U.S. patent application number 14/697564 was filed with the patent office on 2015-10-29 for methods and apparatus for additive manufacturing of glass.
This patent application is currently assigned to MASSACHUSETTS INSTITUTE OF TECHNOLOGY. The applicant listed for this patent is Shreya Dave, Giorgia Franchin, Peter Houk, Chikara Inamura, Markus Kayser, John Klein, Neri Oxman, Michael Stern. Invention is credited to Shreya Dave, Giorgia Franchin, Peter Houk, Chikara Inamura, Markus Kayser, John Klein, Neri Oxman, Michael Stern.
Application Number | 20150307385 14/697564 |
Document ID | / |
Family ID | 54334120 |
Filed Date | 2015-10-29 |
United States Patent
Application |
20150307385 |
Kind Code |
A1 |
Klein; John ; et
al. |
October 29, 2015 |
Methods and apparatus for additive manufacturing of glass
Abstract
In illustrative implementations of this invention, a crucible
kiln heats glass such that the glass becomes or remains molten. A
nozzle extrudes the molten glass while one or more actuators
actuate movements of the nozzle, a build platform or both. A
computer controls these movements such that the extruded molten
glass is selectively deposited to form a 3D glass object. The
selective deposition of molten glass occurs inside an annealing
kiln. The annealing kiln anneals the glass after it is extruded. In
some cases, the actuators actuate the crucible kiln and nozzle to
move in horizontal x, y directions and actuate the build platform
to move in a z-direction. In some cases, fluid flows through a
cavity or tubes adjacent to the nozzle tip, in order to cool the
nozzle tip and thereby reduce the amount of glass that sticks to
the nozzle tip.
Inventors: |
Klein; John; (Cambridge,
MA) ; Franchin; Giorgia; (Cambridge, MA) ;
Stern; Michael; (Cambridge, MA) ; Kayser; Markus;
(Cambridge, MA) ; Inamura; Chikara; (Somerville,
MA) ; Dave; Shreya; (Cambridge, MA) ; Oxman;
Neri; (Cambridge, MA) ; Houk; Peter; (Medford,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Klein; John
Franchin; Giorgia
Stern; Michael
Kayser; Markus
Inamura; Chikara
Dave; Shreya
Oxman; Neri
Houk; Peter |
Cambridge
Cambridge
Cambridge
Cambridge
Somerville
Cambridge
Cambridge
Medford |
MA
MA
MA
MA
MA
MA
MA
MA |
US
US
US
US
US
US
US
US |
|
|
Assignee: |
MASSACHUSETTS INSTITUTE OF
TECHNOLOGY
Cambridge
MA
|
Family ID: |
54334120 |
Appl. No.: |
14/697564 |
Filed: |
April 27, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61984137 |
Apr 25, 2014 |
|
|
|
Current U.S.
Class: |
65/29.11 ;
65/324 |
Current CPC
Class: |
B29C 64/106 20170801;
C03B 17/00 20130101; B33Y 30/00 20141201; C03B 5/021 20130101; C03B
5/26 20130101; C03B 19/00 20130101; C03B 7/098 20130101; C03B 3/00
20130101; C03B 17/025 20130101; C03B 5/0334 20130101; C03B 5/0336
20130101; C03B 19/02 20130101; C03B 7/088 20130101; C03B 7/094
20130101; C03B 17/04 20130101; C03B 25/02 20130101; C03B 7/12
20130101; B33Y 10/00 20141201; B33Y 40/00 20141201 |
International
Class: |
C03B 19/00 20060101
C03B019/00; C03B 17/06 20060101 C03B017/06; C03B 25/02 20060101
C03B025/02 |
Claims
1. A method comprising, in combination: (a) heating of glass
material such that the glass material becomes or remains molten;
and (b) deposition of the molten glass material, in which the
molten glass material is extruded through a nozzle to form an
object; wherein during at least part of the deposition (i) the
object being formed rests on a build platform, (ii) the molten
glass material is deposited layer-by-layer; and (iii) one or more
computers control where in each layer the molten glass material is
deposited, by controlling a set of actuators that actuate movement
of one or both of the nozzle and build platform.
2. The method of claim 1, wherein at least one actuator, out of the
set of actuators, directly or indirectly actuates the nozzle to
move along at least one horizontal axis.
3. The method of claim 1, wherein: (a) the heating occurs in a
kiln; (b) during the deposition, a first actuator, out of the set
of actuators, actuates the kiln and the nozzle to move along a
first horizontal axis; and (c) during the deposition, a second
actuator, out of the set of actuators, actuates the kiln and the
nozzle to move along a second horizontal axis, the first and second
horizontal axes being perpendicular to each other.
