Classifications

• • G—PHYSICS
  • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
  • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
  • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
  • G03F7/0037—Production of three-dimensional images
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y70/00—Materials specially adapted for additive manufacturing
  • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
  • B23H1/00—Electrical discharge machining, i.e. removing metal with a series of rapidly recurring electrical discharges between an electrode and a workpiece in the presence of a fluid dielectric
  • B23H1/04—Electrodes specially adapted therefor or their manufacture
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
  • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
  • B23P15/24—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass dies
  • B23P15/246—Laminated dies
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
  • B29C48/07—Flat, e.g. panels
  • B29C48/08—Flat, e.g. panels flexible, e.g. films
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B29C64/10—Processes of additive manufacturing
  • B29C64/141—Processes of additive manufacturing using only solid materials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B29C64/10—Processes of additive manufacturing
  • B29C64/141—Processes of additive manufacturing using only solid materials
  • B29C64/147—Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
  • B29C67/02—Moulding by agglomerating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
  • B29C69/001—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y10/00—Processes of additive manufacturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y70/00—Materials specially adapted for additive manufacturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44B—MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING
  • B44B1/00—Artist's machines or apparatus equipped with tools or work holders moving or able to be controlled three-dimensionally for making single sculptures or models
  • B44B1/006—Artist's machines or apparatus equipped with tools or work holders moving or able to be controlled three-dimensionally for making single sculptures or models using computer control means
• • G—PHYSICS
  • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
  • G03C—PHOTOSENSITIVE MATERIALS FOR PHOTOGRAPHIC PURPOSES; PHOTOGRAPHIC PROCESSES, e.g. CINE, X-RAY, COLOUR, STEREO-PHOTOGRAPHIC PROCESSES; AUXILIARY PROCESSES IN PHOTOGRAPHY
  • G03C9/00—Stereo-photographic or similar processes
  • G03C9/08—Producing three-dimensional images
• • G—PHYSICS
  • G05—CONTROLLING; REGULATING
  • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
  • G05B19/00—Programme-control systems
  • G05B19/02—Programme-control systems electric
  • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
  • G05B19/4097—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by using design data to control NC machines, e.g. CAD/CAM
  • G05B19/4099—Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C2793/00—Shaping techniques involving a cutting or machining operation
  • B29C2793/0045—Perforating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C48/001—Combinations of extrusion moulding with other shaping operations
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C48/001—Combinations of extrusion moulding with other shaping operations
  • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
  • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/772—Articles characterised by their shape and not otherwise provided for
• • G—PHYSICS
  • G05—CONTROLLING; REGULATING
  • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
  • G05B2219/00—Program-control systems
  • G05B2219/30—Nc systems
  • G05B2219/49—Nc machine tool, till multiple
  • G05B2219/49011—Machine 2-D slices, build 3-D model, laminated object manufacturing LOM
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
  • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

• the invention refers to a method for producing three-dimensiona objects by using a converting machine controlled by compute instructions, at which the material comprises a number of sheet or disc - shaped sections defind in size, which are treated i accordance with given computer instructions, so that parts o material are permanently removed, and the sections treated i this way are connected to each other layer by layer in programmed sequence forming said three-dimensional object.
• Big companies e.g. car industries, which are often confronte with this need, generally have pattern shops of their own wher details are produced at the demand of the constructor i materials that are relatively simple to work or shape.
• Certai industries also use CAD-data bases for model production in e.g. NC-cutters. Small companies engage external pattern shops or i certain cases completely eliminate this step in the produc development work, resulting in high cassation costs at the finis manufacture. It however applies to all pattern manufacturing methods used a present that the recording - and manufacturing work is time consuming and causes discontinuity in the actual working task o the constructor, i.e. to finish and approve the manufacturin basis for the final product or component.
• One way of providing a certain sense of the three-dimensiona geometry of the object is used by some CAD-suppliers, at whic the system allows the constructor to look at the object from a optional visual angle on the viewing screen and by that ex perience a photo-like perspective picture of the object.
• Grea efforts have been made by the supplier aiming at increasing t realism in this type of presentation, e.g. by means of choice colour scheme and shading. In practice it has however proved th this type of appliance are of greater use at sales and aesthet cal presentations than actively contributing to a decreased ne of real physical models in the construction work.
• a method of making physical models by means of CAD-data bases direct connection of the work place of the constructor described in US-A-4,575,330 (C.W. Hull).
• This so called stere lithographic method is based on the principle that a UV-radiati focused light beam cross links and by that cures the point impact on the surface layer of a liquid photo polymer.
