a form of
`a fluid strand.
`24. A system for automatically constructing a three
`dimensional object from a design of the three dimen(cid:173)
`sional object created on a computer machine compris(cid:173)
`ing:
`a) support by which said object is supported while
`being constructed;
`b) material dispensing means for dispensing a fluent
`material in the form of a generally continuous fluid
`strand for constructing said object;
`c) material treatment means for focusing a generally
`concentrated energy beam on said fluid strand after
`dispensing causing said material to undergo a tran(cid:173)
`sition from said fluent state to a fixed state in which
`said material is solidified to build up in layers and
`construct said object while supported by said sup(cid:173)
`port means; and
`d) control means for generating control signals in
`response to said coordinates of said three dimen(cid:173)
`sional design of said object and controlling the
`position of said dispensing means and said material
`treatment means relative to said support means in
`response to said control signals to thereby control
`dispensing and transition of said material to con(cid:173)
`struct said object while supporting with said sup-
`port means.
`25. The system of claim 24 including means for con(cid:173)
`trolling the time and position at which said concen(cid:173)
`trated energy beam contacts said fluid strand of material
`after dispensing.
`26. The system of claim 25 including means for con(cid:173)
`trolling the intensity of said concentrated energy beam
`upon said strand of fluid material.
`27. The system of claim 24 wherein said support
`means comprises a base having a blackened surface
`which absorbs energy from said energy beam to thereby
`prevent reflection of energy upon said fluid strand ex(cid:173)
`cept where it is desired to contact said fluid strand for
`solidification.
`28. The system of claim 24 including servo means for
`indexing the position of said dispensing means and said
`support means relative to each other in a stepidized
`
`so
`
`ss
`
`60
`
`Page 8 of 9
`
`Markforged Ex. 1011
`Markforged v. Continuous Composites, IPR2022-01218
`
`

`

`5,134,569
`
`10
`smoothness of said object in accordance with a dimen(cid:173)
`sion of a cross-section of said strand.
`41. A process for automatically manufacturing a
`three-dimensional object which has been designed on a
`computer machine comprising:
`a) providing a design data file of coordinates repre(cid:173)
`senting said three dimensional design as generated
`by said computer machine;
`b) generating control signals based on said design
`data file;
`c) dispensing a fluid material in a fluent physical state
`in response to said control signals;
`d) treating said fluent material by causing a generally
`concentrated energy beam to physically act upon
`said fluid material after dispensing in controlled
`time and dimensional relation to said dispensing of
`said fluid material to cause said fluid material to
`undergo a transition to a fixed, physical state in
`which said material is solidified in a form of said
`three dimensional object; and
`e) shielding said dispensing means from said energy
`beam in a controlled manner so that said energy
`beam acts upon said fluid material at a prescribed
`position, intensity, and time so as to cause said
`material to solidify and accurately construct said
`three dimensional object.
`42. The process of claim 41 dispensing said fluid ma(cid:173)
`terial with a dispensing m