4. The method of claim 1, wherein, during the deposition: (a) a
first actuator, out of the set of actuators, actuates the nozzle to
move along a horizontal axis; and (b) a second actuator, out of the
set of actuators, actuates the build platform to rotate.
5. The method of 1, wherein: (a) during the deposition, the build
platform is positioned inside an annealing kiln; and (b) after the
deposition, the annealing kiln anneals extruded glass material.
6. The method of claim 1, wherein extrusion of the molten glass
material through the nozzle is actuated by gravitational force and
is not actuated by any other net mechanical force.
7. The method of claim 5, wherein, during the deposition: (a) the
nozzle is stationary relative to a wall of the annealing kiln; and
(b) at least one actuator, out of the set of actuators, actuates
the build platform to cause the build platform to move relative to
the nozzle and the wall.
8. The method of claim 1, wherein: (a) an exit portion of the
nozzle surrounds or is adjacent to an exit orifice of the nozzle;
(b) the method further comprises cooling the exit portion of the
nozzle by causing fluid to flow through a region that adjoins the
exit portion; and (c) the fluid is cooler than molten glass
material exiting the exit orifice.
9. Apparatus comprising, in combination: (a) a build platform; (b)
one or more heating elements for heating of glass material, such
that the glass material becomes or remains molten; (c) a nozzle for
deposition of the molten glass material, such that the molten glass
material is extruded through the nozzle to form an object that
rests on the build platform; (d) a set of actuators; and (e) one or
more computers for controlling the deposition, such that, during at
least a portion of the deposition (i) the molten glass material is
deposited layer-by-layer; and (ii) the one or more computers
control where in each layer the molten glass material is deposited,
by causing the set of actuators to actuate movement of one or both
of the nozzle and build platform.
10. The apparatus of claim 9, wherein at least one actuator, out of
the set of actuators, is configured to actuate the nozzle to move
along at least one horizontal axis.
11. The apparatus of claim 9, wherein: (a) a first actuator, out of
the set of actuators, is configured to actuate the nozzle and at
least some of the heating elements to move parallel to a first
horizontal axis; and (b) a second actuator, out of the set of
actuators, is configured to actuate the nozzle and at least some of
the heating elements to move parallel to a second horizontal axis,
the first and second horizontal axes being perpendicular to each
other.
12. The apparatus of claim 9, wherein: (a) a first actuator, out of
the set of actuators, is configured to actuate the nozzle to move
parallel to a horizontal axis; and (b) a second actuator, out of
the set of actuators, is configured to actuate the build platform
to rotate.
13. The apparatus of claim 9, wherein: (a) the build platform is
positioned inside a kiln; and (b) the kiln is configured to anneal
extruded glass material.
14. The apparatus of claim 9, wherein the apparatus includes a
valve for controlling flow of molten glass material through the
nozzle.
15. The apparatus of claim 13, wherein: (a) the nozzle is
stationary relative to a wall of the kiln; and (b) at least one
actuator, out of the set of actuators, is configured to actuate the
build platform such that the build platform moves relative to the
nozzle and the wall.
16. The apparatus of claim 9, wherein: (a) an exit portion of the
nozzle surrounds or is adjacent to an exit orifice of the nozzle;
and (b) the apparatus further comprises one or more tubes or
cavities adjacent to the exit portion, which tubes or cavities are
configured to cool the exit portion when fluid cooler than the
molten glass material flows through the tubes or cavities.
17. Apparatus comprising: (a) heating elements for heating glass
material, such that the glass material becomes or remains molten;
(b) a nozzle for extruding the molten glass material; (c) tubes or
chambers that are adjacent to a tip of the nozzle; (d) a pump for
pumping fluid through the tubes or chamber to cool the tip of the
nozzle to a temperature that is less than temperature of the molten
glass material; (e) a set of actuators; and (f) a set of computers
that is programmed to control the set of actuators such that the
set of actuators actuate movement of one or both of the nozzle and
build platform during the extruding, such that extruded molten
glass material forms an object in accordance with digital
instructions accessed or generated by at least one computer, out of
the set of computers.
18. The apparatus of claim 17, further comprising a kiln for
annealing the molten glass material.
19. The apparatus of claim 17, wherein: (a) a first actuator, out
of the set of actuators, is configured to actuate the nozzle and at
least some of the heating elements to move parallel to a first
horizontal axis; and (b) a second actuator, out of the set of
actuators, is configured to actuate the nozzle and at least some of
the heating elements to move parallel to a second horizontal axis,
the first and second horizontal axes being perpendicular to each
other.