• the lig source which is controllable in two dimensions above the ba with the UV-curing plastic liquid, can then cure a cross-secti from the desired model.
• the section made in this way is deposit on a table which is movable in the vertical direction of t bath.
• each layer can be bound to each other and a complet model of the ob ect be produced.
• This method which by time reasons only should produce scal models, has up to now been tested successfully only in smal machines having a capacity of some cubic decimeters.
• the dimen sional accuracy has been said to be a problem due to shrinkin and interior tension which cause deformity in the finished model
• the high cost price of the equipment and the relatively time consuming process for model manufacturing of a number of hour per model are factors which limit the utility of the method.
• the US-A-4,752,352 discloses an apparatus and a method fo forming an integral three-dimensional object from laminations.
• sheet - shaped material is cut into the required shapes in a wor station and the individually shaped laminations are assembled i a pre-selected sequence in an assembly station into the form o the three-dimensional object.
• This apparatus leaves quantities o waste material from the cutting operation, which is a drawback.
• the object of the present invention is to provide a method whic enables an interactive manufacture of three-dimensional models which in all essentials are in agreement with the CAD-data bas which the operator intends to reproduce.
• the method shall in thi way provide a quick manufacture of the object in question withou human intervention after the operator, via his or her workin terminal, has ordered manufacture of one or more models, and a apparatus for performing the method.
• the method should admit manufacture models with hollo spaces, which not necessarily need to have a draught fo imaginary cores or other tool parts at shaping, e.g. injectio moulding.
• the method should further allow manufacture i different materials such as stiff homogeneous or foaming plasti materials, elastic rubber - like materials and certain metals an other materials with low melting temperature.
• the method shoul further not leave quantities of waste material after the manu facture of the object.
• An apparatus for performing this method solves the problem by th fact that on each flat side of the respective section there i placeable or placed at least one electrode and that the elec trodes in accordance with given computer instructions ar connectable to an electric voltage source, which is sufficie for providing a spark - over between the electrodes, so th prats or particles of material are removed from or connected wit the respective section.
• Figure 1 shows a typical user situation where an apparat according to the invention enables interactive manufacture models at terminal work.
• Figure 2 shows the device according to fig. 1 in perspective a partial in cross - section, so that the interior of the inventi is shown.
• Figure 3 shows a contact frame in perspective view havi internal contact teeth and on a larger scale a portion of t frame where the contact teeth are shown.
• Figure 4 shows a work piece in perspective view where three the outermost material discs have been separated from the wor piece and from each other, in order to show the direction of th grid threads.
• Figure 5 shows a portion of a material disc with surroundin electrode layers in perspective.
• a voltage source is symbolicall connected between a grid thread on the upper side od the disc an a grid thread adjacent to the underside of the disc, at which spark discharge through the crossing area of the grid threads ha also been illustrated.
• Figure 6 shows a spark discharge between two grid threads in th outermost disc of a piece of material. The crossing area is als shown on an enlarged scale in order to illustrate how the spar can cut undesired rests of grid threads.
• Figure 7 a shows an alternative apparatus according to th invention in which the grid threads continuously can be remove from the piece of material through extraction after complete material treatment in every cross - section.
• the figure als shows both end portions of the grid threads on an enlarged scale
• Figure 7b shows a section through the enlarged, right end portio of fig. 7a, as seen in the direction of the arrow in fig. 7a.
• Figure 8 shows how a cross - section S - S in an object is shape in a material disc with its surrounding electrodes.
• Figure 9 shows in perspective an apparatus with moveabl treatment tool according to the invention.
• Figure 10 is a side view of the device in fig. 9. The workin station of the treatment tool is enlarged in order to show th details more clearly.
• Figure 11 is a side view of a further apparatus with fixe electrode disc.
• the working station of the treatment tool i enlarged in order to show the details more clearly.
• Figure 12 shows how a flatbed plotter can be provided wit accessories which can treat discs according to the method of th invention.
• Figure 13 is a side view of an apparatus according to th invention where a single - row spark electrode cam can be brough close to an untreated material disc with very high speed.
• Figure 14 shows the apparatus according to fig. 13 from above. Description of embodiments
• a terminal or working station connected to a CAD-computer o the like.
• a model manufactured according to the invention 4.
• control unit connected to a CAD-computer or the like.
• a connection member e.g. a cable, between control unit an contact teeth.
• a frame with internal contact means for electric connection t grid threads called contact frame.
• a sheet -, path- or disc shaped section of material call material .disc.
• a spark or arc 19.
• a voltage- / current source 19.
