United States Patent [19]
`Lipsker
`
`US006153034A
`[11] Patent Number:
`[45] Date of Patent:
`
`6,153,034
`Nov. 28, 2000
`
`[54] RAPID PROTOTYPING
`
`[75] Inventor: Daniel Lipsker, Atlit, Israel
`
`[73] Assignee: Micromod R.P. LTD, Granot, Israel
`
`[21] Appl. No.: 09/128,100
`[22]
`Filed:
`Aug. 3, 1998
`[30]
`Foreign Application Priority Data
`
`Aug. 3, 1997
`
`[IL]
`
`Israel ...................................... .. 121458
`
`[51] Int. Cl.7 .................................................... .. B32B 31/16
`[52] US. Cl. ....................... .. 156/73.1; 156/167; 156/510;
`156/580.1
`[58] Field of Search ................................ .. 156/73.1, 73.2,
`156/250, 256, 510, 580.1, 580.2, 166, 167
`
`[56]
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`7/1962 Tupper .................................. .. 156/167
`3,046,178
`4/1966 Nixon.
`3,248,444
`7/1966 Crooks et a1. .
`3,262,808
`2/1968 Wissinger et a1. .
`3,368,989
`3,410,310 11/1968 Ray.
`3,411,686 11/1968 Bender.
`3,507,660
`4/1970 Nishio et a1. .
`3,633,113
`1/1972 Grubel et a1. .
`4,961,154 10/1990 PomerantZ et a1. .
`5,031,120
`7/1991 PomerantZ et a1. .
`5,139,338
`8/1992 PomerantZ et a1. .
`5,157,423 10/1992 Zur.
`5,177,689
`1/1993 Kinasi et a1. .
`5,263,130 11/1993 PomerantZ et a1. .
`5,287,435
`2/1994 Cohen et a1. .
`5,289,214
`2/1994 Zur.
`5,307,499
`4/1994 Yin .
`5,386,500
`1/1995 PomerantZ et a1. .
`5,398,193
`3/1995 de Angelis .
`5,426,722
`6/1995 Batchelder .
`5,433,280
`7/1995 Smith .
`5,448,687
`9/1995 Hoogerhyde et a1. .
`5,453,933
`9/1995 Wright et a1. .
`5,453,934
`9/1995 Taghavi et a1. .
`
`5,458,825 10/1995 Grolman et a1. .
`5,459,868 10/1995 Fong.
`5,491,643
`2/1996 Batchelder .
`5,515,903
`5/1996 Hronas et a1. .
`5,542,070
`7/1996 LeBlanc et a1. .
`5,544,550
`8/1996 Smith .
`5,545,367
`8/1996 Bae et a1. .
`5,578,227 11/1996 Rabinovich .
`
`OTHER PUBLICATIONS
`
`M.K. Raymond,“Unraveling Rapid Prototype Methods”,
`American Machinist, pp. 24—31, Jun. 1996.
`NSF Workshop on Design Methodologies for Solid F reeform
`Fabrication, Jun. 1995.
`Brochure:“Rapid Tooling Tops Bill at RP Conference”,
`Machine Design, p. 44, Apr. 20, 1995.
`Brochure:“CAD/CAM Planning Guide”, p. 9A, 1996.
`Brochure:“Faster Rapid Prototype is Designed for the Desk
`top”, Machine Design, p. 26, Dec. 14, 1995.
`Brochure:“Rapid Ptototyping Produces Metal Parts”,
`Machine Design, p. 22, Jan. 26, 1995.
`Brochure:“Prototyping Machine Builds Models With Ink—Jet
`Methods”, Machine Design, p. 52, May 11, 1995.
`Brochure:“Neuractor, Computer Nurnerically Controlled
`Desktop Manufacturing System”, US. Cyberlab, Inc.
`Brochure:“Rapid GroWth for Rapid Prototyping”.