20. The apparatus of claim 17, wherein: (a) a first actuator, out
of the set of actuators, is configured to actuate the nozzle to
move parallel to a horizontal axis; and (b) a second actuator, out
of the set of actuators, is configured to actuate the build
platform to rotate.
Description
RELATED APPLICATIONS
[0001] This application is a non-provisional of, and claims the
benefit of the filing date of, U.S. Provisional Patent Application
No. 61/984,137, filed Apr. 25, 2014, the entire disclosure of which
is herein incorporated by reference.
FIELD OF TECHNOLOGY
[0002] The present invention relates generally to additive
manufacturing of glass, by extrusion of molten glass through a
nozzle.
SUMMARY
[0003] In illustrative implementations of this invention, a
crucible kiln heats glass such that the glass becomes or remains
molten. A nozzle extrudes the molten glass while one or more
actuators actuate movements of the nozzle, a build platform or
both. A computer controls these movements such that the extruded
molten glass is selectively deposited to form a 3D glass
object.
[0004] In some implementations, the actuators actuate the crucible
kiln and nozzle to move in horizontal x, y directions and actuate
the build platform to move in a z-direction. In other
implementations, "polar printing" occurs in which motion occurs in
linear r, angular theta, and linear z directions: the actuators (a)
actuate the crucible kiln and nozzle to move along a single
horizontal "r" axis; (b) actuate the build platform to rotate about
its center line in an angular theta direction, and (c) actuate the
build platform to move up and vertically in a z direction. In yet
other implementations, the nozzle and crucible kiln are stationary,
and the actuators actuate the build platform to move relative to
the nozzle.
[0005] In illustrative implementations, the nozzle is independently
heated by a nozzle kiln. In some cases, the nozzle kiln is
partially housed in the crucible kiln, and partially protrudes
below the crucible kiln.
[0006] In illustrative implementations, the build platform is
located inside an annealing kiln, and the nozzle protrudes into the
annealing kiln. Thus, the selective deposition of molten glass
occurs inside the annealing kiln. The annealing kiln heats the
extruded glass during the selective deposition, and anneals the
glass by slowly and progressively lowering the temperature of the
extruded glass after the selective deposition.
[0007] In some implementations, a fluid flows through a cavity or
tubes adjacent to the nozzle tip, in order to cool the nozzle tip
and thereby reduce the amount of glass that sticks to the nozzle
tip. The lower the temperature of the nozzle tip, the less glass
sticks to the nozzle tip or the easier it is to remove it.
[0008] In some implementations, one or more refractory metal sheets
are press-formed to fit around the exit orifice of the nozzle and
thereby protect the nozzle tip from becoming clogged by glass. When
glass becomes stuck to a disposable sheet, the disposable sheet is
removed.
[0009] In some implementations, a valve controls flow of molten
glass through the nozzle. For example, in some cases, the valve
comprises a pair of refractory shears. When the shears are closed,
they cut the filament of molten glass exiting the nozzle and block
flow of molten glass through the nozzle. In other cases, a motor
raises a rod up and down. When the rod is fully lowered, it extends
into the nozzle, touching interior walls of the nozzle tip and
blocking flow of molten glass through the nozzle.
[0010] In some implementations, the sole impetus for the flow of
molten glass through the nozzle is the force of gravity. In other
implementations, molten glass is actively pushed out of the nozzle.
For example, in some cases, a refractory plunger or compressed air
exerts pressure against molten glass in the crucible and thereby
pushes the molten glass through the nozzle.
[0011] In some cases, a tube extends into the nozzle almost to the
tip of the nozzle. Air is blown through the tube, such that a
column of air infiltrates the filament of molten glass as it is
extruded from the nozzle. The column of air is trapped inside the
filament and is co-axial with the filament.
[0012] In illustrative implementations, the 3D glass object
produced by the selective deposition is optically transparent.
[0013] The description of the present invention in the Summary and
Abstract sections hereof is just a summary. It is intended only to
give a general introduction to some illustrative implementations of
this invention. It does not describe all of the details and
variations of this invention. Likewise, the descriptions of this
invention in the Field of Technology section and Field Of Endeavor
section are not limiting; instead they identify, in a general,
non-exclusive manner, a field of technology to which exemplary
implementations of this invention generally relate. Likewise, the
Title of this document does not limit the invention in any way;
instead the Title is merely a general, non-exclusive way of
referring to this invention. This invention may be implemented in
many other ways.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1A is a cross-sectional view of an apparatus for
additive manufacture of glass.