• a symbolically illustrated circuit breaker or other memb which can form the intended circuit and which can be controll by the control unit.
• An insulating layer e.g. a lacquer layer, surrounding a gr thread.
• An insulating layer e.g. a lacquer layer, surrounding a gr thread.
• a connection means e.g. a conical hole, for grid threads the connection means of the control unit.
• a store of untreated disc - shaped material e.g. a roll.
• a guide e.g. a gear rack, for guiding and driving the X - servo.
• a model manufactured according to the invention, durin manufacture.
• An assembly plate for fixing e.g. through vacuum, the firs finished disc section of a model.
• a base plate which is fixed with respect to the holding - o plate.
• a treatment tool e.g. a spark electrode or laser gun, calle tool.
• 48. A spring device which prestresses the store of unconnected material discs against gussets.
• a heat radiating element e.g. an infrared tube.
• a layer of thermally effectable joining agent e.g. a meltin glue.
• the method according to which the invention is applied enable different principles for the design and the function of the wor piece material and the apparatus. According to one principle good three-dimensional steerability of the treatment is enable with a considerably smaller number of grid threads per materia disc than the case would be if every single spark discharge spo was connected to separate conductors. Figs. 2,3,4,5, and 6 sho apparatuses according to this principle.
• the workpiece material e.g. a block with bigger dimensions tha the finished model 3, consists of a great number of sections 1 physically connected to the block or consisting of loose disc 16a and 16b, between which a great number of electricall conductive, thread - shaped and in their longitudinal directio parallel eletrodes 17, called grid threads, are electricall insulated from each other and applied in a grid - like patter along the entire surface formed in the cross - section betwee each material disc 16. Each such electrode layer is beside arranged transverse to adjacent electrode layers.
• the workpiec material 6 can thus in its longitudinal direction (according t fig.
• workpiece material 6 composed in this way shall be uniforml joined together and externally have flat limiting surfaces wit dimensional accuracy.
• Each separate net thread 17 should at on end be terminated with, or in connection with, one of the oute limiting surfaces of the workpiece material.
• desired patterns of holes can in this way be provide in the material discs 16. If the graduation of the net thread 17 are adapted to the size of the holes, the holes can overla each other, at which spark discharges in adjacent crossing area form street - shaped hollow spaces.
• the conductivity of th material can also be adapted to cause the spark discharge t initially occur through an earlier created ad acent hole, a which the arc takes the shortest way through the material throug the crossing area.
• the arc 18 can in this way "draw" a hole pat between two adjacent crossing points.
• the control unit of the apparatus should also burn o material 25b in the workpiece material, so that the operator c separate rests of the workpiece material and expose the model.
• the ability of the model 3 to reproduce the geometries of the C data base depends on the thickness of the material discs 16 a the relative graduation of the eletrodes 17.
• the workpie material 6 can be compared with a three-dimensional grid die which material can be evaporated or melted through a controll spark discharge. The resolution of the net die thus gives t digital surface structure of the model.
• An apparatus for performing this method could thus consist of frame 9 in which thin pointed contact teeth 13 are internal arranged with the same graduation as the net threads.
• the fra 9 should with high accuracy surround the outer limiting surfaces of the workpiece material 6, at which the contact teeth 13 projecting from the frame are caused to penetrate into the workpiece material 6 to some degree.
• the contact teeth 13 are in this way brougth to galvanic contact with the grid threads 17 or sufficiently close, so that energy can be transferred with a controlled spark discharge.
• the frame should further be provided with a feeding device 4 and 5 which with high accuracy can feed the workpiece materal 6 through the frame 9, so that the contact teeth are in unambiguous contact with the net threads 17 surrounding the material disc 16 in question.
• the feeding device 4 and 5 should, upon actuation by the control unit 7, press the workpiece material 6 through the frame 9 so that the connections of the contact teeth 13 shift to one electrode layer at a time.
• the workpiece material 6 can preferably be made with such a length in the longitudinal direction, so that several models can be manufactured from one and the same workpiece.
• the apparatus 1 finally should include a way of removing or in some other way eliminate remaining net threads 17 from the model 3. This can be provided by evaporating or melting the net threads 17 concurrently with that they are consumed and no longer needed in the process.
• Fig. 3 illustrates a way of performing this.
• the net threads 17 should have essentially the same thermal properties as the rest of the workpiece material 6.
• the net threads 17 can in this case preferably consist of strings 17 with low resistivity in the material disc 16. This can be provided by injecting conductive particles, e.g. powdered carbon, in thin nozzles during the manufacture of the material disc, e.g. at extrusion.