`
`Primary Examiner—James Sells
`Attorney, Agent, or Firm—Darby & Darby
`
`[57]
`
`ABSTRACT
`
`Rapid prototype apparatus including an adhesive dispenser
`for dispensing an adhesive and an actuator Which moves the
`adhesive dispenser in at least one of six degrees of freedom
`(preferably in at least four degrees of freedom, and most
`preferably in six degrees of freedom) in accordance With a
`geometry of an object. The adhesive dispenser then dis
`penses the adhesive in accordance With the geometry of the
`object, applying successive layers of adhesive one on top of
`the previous layer. The adhesive layers cure and bond to
`each other, thus forming a prototype of the object.
`
`11 Claims, 4 Drawing Sheets
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`Page 1 of 9
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`U.S. Patent
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`Nov. 28,2000
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`Sheet 1 of4
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`1
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`FIG.
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`U.S. Patent
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`Nov. 28,2000
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`Sheet 2 of4
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`6,153,034
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`FIG.
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`2
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`U.S. Patent
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`Nov. 28,2000
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`Sheet 3 of4
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`U.S. Patent
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`Nov. 28,2000
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`Sheet 4 of4
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`6,153,034
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`1
`RAPID PROTOTYPING
`
`FIELD OF THE INVENTION
`
`The present invention relates generally to apparatus and
`methods for rapid prototyping, and particularly to rapid
`prototype deposition modeling techniques and apparatus.
`
`BACKGROUND OF THE INVENTION
`
`Rapid prototyping systems are Well knoWn. The following
`US. Pat. Nos. are believed to be representative of the state
`of the art: 5,545,367, 5,544,550, 5,542,070, 5,515,903,
`5,491,643, 5,459,868, 5,458,825, 5,453,934, 5,448,687,
`5,433,280, 5,426,722, 5,398,193, 5,386,500, 5,307,499,
`5,289,214, 5,287,435, 5,263,130, 5,177,689, 5,157,423,
`5,139,338, 5,031,120, 4,961,154, 3,633,113, 3,507,660,
`3,411,686, 3,410,310, 3,368,989, 3,262,808, and 3,248,444.
`Rapid prototyping methods of the art include
`stereolithography, solid ground curing, selective laser
`sintering, fused deposition modeling and droplet deposition,
`Which are all discussed brie?y in “Unraveling rapid proto
`type methods”, M. K. Raymond, American Machinist, June
`1996, pages 24—31.
`Fused deposition modeling (FDM) is an extrusion method
`for thermoplastic material, developed and commercialiZed
`by Stratasys Inc., Eden Prairie, MN. In FDM, a continuous
`?lament of a thermoplastic polymer or Wax is passed
`through a heated noZZle. The material is delivered as a Wire
`into an extrusion head and heated so that it is extruded at a
`temperature slightly above the How point. The material
`solidi?es rapidly after deposition, each layer being fused to
`the previous layer. A draWback of FDM is that external
`supports are generally needed to support the deposited
`layers. The external supports must be removed after com
`pleting the model.
`US. Pat. No. 5,578,227 to Rabinovich describes a model
`making method including delivering thin, continuous feed
`stock of materials Which have various pro?les With opposite
`?at sides and fusing the feedstock by adhesion or Welding of
`a ?at side With an energy source to a ?at side of a previous
`layer, While keeping the feedstock cross-section in substan
`tially original shape. The “adhesion” of the Rabinovich
`method is not adhesive but rather a term used alternatively
`to “Welding” to describe the joining of one layer to a
`previous layer. Rabinovich is limited to laser Welding one
`?at side of a layer to another ?at side of a previous layer, and
`the method cannot be used for any cross-sectional shape.
`Additionally, the method is limited to Weldable materials.
`
`SUMMARY OF THE INVENTION
`The present invention seeks to provide improved rapid
`prototype deposition modeling techniques and apparatus,
`Wherein a building material is added layer by layer to build
`an accurate replica of a given object, Without having to
`remove building material to arrive at the ?nished prototype.
`No heating of deposited material is required and no external
`supports are generally needed to support the deposited
`layers. The invention is applicable to a much Wider variety
`of materials and slender building elements than the prior art.