[0015] FIG. 1B is a cross-sectional view of a crucible kiln.
[0016] FIG. 1C is a cross-sectional view of a nozzle kiln.
[0017] FIG. 1D is a cross-sectional view of an annealing kiln.
[0018] FIG. 2 is a perspective view of an apparatus for additive
manufacture of glass.
[0019] FIG. 3 shows deposition of molten glass.
[0020] FIGS. 4A, 4B and 4C are cross-sectional views of tubes or
cavities for cooling a nozzle tip.
[0021] FIGS. 5A and 5B are cross-sectional views of valves for
controlling flow of molten glass from the crucible.
[0022] FIG. 6A is a cross-sectional view of a disposable metal
sheet that is positioned adjacent to a nozzle tip.
[0023] FIG. 6B is a cross-sectional view of two disposable metal
sheets that are positioned adjacent to a nozzle tip.
[0024] FIG. 7 is a cross-sectional view of insulation skirts.
[0025] FIG. 8A is a cross-sectional view of an apparatus in which
the print head is stationary.
[0026] FIG. 8B is a cross-sectional view of an apparatus, in which
a first actuator causes the build platform to rotate, and a second
actuator causes the crucible kiln to move along a linear axis.
[0027] FIG. 9 is a block diagram showing hardware components that
interface with, or are controlled by, one or more computers.
[0028] FIG. 10A is a flowchart that describes steps in a method for
additive manufacture of glass.
[0029] FIG. 10B is a flowchart that shows steps in a method for
additive manufacture of glass.
[0030] FIG. 11A is a cross-sectional view of an apparatus, in which
a plunger exerts pressure that actively extrudes molten glass
through a nozzle.
[0031] FIG. 11B is a cross-sectional view of an apparatus, in which
air exerts pressure that actively extrudes molten glass through a
nozzle.
[0032] FIGS. 12A, 12B, 12C, 12D, 12E and 12F each show material
being fed into the printer.
[0033] FIG. 13 is a cross-sectional view of an apparatus, in which
an air tube blows air into molten glass.
[0034] FIGS. 14A, 14B, 14C and 14D show non-limiting examples of
glass objects printed by a 3D printer. FIG. 14A is a
cross-sectional view that shows multiple internal cavities. FIG.
14B shows multiple, distinct layers of optically transparent glass.
FIG. 14C shows a spiral filament of glass. FIG. 14D is a
cross-sectional view of an elongated cavity in the spiral
filament.
[0035] The above Figures show some illustrative implementations of
this invention, or provide information that relates to those
implementations. However, this invention may be implemented in many
other ways.
DETAILED DESCRIPTION
Prototype
[0036] The following is a description of a prototype of this
invention. This prototype is a non-limiting example of this
invention; this invention may be implemented in many other
ways.
[0037] In this prototype, a 3D printer fabricates 3D glass objects,
such as objects that comprise optically transparent glass. The 3D
printer operates at high temperatures, extrudes highly viscous
molten glass, and overcomes large inertias during the 3D printing
process.
[0038] In this prototype, a crucible kiln maintains molten glass at
a temperature of 1900-2000 degrees Fahrenheit. The temperature of
the feed affects the dimensional accuracy of the print due to the
change in viscosity across the temperature range. Electrical
specifications of the crucible kiln are: 180 0W, 120V, 15 A, 1
phase, 20 A breaker. The kiln is made of alumina-silica fiber board
(Duraboard.RTM.) and it is heated through Kanthal.RTM. A-1 1.8 mm
diameter, 0.57 Resistance .OMEGA.m 20.degree. C. coils. Temperature
of the crucible kiln is read by a Type K thermocouple.
[0039] In this prototype, a nozzle kiln provides independent
heating to the printer nozzle. The electrical specifications of the
nozzle kiln are: 300 W, 48V, 6 A, 1 phase, 15 A breaker. The kiln
is made of alumina-silica fiber board (Duraboard.RTM.) and it is
heated through Kanthal.RTM. A-1 1 mm diameter, 1.85 Resistance
.OMEGA.m 20.degree. C. coils. Temperature of the nozzle kiln is
read by a Type S thermocouple. The characteristics of the flow of
molten glass are highly temperature dependent. The nozzle kiln is
partially housed in a bottom wall of the crucible kiln, and also
protrudes below the bottom of the crucible kiln.