• Another way is to join the material discs 16 with a conductive glue with substantially the sa thermal properties as the material discs.
• Fig. 6 shows the sequence, according to the arr P, at which suitable net threads 17b must be connected via t symbolically denoted circuit breakers 21a-21n in order consume, i.e. burn away, the net threads 17 in a correct way.
• a thermal blocking layer 22 e.g. crystalline glue with high melting point, can be applied in t dividing plane between each material disc 16.
• the blocking lay 22 ensures that the net threads only can be burnt from one side
• connection direction P and this blocking layer 22 ensur that the net threads 17a remains uneffected until it is longer needed in the process. Rests of the thermal blocking lay 22 will however remain, which preferably can have a very britt mechanical strength. The layer 22 will therefore not alone able to form a self-supporting structure in the areas of t workpiece material which have been evaporated or melted off, i. the layer 22 transforms to some kind of dust or powder, sin this is not supported by material discs 16.
• Another way of removing the grid threads is by burning off certain amount of material at the outer limiting surfaces of t workpiece 6, so that the net threads 17 are exposed as projec ing fringes, at which removal by means of rollers, arranged abo the outlet opening of the workpiece are facilitated.
• a further way of removing net threads 17 is thermal burning, a which every net thread 17 has to be in galvanic contact at bot ends with a power supply circuit.
• the inner resistance of th threads will very rapidly cause a burning of the thread, whic does not necessarily effect the surrounding material due to th big difference in mass and cooling effect.
• FIG. 7 Another way according to the invention is shown in fig. 7 wher the longitudinal direction of the net threads parallel with th feeding direction of the workpiece material 6 out of th apparatus 1, and where end surfaces of the threads 17 located i the material block form electrode surfaces.
• This principl implies that the apparatus 1 can draw the net threads 17 out o the workpiece material in a controlled way.
• Each net thread 1 is electrically insulated from the environment with e.g. lacquer layer. Both end surfaces of the threads 17 are howeve uninsulated.
• All grid threads 17 are at its other end attached to a contact block 23, which also allow galvanic connection of the grid threads via connection means 26 to a control unit 7.
• a contact block 23 which also allow galvanic connection of the grid threads via connection means 26 to a control unit 7.
• connection means 26 to a control unit 7.
• the device should thus step for step draw out the net threads through a relative m ⁇ ve- ment between the contact block 23 and the workpiece material 6.
• the advantage of the last mentioned apparatus is that the finished models directly are free from remaining net threads 17.
• the disadvantage is that the number of net threads is co siderably larger than required in the first mentioned principle
• the treatment tool 36 is movable in X - and Y - direction (arro C and D) along a holding-on plate 37, which also is an electro plate.
• Untreated material disc e.g in the form of a continuo band 16 is fed stepwise from a roll 28 (arrow A) in a positi behind the holding-on plate 37, as seen from the tool 36, a holds e.g by means of vacuum, the material disc 16 against t holding-on plate 37.
• the control unit not shown, controls t tool 36 in the X- and Y - direction by means of a servo means in a path 25 corresponding to e.g.
• the tool 36 is then capable of either separating materi e.g. through melting or evaporation, or joining materi together, e.g. through thermal curing and/or sintering, to a di section, not shown in fig. 9, which in all essential detai reproduces the shape in question of the object.
• the stamp 32 with the unfinished mod 31 is brought to contact with the finished disc section (arr B).
• this finished disc section will be pressed between t outermost and last mounted disc section of the model 31 and t holding-on plate 37.
• a melting glue on t latest finished disc section can join said disc section with t earlier produced staple of disc sections 31.
• Fig. 10 shows treatment of the sections 16 by means of an arc 1 caused by a spark-over between a spark electrode 42 in the too 36 and an electrically conductive foil layer 43 on the backsid of the material disc 16.
• the holding-on plate 37 should then hav an optimated electrical and thermal resistance, so that the ar 18 is not disturbed or in any other way is effected negatively
• the supplied energy in the arc 18 and the movement speed of th servo means 29 will then effect the geometry of the treate hollow space 25.
• a sliding contact 41 connected to e.g. electrical earth via th cable 40 enables the creation of an electrically closed syste between the foil layer 43 and the spark electrode 42.
• the tool 36 could also be an energy-radiating means, e.g. a lase gun which emits a well focused beam.
• the energy of the beam mus then be adapted so that a suitable hollow space 25 can b provided through melting or evaporation.
• the holding-on plate 3 should then be made of a material which is permeable for th laser beam and which has a sufficient thermal resistance, e.g quartz glass.
