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Our Technologies: Rapid Prototyping (RP), Rapid Tooling (RT), and Rapid Manufacturing (RM) Technologies

J. Jang, Wen C. Huang and W. H. Zhong “Improved Layer Manufacturing Process and Apparatus,” U.S. Patent No. 6,401,002 (June 4, 2002).
A solid freeform fabrication process and apparatus for making a three-dimensional object. The process comprises the steps of (1) operating a multiple-channel material deposition sub-system for dispensing droplets of selected liquid compositions and solid powders at predetermined proportions; (2) providing an object platform in close working vicinity to the deposition sub-system to receive the deposition materials therefrom; and (3) during the material deposition process, moving the deposition sub-system and the platform relative to each other in an X-Y plane defined by first and second directions and in a Z direction orthogonal to the X-Y plane so that the materials are deposited to form a first layer of the object. These steps are repeated to deposit multiple layers for forming a three-dimensional shape. These steps are preferably executed under the control of a computer system by taking additional steps of (4) creating an image of the object on the computer with the image including a plurality of segments defining the object and each segment being preferably coded with a color and/or a material composition; (5) generating programmed signals corresponding to each of the segments in a predetermined sequence; and (6) moving the deposition sub-system and the platform relative to each other in response to said programmed signals. Preferably, the system is also operated to generate a support structure for any unsupported feature of the object.
B. Z. Jang, J. Duan, K. Chen, Xin Lu, and E. J. Ma, “Rapid Prototyping and Tooling System,” U.S. Patent No. 6,405,095 (06/11/2002).
A solid freeform fabrication process and apparatus for making a three-dimensional object. The process comprises the steps of (1) operating a material deposition sub-system for dispensing droplets of solidifiable liquid compositions on demand onto selected spots of an object work surface, for using a focused heat source to maintain a heat-affected zone on the work surface, and for creating a weld pool of molten materials on this work surface by injecting selected powder particles into this heat-affected zone and (2) during the material deposition process, moving the deposition sub-system and the work surface relative to each other in an X-Y plane defined by first and second directions and in a Z direction orthogonal to the X-Y plane so that the materials are deposited to form a first layer of the object. The material in the weld pool solidifies after the heat-affected zone moves away to build portions of a layer. These steps are repeated to deposit multiple layers for forming a three-dimensional shape. Preferably, the peripheral areas and the staircase step zones between layers are built with fine droplets for improved part accuracy while the bulk of the object is built with solidification of weld pool materials. These steps are preferably executed under the control of a computer system. Preferably, the system is also operated to generate a support structure for any un-supported feature of the object.
B. Z. Jang and J. S. Yang, “Layer Manufacturing Using Focused Chemical Vapor Deposition,” U.S. Patent No. 6,180,049, 01/30/2001.
A solid freeform fabrication process and apparatus for making a three-dimensional object. The process includes the steps of (1) positioning a material deposition sub-system a selected distance from a target surface, (2) operating this sub-system to deposit materials onto the target surface by carrying out the sub-steps of (a) operating a multiple-channel fluid phase delivery device of the deposition sub-system for supplying multiple fluid compositions to a small region proximate the target surface and (b) operating a focused energy source to produce a phase change zone at this region, thereby inducing deposition of materials onto the target surface, and (3) during the material deposition process, moving the deposition sub-system and the target surface relative to one another in a plane defined by first and second directions and in a third direction orthogonal to this plane to form deposition materials into a three dimensional shape. These steps are preferably executed under the control of a computer system. Preferably, the system is also operated to generate a support structure for any unsupported feature of the object.
B. Z. Jang, J. S. Yang, J. H. Liu and L. J. Pan “Layer Manufacturing Using Deposition of Fused Droplets,” U.S. Patent No. 6,401,001 (June 4, 2002).