[0040] In this prototype, the crucible, crucible kiln, nozzle and
nozzle kiln together comprise a compact unit, which is sometimes
referred to herein as the "print head". All heating elements and
thermocouples exit on the same side of the print head in order not
to limit the print head movements.
[0041] In this prototype, molten glass is contained in a refractory
crucible positioned inside the crucible kiln. The molten glass
flows out of the crucible, then through an alumina nozzle, and then
exits the tip of the nozzle and is deposited. The nozzle kiln has a
hole, into which the nozzle is inserted. After the nozzle is
inserted, the crucible and the nozzle are assembled with a
refractory mortar. The nozzle is machined from bulk alumina
rods.
[0042] In this prototype, the print head (including nozzle,
crucible, crucible kiln and nozzle kiln) is mounted on a carriage
that comprises supports mounted on roller bearings that travel on
structural tracks. The nozzle kiln and nozzle protrude out of the
bottom of the crucible kiln, and thus protrude below the carriage
into the annealing chamber. The nozzle deposits molten glass,
precisely controlling layer height. The layers of deposited glass
adhere to each other.
[0043] In this prototype, the molten glass is deposited into an
annealing chamber. Thus, the 3D object formed by the deposited
glass is created inside the annealing chamber. The annealing
chamber reduces the cooling rate of the glass, such that the 3D
object being manufactured comprises crack-free glass with strong
adhesion between layers.
[0044] In this prototype, the annealing chamber operates at 900
degrees Fahrenheit, before slowly cooling during annealing. The
annealing chamber remains stationary. A build platform supports the
3D glass object being fabricated. The build platform is positioned
inside the annealing chamber. An actuator moves the build platform
up and down vertically. The print head moves horizontally in X-Y
directions.
[0045] In this prototype, the heating elements of the annealing
chamber draw 4000 Watts. Power for the heating elements is obtained
by plugging into a 208 V wall outlet. The annealing chamber
includes two refractory doors. One door provides access to the
nozzle. The other door may be opened, in order to remove the 3D
printed object from the annealing chamber. In addition, the
annealing chamber includes a heat-resistant Neoceram.RTM. window,
through which a user may look to visually monitor progress of a
print job.
[0046] In this prototype, the top of the annealing kiln has a hole,
into which the nozzle of the print head protrudes in order to
deposit molten glass into the annealing chamber. Two light, thin,
refractory Duraboard.RTM. insulation skirts, together with the
carriage for the print head, block this hole and reduce the amount
of heat that is lost through this hole. One skirt is mounted on top
of the annealing chamber, whereas the other one is mounted to the
moving carriage below the crucible kiln.
[0047] In this prototype, a frame provides structural support for
the printer, and is positioned along the exterior of the printer.
The frame is made from 80/20 aluminum 1'' stock and 1018, 1''
square steel tube. Aluminum is used for elements not exposed to
high heat, while the heavier steel is reserved for central
components that may become hot from the feed kiln, annealing kiln,
or radiating molten glass. The print head is mounted on a moveable
carriage. The carriage comprises steel supports mounted on shielded
roller bearings that travel on structural steel tracks. The entire
assembly, including the frame, print head, carriage, and annealing
chamber, fits through a standard door frame.
[0048] This prototype includes three independent stepper motor-lead
screw gantry systems. Out of these three stepper motor-lead screw
gantry systems, one actuates x motion of the print head carriage,
one actuates y motion of the print head carriage, and one actuates
z motion of the build carriage.
[0049] In this prototype, each stepper motor is electronically
controlled by a driver circuit, which in turn is electronically
controlled by an Arduino.RTM. PCB and an Arduino.RTM. Shield PCB.
The stepper motors are NEMA 23 in size and have a rated holding
torque of 400 oz-inches. The stepper motors operate in their
high-torque range due to the inertia of the crucible kiln and
carriage assembly. The driver circuits permit a maximum current of
7.8 Amps to the stepper motors and are powered separately from the
electronic controls with a 48 V power supply.
[0050] In this prototype, each of the x and y motors are connected
to an ACME 1/2-10 five-start fast travel lead screw with a flexible
helical coupling that accommodates slight misalignments during
operation. The x and y motors are isolated from axial and radial
loads by bearing blocks. Each of the x and y motors is mounted at
the corner of the travel range actuated by the motor. The lead
screws for the x and y motors, respectively, are attached to the
carriage with a brass nut and the far end is not constrained in
order to reduce risk of jamming due to substantial vibration when
operating at full speeds. Plates and mounts are made of mild
steel.