`There is thus provided in accordance With a preferred
`embodiment of the present invention, rapid prototype appa
`ratus including an adhesive dispenser for dispensing an
`adhesive and an actuator Which moves the adhesive dis
`penser in at least four degrees of freedom in accordance With
`a geometry of an object. The adhesive dispenser then
`dispenses the adhesive in accordance With the geometry of
`
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`the object, applying successive layers of adhesive one on top
`of the previous layer. The adhesive layers cure and bond to
`each other, thus forming a prototype of the object.
`In accordance With a preferred embodiment of the present
`invention, a Wire dispenser is also provided for dispensing a
`Wire, Wherein the actuator moves the Wire dispenser in at
`least four degrees of freedom in accordance With the geom
`etry of the object, and the adhesive dispenser applies adhe
`sive to the Wire so as to bond a previously dispensed portion
`of Wire to a presently dispensed portion of Wire. Preferably
`the adhesive dispenser and the Wire dispenser are juxtaposed
`With each other and the adhesive dispenser dispenses the
`adhesive as the Wire is dispensed by the Wire dispenser.
`Alternatively, the adhesive dispenser may be located so as to
`dispense the adhesive into the Wire dispenser such that the
`Wire is dispensed from the Wire dispenser pre-coated With
`the adhesive.
`It is noted that throughout the speci?cation and the claims
`the term “Wire” encompasses any slender, dispensable build
`ing element, such as, but not limited to, Wire, rod, bar, string,
`rope, thread, yarn, cord, ?lament, ?ber, tWine, strand, chain,
`cable, or Wire tWist.
`The Wire may be constructed from one or materials, such
`as, but not limited to, metals, plastics, especially
`thermoplastics, natural (vegetable and animal) and synthetic
`?bers, composite materials, putty, elastomers, and adhe
`sives. Even extrudable food products, such as dough, may be
`used.
`The adhesive is preferably a quick curing adhesive, such
`as, but not limited to, cyanoacrylates or ultraviolet curable
`adhesives. HoWever, the invention can be carried out With
`other adhesives such as epoxies, animal glues and vegetable
`glues.
`Additionally in accordance With a preferred embodiment
`of the present invention, a cutter is provided for cutting the
`Wire after being dispensed by the Wire dispenser. The cutter
`is particularly useful in forming discrete or non-continuous
`portions of the object.
`There is also provided in accordance With a preferred
`embodiment of the present invention, a method for produc
`ing a rapid prototype including dispensing layers of an
`adhesive in at least four degrees of freedom in accordance
`With a geometry of an object, and curing the layers to form
`a prototype of the object.
`In accordance With a preferred embodiment of the present
`invention, a previously dispensed portion of adhesive is
`bonded to a presently dispensed portion of adhesive. Pref
`erably a successive layer of adhesive is dispensed one on top
`of a previous layer.
`There is also provided in accordance With a preferred
`embodiment of the present invention, a method for produc
`ing a rapid prototype including dispensing layers of a Wire
`in at least four degrees of freedom in accordance With a
`geometry of an object, applying adhesive to the Wire so as
`to bond a previously dispensed portion of Wire to a presently
`dispensed portion of Wire, and curing the adhesive so that
`the layers of the Wire form a prototype of the object.
`Preferably the adhesive at least partially covers a perimeter
`of the Wire.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`The present invention Will be understood and appreciated
`more fully from the folloWing detailed description, taken in
`conjunction With the draWings in Which:
`FIG. 1 is a simpli?ed pictorial illustration of rapid pro
`totype apparatus, constructed and operative in accordance
`With a preferred embodiment of the present invention;
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`FIG. 2 is a simpli?ed pictorial illustration of the rapid
`prototype apparatus of FIG. 1 forming a prototype of a
`three-dimensional object;
`FIG. 3 is a simpli?ed sectional illustration of a portion of
`a prototype formed With the apparatus of FIG. 1, taken along
`lines III—III in FIG. 2;
`FIGS. 4A, 4B, 4C and 4D are simpli?ed pictorial illus
`trations of Wire dispensers, constructed and operative in
`accordance With different preferred embodiments of the
`present invention;
`FIG. 5 is a simpli?ed pictorial illustration of an alternative
`method of applying adhesive to a Wire in accordance With a
`preferred embodiment of the present invention; and
`FIG. 6 is a simpli?ed pictorial illustration of an actuator
`capable of moving an adhesive dispenser and a Wire dis
`penser in at least four degrees of freedom in accordance With
`a geometry of an object, constructed and operative in
`accordance With a preferred embodiment of the present
`invention.