• the servo means has bee replaced with an electrode die which is fixed with respect to th material disc, or a grid of conductive rods 42, e.g. spar electrodes, which can be sequentially connected with control dat from the control unit, not shown, in the cable 45 via series/ parallel converting drive circuits 44.
• holder - on plate 37 or a foil layer 43 makes the counte electrode.
• a further embodiment is shown in fig. 12 where a simpl accessories makes it possible to use a common standard flatbe plotter 46 as converting machine according to the invention.
• the pen in the holder of the plotter 46 i replaced by a treatment tool 36.
• This tool can e.g. be a spa electrode from which an arc passes to a counter electrode in t form of a fixed plate or an electrically conductive foil.
• the embodiment of figs. 13 and 14 are based on a linear displaceably cam of spark electrodes 56. This can with hi speed be led by the servo device 51 immediately above the surfa of an untreated material disc. 16. Every material disc 16, whi is not joined with any other material disc before its treatment is provided with a conductive layer 43 and a thermally effectab layer of e.g. a melting glue 55 on the side of the material di which faces away from the spark eletrodes 42. These layers 43 a 55 can preferably be integrated in one and the same layer, e.g. conductive layer of melting glue.
• the devi can in this way treat one disc per sweep of the servo devi 51.
• Thes first disc treated in this way of each new model can af completed treatment and transport by the electrode cam 56 to position aside, be gripped by an oscillating assembly plate by e.g. vacuum forces.
• the finished material disc can then pulled loose from the store 49 out of four gussets 52.
• assembly plate 32 and the material disc held thereon h returned to their initial position the servo 51 can be restar and drive the electrode cam 56 over the next material di which by the spring device 48 has been pressed in posit against the four gussets 52, when the previous disc was pul loose.
• the treatment can then be repeated.
• a heat-radiating u 53 mounted on the servo device 51 will simultaneously with treatment or separately heat a melting glue 55 applied on th backside of the previously treated disc.
• the device according to figs. 13 and 14 can after that at a ver high speed repeat this sequence, at which a new material disc 1 is supplied to the model 31 for each sweep with the electrode ca 56 and the assembly plate 32.
• a new material disc 1 is supplied to the model 31 for each sweep with the electrode ca 56 and the assembly plate 32.
• the model is completed th vacuum force between the model and the assembly plate can b discontinued, at which the finished model and the surroundin waste material 54 can be released from the device.
• the invention is not limited to the examples of treatment processes and apparatuses described here, but a plurality o variants and combinations are possible within the scope of th invention.
• mak apparatuses with fixed needle-shaped electrodes instead of gri thread provided workpiece material, said needle electrode penetrate into the work piece materials and by that enabl partial evaporation or melting. It is also possible to provid workpiece materials of easily fusible homogeneous or sintere metal alloys. It is also possible to use ceramic materials in cases where th treatment can be provided through decomposition of the materia through concentrated mechanical oscillation energy, e.g. focuse ultrasonics.
• This method can very rapidly and without human interventio manufacture three-dimensional models and objects with dimen sional accuracy in an apparatus or machine, which can be place in a common office environment. It should be possible to marke the equipment and the material disc to a relatively low cost an the method should therefore give the opportunity to man constructors, designers and architects to have a direct access t the invention at their work place.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Mechanical Engineering (AREA)
• Materials Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Physics & Mathematics (AREA)
• Composite Materials (AREA)
• General Physics & Mathematics (AREA)
• Optics & Photonics (AREA)
• Human Computer Interaction (AREA)
• Automation & Control Theory (AREA)
• Ceramic Engineering (AREA)
• Civil Engineering (AREA)
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• General Engineering & Computer Science (AREA)
• Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)

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Citations (5)

• 1988
  • 1988-08-30 SE SE8803017A patent/SE461752B/sv not_active IP Right Cessation
• 1989
  • 1989-08-18 KR KR1019900700803A patent/KR900702415A/ko active IP Right Grant
  • 1989-08-18 AU AU40684/89A patent/AU4068489A/en not_active Abandoned
  • 1989-08-18 WO PCT/SE1989/000437 patent/WO1990002361A1/en not_active Application Discontinuation
  • 1989-08-18 EP EP89909447A patent/EP0431005A1/en not_active Withdrawn
  • 1989-08-18 JP JP1508865A patent/JPH04500180A/ja active Pending
  • 1989-08-29 ES ES8902968A patent/ES2014902A6/es not_active Expired - Lifetime
  • 1989-08-30 CN CN89106649A patent/CN1043805A/zh active Pending

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