[0051] In this prototype, the Z motor is mounted at the base of the
frame and drives a standard travel lead screw through radial
bearings to the build platform. The build platform support rod
extends through a hole at the base of the annealing chamber
kiln.
[0052] In this prototype, an emergency stop button is wired to cut
power to the drivers and motors and mounted to the frame for easy
access. Limit switches are mounted at the "zeros" of the X and Y
axes both to provide homing information to the control software and
to protect the system from mechanical crashes. These prevent the
motor from driving when activated and are connected directly to the
Arduino.RTM. shield. The limit switch cables are bundled separately
from the motor cables to prevent interference.
[0053] In this prototype, a computer slices a CAD model of the
desired three-dimensional glass object. To do so, the computer
performs a C# script in Grasshopper Build 0.9.76.0, and imported
into an open source printing software, Repetier-Host V1.0.6. Open
source Repetier firmware is used to direct the 3D printer. The
Repetier firmware is adapted for the acceleration, velocities, and
size of the 3D printer.
[0054] In this prototype, a computer performs an algorithm that
includes the following steps. The slicing script draws a helix
around the CAD model structure, providing information for
continuous flow and accommodating for the specific filament
diameter of extruded glass. This helix is then represented in
Cartesian coordinates in the form of g-code. The g-code generator
may take two different types of inputs to create the code: a
free-form spline/polyline curve or a non-uniform rational basis
spline (nurbs) surface. The layer height and curve discretization,
as well as the feed rate, may be modified in real-time, while
watching the toolpath update live in the preview pane. Users may
also define specific velocities for each point. The algorithm for
the wrapping toolpath takes the input surface, intersects it based
on the layer height, discretizes each intersection curve based on
the input resolution, and then incrementally remaps the discretized
points with increasing z values. The remapped points are then
connected with a polyline to create the continuous wrapping
toolpath for any given complex geometry. All remapped points are
ordered and formatted to g-code syntax which is then be imported
directly into Repetier software.
[0055] In this prototype, the 3D printer selectively deposits
molten glass with a spatial precision of about 2 mm. The crucible
kiln, nozzle kiln and annealing kiln are able to heat up to
2300.degree. F., and the maximum build volume is 0.7 cubic
feet.
[0056] This invention is not limited to the prototype described
above. Instead, this invention may be implemented in many different
ways.
DRAWINGS
[0057] Turning now to the drawings, FIG. 1A is a cross-sectional
view of an apparatus 100 for additive manufacture of glass, in an
illustrative implementation of this invention. In FIG. 1A, a
crucible kiln 107 heats glass 103 in crucible 105 until the glass
melts. A nozzle kiln 109 is partially housed in a bottom wall of
the crucible kiln 107. Part of the nozzle kiln 109 protrudes below
the bottom wall of the crucible kiln 107. The nozzle kiln 107 heats
glass in nozzle 15.
[0058] In FIG. 1A, the crucible kiln 107 and nozzle kiln 109 are
positioned above an annealing kiln 111. A build platform 108 is
positioned inside the annealing kiln 111. A support rod 106
supports the build platform 108. The support rod 106 is operatively
connected to a gear 104 that transmits mechanical force from an
actuator. The force causes rod 106, and thus build platform 108, to
move up and down vertically.
[0059] FIG. 1B is a cross-sectional view of a crucible kiln 107, in
an illustrative implementation of this invention. In FIG. 1B,
electrical heating elements 115 heat a crucible 105 containing
glass 103. For example, in some cases, heating elements 115 in
crucible kiln 107: (a) heat the glass 103 in crucible 105 to a
temperature of 2000 degrees Fahrenheit for at least two hours,
during a melting and fining step; and (b) heat the glass 103 in
crucible 105 to a temperature of 1900 degrees Fahrenheit during
deposition of the glass to form the 3D glass object being
manufactured (i.e., during "printing"). During the fining step,
bubbles are removed from the melted glass. In some cases, fining
agents are placed in the crucible 105 prior to the fining step, and
facilitate the fining (removal of bubbles). For example, in some
cases, the fining agents comprise a sulfate (e.g., 2SO.sub.3),
4CeO.sub.2, arsenic oxide or an antinomy oxide.
[0060] In FIG. 1B, the side and bottom walls 111 of the crucible
kiln 107 are insulated. Likewise, the lid 113 of the crucible kiln
107 is insulated. A temperature sensor 117 measures temperature in
the crucible kiln 107. For example, in some cases: (a) the
temperature sensor 117 comprises a Type K thermocouple; (b) wires
that are rated for high temperatures connect the temperature sensor
117 and heating elements 115 to a PID
(proportional-integral-derivative) controller; and (c) the PID
controller controls heating elements 115.