`
`DETAILED DESCRIPTION OF A PREFERRED
`EMBODIMENT
`
`Reference is noW made to FIG. 1 Which illustrates rapid
`prototype apparatus 10, constructed and operative in accor
`dance With a preferred embodiment of the present invention.
`Rapid prototype apparatus 10 preferably includes an
`adhesive dispenser 12 for dispensing an adhesive 14. Adhe
`sive dispenser 14 is may be any conventional adhesive
`dispenser and is preferably an electrically operated and
`controlled dispenser Widely used in the packaging industry.
`Adhesive 14 is preferably a quick curing adhesive, such as,
`but not limited to, cyanoacrylates or ultraviolet curable
`adhesives. The present invention can also be carried out With
`other adhesives such as thermocurable adhesives, epoXies,
`animal glues, vegetable glues, lacquers, polymers,
`monomers, self-adhesive materials, double-sided adhesives,
`single side adhesives, and so-called “hot” glues.
`In the case of thermocurable adhesives, heat is applied,
`preferably in a controlled manner, to cure the adhesive. In
`the case of ultraviolet curable adhesives, an optic ?ber 15
`may be used to transmit ultraviolet energy to the adhesive
`for curing purposes. As is knoWn in the art, the ultraviolet
`energy is transmitted at a frequency and poWer level selected
`for the particular adhesive.
`AWire dispenser 16 is preferably provided for dispensing
`a Wire 18. Wire dispenser preferably has a storage receptacle
`20 for storing therein Wire 18 Which may be dispensed
`through a noZZle 22. Preferably adhesive dispenser 12 and
`Wire dispenser 16 are juxtaposed With each other and
`adhesive dispenser 12 dispenses adhesive 14 as Wire 18 is
`dispensed by Wire dispenser 16. The How of adhesive 14 on
`Wire 18 Will be described more in detail hereinbeloW.
`Adhesive dispenser 12 and Wire dispenser 16 may be ?Xedly
`attached to each other, such as by means of a bracket 24.
`Wire 18 is typically dispensed on a bed 26.
`The type of Wire dispenser 16 used depends on the form
`of Wire 18. Preferably apparatus 10 includes a set of inter
`changeable Wire dispensers 16 and/or noZZles 22 to suit a
`particular Wire 18 and selected material. For example, for
`slender, soft Wires, such as string or thread, Wire dispenser
`16 may comprise a bobbin for holding the Wire 18 and Wire
`18 may simply be spooled off from the bobbin, such as
`through Wheels and guides to prevent snagging, in a manner
`similar to that of a seWing machine. Referring to FIG. 4A,
`it is seen that noZZle 22 may comprise a folded conical
`
`4
`noZZle 27 Which ensures that a soft Wire 18 is accurately fed
`from a tip of noZZle 27, regardless of the position of the rest
`of Wire 18 upstream from the tip of noZZle 27. For harder, yet
`malleable materials, such as copper Wire, Wire dispenser 16
`may comprise feeding equipment for feeding a generally
`continuous Wire Which is dispensed through noZZle 22. In
`such a case, the Wire is generally annealed before dispensing
`thereof, or may even be preheated.
`Reference is noW made to FIG. 4B Which illustrates a Wire
`dispenser 17, constructed and operative in accordance With
`another preferred embodiment of the present invention. Wire
`dispenser 17 as illustrated is a capillary type of dispenser
`commercially available from such companies as Micro
`SWiss Ltd., PO. BOX 90, Yokneam Elite, Israel, that is used
`in the semiconductor interconnect industry. Such a dispenser
`is particularly useful to dispense very thin Wires such as gold
`Wires used to interconnect integrated circuits and I/O leads
`in microelectronics. Such Wires may be bonded to each other
`by ultrasonic Welding at frequencies of 50—70 KHZ, for
`eXample. Wire dispenser 17 has an inner diameter D that is
`slightly larger than the diameter of the Wire being dispensed.