A solid freeform fabrication process and apparatus for making a three-dimensional object. The process comprises the steps of (1) positioning a material deposition sub-system a selected distance from a target surface, (2) operating this sub-system to deposit materials onto the target surface by carrying out the sub-steps of (a) operating a multiple-channel powder delivery device for supplying selected powder compositions at a predetermined flow rate to travel toward the target surface and (b) operating a focused energy beam to produce a fusion zone through which the powder particles, preferably in micron or nanometer sizes, are melted while in flight, thereby producing liquid droplets traveling to deposit onto the target surface, and (3) during the material deposition process, moving the deposition sub-system and the target surface relative to one another along selected directions in a plane defined by first and second coordinate directions and in a third direction orthogonal to this plane to form deposition materials into a three dimensional shape. These steps are preferably executed under the control of a computer system. Preferably, the system is also operated to generate a support structure for any un-supported feature of the object.
W. C. Huang, “Direct Write Method for Polarized Materials,” U.S. Patent No. 6,706,234, March 16, 2004.
A direct-write method for depositing a polarized material of a predetermined computer-aided pattern onto a target surface, the method including the following steps: (1) forming a solution of a material capable of being polarized using a polarization solvent which can be removed by evaporation to provide a polarized material; (2) operating dispensing devices to dispense and deposit the solution onto the target surface substantially point by point and at least partially removing the solvent from the deposited solution to form a thin layer of substantially solidified material of the predetermined pattern; and (3) during the solvent-removing step, operating a high DC voltage for poling the deposited solution to achieve polarization in the material. The invention also provides a freeform fabrication method for building a multi-layer device, such as a micro-electro-mechanical system (MEMS), which exhibits piezoelectric or pyroelectric properties.
W. C. Huang, “Direct Write Process and Apparatus,” US Pat. Pending, 10/619,287 (07/15/2003). B. Z. Jang and E. J. Ma, “Layer Additive Method and Apparatus for Freeform Fabrication of 3-D Objects,” U.S. Patent No. 6,471,800 (Oct. 29, 2002).
A method and apparatus for fabricating a three-dimensional object from porous solid preform layers and at least a pore-filling material. The method includes: (a) providing a work surface parallel to an X-Y plane of a Cartesian coordinate system; (b) feeding a first porous solid preform layer to the work surface; (c) using dispensing devices to dispense a first pore-filling material onto predetermined areas of the first preform layer to at least partially fill in the pores in these areas (hardened areas) for forming the first section of the object; (d) feeding a second porous preform layer onto the first layer, dispensing a second pore-filling material onto predetermined areas of the second layer for forming the second section (the second pore-filling material being the same as or different than the first); (e) repeating the operations from (b) to (d) to stack up and build successive preform layers along the Z-direction for forming multiple layers of the object with the remaining un-hardened areas of individual layers staying as a support structure; (f) sequentially or simultaneously affix successive layers together to form a unitary body; and (g) removing the support structure by exposing the un-hardened areas of the unitary body to a support-collapsing environment, causing the 3-D object to appear.
J. H. Liu and B. Z. Jang, “Layer Manufacturing Using Electrostatic Imaging and Lamination,” U.S. Patent No. 6,376,148 (04/23/2002). J. H. Liu and B. Z. Jang, “Layer Manufacturing of a Multi-Material, Multi-Color Object Using Electrostatic Imaging and Lamination,” U.S. Patent No. 6,780,368 (Aug.24, 2004).
A solid freeform fabrication method and related apparatus for fabricating a three-dimensional object from successive layers of a primary body-building powder material and a binder powder in accordance with a computer-aided design of the object, the method including: (a) providing a work surface; (b) feeding a first layer of the primary body-building powder material to the work surface; (c) operating an electrophotographic powder deposition device to create a binder powder image in accordance with this design; (d) transferring this binder powder image to the first layer of body-building powder; (e) applying energy sources to fuse the binder powder, forming a binder fluid to permeate through the first layer of body-building powder for bonding and consolidating the powder particles to form a first cross-section of the object; (f) feeding a second layer of the primary body-building powder onto the first layer and repeating the operating, transferring, and applying steps to form a second cross-section of the object; (g) repeating the feeding, operating, transferring, and applying steps to build successive layers in a layer-wise fashion in accordance with the design for forming the multiple-layer object; and (h) removing un-bonded powder particles, causing the 3-D object to appear.