[0061] FIG. 1C is a cross-sectional view of a nozzle kiln 109, in
an illustrative implementation of this invention. In FIG. 1C,
electrical heating elements 129 heat glass in a nozzle 125. For
example, in some cases, the nozzle kiln heats glass in the nozzle
to a temperature of 1850 degrees Fahrenheit. Glass enters the
nozzle 125 from the crucible 105 and exits the nozzle at the nozzle
tip 127. The walls 121 of the nozzle kiln 109 are insulated. A
temperature sensor 128 measures temperature in the nozzle kiln 109.
For example, in some cases: (a) the temperature sensor 128
comprises a Type S thermocouple; (b) wires that are rated for high
temperatures connect the temperature sensor 128 and heating
elements 129 to a PID controller; and (c) the PID controller
controls heating elements 129.
[0062] FIG. 1D is a cross-sectional view of an annealing kiln 111,
in an illustrative implementation of this invention. The walls 131,
133 of annealing kiln 111 are insulated. In FIG. 1D, electrical
heating elements 139 heat the interior cavity (annealing chamber)
of the annealing kiln 111. For example, in some cases: (a) heating
elements 139 maintain a temperature of at least 900 degrees
Fahrenheit in the annealing chamber during deposition of the molten
glass; and (b) after deposition of the molten glass is complete,
heating elements 139 continue to heat the annealing chamber, but at
slowly decreasing temperature setpoints. For example, in some
cases, starting when deposition of the glass is complete, the
temperature setpoint for the annealing chamber is set to
900.degree. F. for one hour, then 750.degree. F. for three hours,
then 300 20 F. for five hours, then 175.degree. F. for 1.5 hours,
and then 70.degree. F. for 0.5 hours. Slowly lowering the
temperature of the glass (i.e., annealing the glass) releases
thermal stresses in the glass and causes the glass to be crack free
and much stronger than it would if it were allowed to quickly cool
to room temperature.
[0063] In FIG. 1D, a temperature sensor 141 measures temperature in
the annealing kiln 111. For example, in some cases: (a) the
temperature sensor 141 comprises a Type K thermocouple; (b) wires
that are rated for high temperatures connect the temperature sensor
141 and heating elements 139 to a PID controller; and (c) the PID
controller controls heating elements 139.
[0064] In FIG. 1D, a window 137 allows a user outside the annealing
chamber to look through the window 137 into the annealing chamber.
For example, in some cases, window 13 comprises a Neoceram.RTM.
window that is rated for high temperatures.
[0065] In FIG. 1D, a refractory door 135 provides access to the
interior of the annealing chamber, allowing a user to access the
nozzle tip in the annealing chamber. Door 135 has a handle 136. A
second, wider refractory door (not shown in FIG. 1D) also provides
access to the interior of the annealing chamber. This second door
is sufficiently wide that a user may reach into the annealing
chamber and remove the 3D glass object that has been created by the
printer.
[0066] In FIGS. 1B, 1C, 1D, the heating elements 115, 129, 139
comprise resistive heating elements or inductive heating elements.
For example, in some cases, each heating element 115, 129, 139
comprises a Kanthal.RTM. resistive coil. For example, in some other
cases, each heating element 115, 129, 139 comprises an
electromagnet that undergoes inductive heating when subjected to a
high frequency alternating current. For example, in some cases, the
high frequency AC current is generated by an electronic oscillator
(not shown).
[0067] FIG. 2 is a perspective view of an apparatus for additive
manufacture of glass, in an illustrative implementation of this
invention. In FIG. 2, actuators cause x, y motion of the print head
(including the crucible kiln) and z-motion of the build
platform.
[0068] As used herein, "x, y motion" means motion in two horizontal
axes that are perpendicular to each other. As used herein, "z
motion" means vertical motion. Likewise, as used herein, "x" and
"y" directions means two directions that are horizontal and are
perpendicular to each other, and "z" direction means a vertical
direction. Likewise, as used herein, "x" and "y" axes mean two axes
that are horizontal and are perpendicular to each other, and a "z"
axis means a vertical axis.
[0069] In FIG. 2, motor 211 actuates x movement of the print head
(including nozzle 125, crucible kiln 107, crucible 105, and nozzle
kiln 109) in a direction parallel to a horizontal x axis 272. Motor
221 actuates y movement of the print head (including nozzle 125,
crucible kiln 107, crucible 105, and nozzle kiln 109) in a
direction parallel to horizontal y axis 271. X-axis 272 and y-axis
271 are horizontal and perpendicular to each other. Motor 201
actuates movement of the build platform 205 and support rod 203 in
a direction parallel to vertical z axis 273.