`The eXample of Wire dispenser 17 emphasiZes the applica
`bility of the present invention to even very small diameter
`Wires such as 0.001 mm.
`Reference is noW made to FIG. 4C and FIG. 4D Which
`illustrates a Wire dispenser 19, constructed and operative in
`accordance With yet another preferred embodiment of the
`present invention. Wire dispenser 19 is a holding instrument,
`such as tWeeZers, tongs or pliers, for eXample. In this
`embodiment, a Wire cutter 21 may be provided together With
`the dispenser 19, for cutting Wire 18.
`No matter What form Wire dispenser 16 and Wire 18 are
`provided, Wire 18 is preferably dispensed from Wire dis
`penser 16 such that only a required amount of Wire 18
`protrudes from and is fed by noZZle 22 and the rest of Wire
`18 remains on its spool or bobbin or other storage apparatus.
`Wire 18 may be constructed from one or materials, such
`as, but not limited to, metals, plastics, especially
`thermoplastics, natural (vegetable and animal) and synthetic
`?bers, composite materials, putty, elastomers, glass and
`adhesives. Even eXtrudable food products, such as dough,
`may be used. Wire 18 generally has a round cross section,
`although any other arbitrary cross section such as rectangu
`lar or triangular is of course possible. The accuracy of the
`?nished prototype depends largely on the thickness of Wire
`18. Wires With a diameter of 0.001 mm may be used to
`achieve especially high accuracy.
`In accordance With a preferred embodiment of the present
`invention, a cutter 28 is provided for cutting Wire 18 after
`being dispensed by Wire dispenser 16. Cutter 28 is particu
`larly useful in forming discrete or non-continuous portions
`of an object. Cutter 28 is illustrated as an electrically
`operated and controlled knife, but it is appreciated that cutter
`28 may comprise other cutting instruments, such as a laser
`or Water jet. Cutter 28 is illustrated disposed intermediate
`adhesive dispenser 12 and Wire dispenser 16, hoWever, it is
`appreciated that cutter 28 may be placed in any other
`suitable location.
`Apparatus 10 includes an actuator 30 Which moves adhe
`sive dispenser 12 and Wire dispenser 16 in at least one of siX
`degrees of freedom (preferably in at least four degrees of
`freedom, and most preferably in siX degrees of freedom).
`For simplifying the description of the embodiment, FIG. 1
`illustrates a greatly simpli?ed version of actuator 30,
`hoWever, a more detailed illustration of a preferred embodi
`ment of an actuator is given With reference to FIG. 6.
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`Actuator 30 preferably communicates With a computer 32
`Which contains a data base containing the three-dimensional
`geometry of an object 34. As is Well knoWn in the art of rapid
`prototyping, readily available softWare may be used to
`communicate the geometry of object 34 to actuator 30 in
`accordance With a variety of protocols and coordinate
`systems, such as Cartesian, polar or cylindrical. Optionally,
`customiZed softWare may be developed in accordance With
`a particular need.
`Preferably a user can interact With the softWare and input
`data, such as Wire thickness, type of material, and type of
`adhesive. Using stored data of physical and mechanical
`properties of adhesives and Wire materials, and using Well
`knoWn principles of mechanical engineering, the softWare
`can calculate and control movement of actuator 30 in
`accordance With the chosen adhesive and material.
`Actuator 30 thus may be used to move adhesive dispenser
`12 and Wire dispenser 16 in accordance With the geometry
`of object 34. Computer 32 may be in Wired or Wireless
`communication With adhesive dispenser 12, Wire dispenser
`16, cutter 28 and actuator 30.
`Reference is noW made to FIG. 2 Which illustrates rapid
`prototype apparatus 10 forming a prototype of three
`dimensional object 34 (FIG. 1). Actuator 30 preferably
`dispenses layers of Wire 18 in accordance With the geometry
`of object 34, and adhesive dispenser 12 applies adhesive 14
`to Wire 18 so as to bond a previously dispensed portion of
`Wire 18 to a presently dispensed portion of Wire 18. A
`successive layer of Wire 18 may be dispensed one on top of
`a previous layer. Adhesive 14 then cures so that the layers of
`Wire 18 form a prototype 40 of object 34.
`If necessary, Wires of different materials may be dispensed
`to form a multi-material prototype. Moreover, a portion of
`the prototype may be formed With a discardible Wire, i.e., a
`Wire Which serves as a support for other Wires and Which is
`purposely removed later to form the ?nished prototype. For
`example, a portion of the prototype may be formed With Wax
`Wires Which serve as a support for structural Wires, such as
`metal Wires. The Wax Wires are later removed by melting,
`thereby leaving a metal Wire prototype.
`Reference is noW made to FIG. 3 Which illustrates a
`portion of prototype 40 formed With Wire 18 and adhesive
`14. It is seen that preferably adhesive 14 at least partially
`covers a perimeter of Wire 18. Adhesive dispenser 12 may
`control application of adhesive 14 to control the degree of
`covering of Wire 18 and, to some extent, the ?nished
`appearance of the surface of prototype 40. Adhesive 14
`generally Wicks by capillary action betWeen successive
`layers of Wire 18. Adhesive 18 may be applied to bond Wire
`18 to bed 26, if desired, in order to ?x the ?rst layer of Wire
`18 in place.
`Reference is noW made to FIG. 5 Which illustrates an
`alternative method of applying adhesive 14 to Wire 18, in
`accordance With a preferred embodiment of the present
`invention. Adhesive dispenser 12 may be located so as to
`dispense adhesive 14 into noZZle 22 such that Wire 18 is
`dispensed from Wire dispenser 16 pre-coated With adhesive
`14. Indeed application of the Wires and adhesive may be
`synchroniZed in any desired manner.
`In accordance With another preferred embodiment of the
`present invention, prototype 40 may be produced by only
`dispensing layers of adhesive 14 in at least one of six
`degrees of freedom, (preferably in at least four degrees of
`freedom, and most preferably in six degrees of freedom) in
`accordance With the geometry of object 34, and thereafter
`curing the layers of adhesive 14. Preferably a previously
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`6,153,034
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`dispensed portion of adhesive 14 is bonded to a presently
`dispensed portion of adhesive 14. A successive layer of
`adhesive 14 may be dispensed one on top of a previous layer.
`In this embodiment, engineering and design parameters,
`such as siZe of an adhesive bead being dispensed, viscosity
`and density of adhesive, bonding and curing characteristics
`of the adhesive, should be carefully chosen in order that each
`subsequent layer of adhesive bonds and cures properly With
`previous layers.
`Reference is noW made to FIG. 6 Which illustrates an
`actuator 50, constructed and operative in accordance With a
`preferred embodiment of the present invention.
`Actuator 50 preferably includes a three-dimensional
`motion system 52, such as the NEURACTOR CNC® com
`puter numerically controlled desktop manufacturing system,
`commercially available form U.S. Cyberlab, Inc., 14786
`Slate Gap Rd., West Fork, Ark. It is appreciated that other
`three-dimensional motion systems or computer numerically
`controlled systems may be used to carry out the invention as
`Well. Such a system is readily controlled by computer 32 as
`described hereinabove.
`System 52 preferably includes a motion head 54 mounted
`on a guide element 56. Opposite ends of guide element 56
`are preferably disposed for sliding motion in a pair of rails
`58 generally along an axis 60. Motion head 54 is preferably
`disposed for sliding motion in a track 62 of guide element 56
`generally along an axis 64, generally perpendicular to axis
`60. Motion head 54 preferably includes a track 66 in Which
`a block 68 is disposed for sliding motion generally along an
`axis 70, generally orthogonal to axes 60 and 64. Axes 60, 64
`and 70 thus form a Cartesian coordinate system. Motion
`control circuitry 79 controls motion of motion head 54.
`AWire dispenser 80 dispenses a Wire 82 to motion head.
`As described hereinabove for adhesive dispenser 12, an
`adhesive dispenser (not shoWn) may be ?xedly attached to
`motion head 54. Thus, actuator 50 is capable of moving an
`adhesive dispenser and a Wire dispenser in at least one of six
`degrees of freedom in accordance With a geometry of an
`object. A UV lamp 84 may be provided Which transmits UV
`light via an optic ?ber 86 to the vicinity of motion head 54
`to cure the layers of adhesive. A control panel 88 With
`control buttons may be provided for convenient operation of
`the system.
`In summary, the present invention provides an improved
`technique for building any siZe prototype, Wherein a build
`ing material is added layer by layer to build an accurate
`replica of a given object, Without having to remove building
`material to arrive at the ?nished prototype. The prototype
`may afterWards be coated or ?nished by any suitable coating
`or ?nishing technique, such as painting or electrochemical
`?nishing, for example.
`The present invention may be conveniently used to scan
`an object for inputting three-dimensional data of the object
`into a computer program. The noZZle 22 of Wire dispenser 16
`may be replaced With a scanning tip Which is passed over the
`object, as is knoWn in the art.
`It is appreciated that various features of the invention
`Which are, for clarity, described in the contexts of separate
`embodiments may also be provided in combination in a
`single embodiment. Conversely, various features of the
`invention Which are, for brevity, described in the context of
`a single embodiment may also be provided separately or in
`any suitable subcombination.
`It Will be appreciated by persons skilled in the art that the
`present invention is not limited by What has been particu
`larly shoWn and described hereinabove. Rather the scope of
`the present invention is de?ned only by the claims Which
`folloW:
`
`Page 8 of 9
`
`Markforged Ex. 1006
`Markforged v. Continuous Composites, IPR2022-01220
`
`

`

`6,153,034
`
`7
`
`What is claimed is:
`1. A method for producing a prototype of an object,
`comprising:
`dispensing layers of a Wire in at least four degrees of
`freedom in accordance With a geometry of the object;
`and
`bonding a previously dispensed portion of the Wire to a
`presently dispensed portion of the Wire With adhesive,
`said adhesive being formed of a material Which is
`different and distinct from said Wire.
`2. A method according to claim 1 and comprising curing
`the adhesive so that the layers of the Wire form a prototype
`of the object.
`3. Amethod according to claim 2 Wherein the adhesive at
`least partially covers a perimeter of the Wire.
`4. A method according to claim 1 Wherein the adhesive is
`selected from the group consisting of: quick curing
`adhesives, cyanoacrylates, ultraviolet curable adhesives,
`thermocurable adhesives, epoXies, animal glues, vegetable
`glues, lacquers, polymers, monomers, self-adhesive
`materials, double-sided adhesives, single side adhesives, and
`hot glues.
`5. A method according to claim 1 Wherein said bonding
`further comprises ultrasonic Welding.
`6. A method according to claim 1 Wherein the Wire is
`selected from the group consisting of: metals, plastics,
`thermoplastics, vegetable ?bers, animal ?bers, synthetic
`
`8
`?bers, composite materials, putty, elastomers, adhesives and
`eXtrudable food products.
`7. Apparatus for producing a prototype of an object,
`comprising:
`a Wire dispenser for dispensing a Wire;
`an adhesive dispenser for dispensing an adhesive, Which
`is formed of a material Which is different and distinct
`from said Wire; and
`an actuator Which moves the Wire dispenser and the
`adhesive dispenser in at least four degrees of freedom
`in accordance With a geometry of said object.
`8. Apparatus according to claim 7 Wherein the adhesive
`dispenser and the Wire dispenser are ?Xedly attached to each
`other.
`9. Apparatus according to claim 7 Wherein the adhesive
`dispenser dispenses the adhesive as the Wire is dispensed by
`the Wire dispenser.
`10. Apparatus according to claim 7 Wherein the adhesive
`0 dispenser dispenses the adhesive into the Wire dispenser
`such that the Wire is dispensed from the Wire dispenser
`pre-coated With the adhesive.
`11. Apparatus according to claim 7 and comprising a
`cutter for cutting the Wire after being dispensed by the Wire
`dispenser.
`
`Page 9 of 9
`
`Markforged Ex. 1006
`Markforged v. Continuous Composites, IPR2022-01220
`
`