[0070] In FIG. 2, motor 221 is attached to frame 280 and is
stationary with respect to frame 280. Motor 221 causes moveable
component 217 (and the print head, which is supported by moveable
component 217) to move in a y direction. Moveable component 217
includes roller bearings that travel in a direction parallel to
horizontal y axis 271 along structural tracks that are part of
frame 280.
[0071] In FIG. 2, motor 211 is attached to moveable component 217
and is stationary with respect to moveable component 217. Motor 211
causes a carriage 219 to move in an x direction parallel to
horizontal x-axis 272, along support rails that are part of
moveable component 217. Carriage 219 rests on roller bearings that
travel along these support rails. In some cases, carriage 219
comprises steel.
[0072] In FIG. 2, the print head (including nozzle 125, crucible
kiln 107, crucible 105, and nozzle kiln 109) is attached to, and
supported by, carriage 219. The print head moves with carriage
219.
[0073] In FIG. 2, motor 201 actuates z movement and is positioned
beneath the annealing kiln (not shown in FIG. 2). Support rod 203
passes through the bottom wall of the annealing kiln and supports
the build platform 205.
[0074] In some cases, x, y and z motions are actuated by three lead
screw gantry systems that include motors 211, 221 and 201,
respectively. In some cases, motors 201, 211, and 221 comprise
stepper motors or servo motors. In some cases, the motors are
controlled by driver circuits that are controlled by one or more
microcontrollers (e.g., an Arduino.RTM. board and shield). The
microcontrollers are in turn controlled by another computer.
[0075] FIG. 3 shows deposition of molten glass, in an illustrative
implementation of this invention. In FIG. 3, a nozzle tip 127 is
positioned at a height equal to the top of the layer 303 of molten
glass being deposited, while molten glass flows through the nozzle
tip 127. Positioning the nozzle tip at this height (equal to the
top of the layer then being deposited) tends to create stronger
bonds between layers and print objects with consistent layer
height, as compared to positioning the nozzle tip at a greater
height. The better adhesion and the bigger contact surface between
layers lead to higher transparency in the vertical direction.
[0076] In some cases, the molten glass comprises a soft, flexible
filament of molten glass as it exits the nozzle.
[0077] In the example shown in FIG. 3, the molten glass is
selectively deposited layer-by-layer. For each layer, actuators
(e.g., motors 211, 221) move the print head (including the nozzle
125, crucible kiln 107, crucible 105, and nozzle kiln 109) in x, y
movements to control the x, y coordinates of where the glass is
deposited in the layer. The region(s) in which glass is deposited
may vary from layer to layer. Printing instructions (e.g., g-codes)
generated by a computer from a CAD file control the movement of the
print head and thus the region(s) in which glass is deposited in
each layer. While each layer is being deposited, an actuator (e.g.
motor 201) gradually lowers the build platform by a vertical
distance equal to the vertical thickness of the layer. Printing
instructions control the actuator (e.g., motor 201) that causes the
z movement of the build platform.
[0078] Alternatively or in addition, in some cases, at least a
portion of the deposition of glass is not layer-by-layer. For
example, in some cases, molten glass is deposited at a position
such that the glass dribbles down the edge of one or more
previously deposited layers and stops at a level lower than the
layer most recently deposited.
[0079] In the example shown in FIG. 3, only part of the layers of
the glass object 301 have been deposited, the remaining layers of
glass object 301 have not yet been deposited.
[0080] In some implementations of this inventions, cool fluid flows
through tubes or cavities near the tip of the nozzle and cools the
nozzle tip, in order to reduce the amount of glass that sticks to
the nozzle tip, and thus to reduce fouling of the nozzle. As used
herein, to "foul" means to build up glass on a surface of the
nozzle tip. For example, in some cases, glass is heated to
approximately 1850.degree. Fahrenheit in the nozzle, and it is
desirable that the nozzle tip be at a lower temperature than the
glass. This is because lowering the temperature of the nozzle tip
tends to reduce the amount of glass that sticks to the nozzle
tip--that is, the lower the temperature of the nozzle tip, the less
amount of molten glass that sticks to the nozzle tip.
[0081] FIGS. 4A, 4B and 4C are cross-sectional views of tubes or
cavities for cooling a nozzle tip, in an illustrative
implementation of this invention. In FIG. 4A, a cool fluid flows
through tubes 401, and thereby cools nozzle tip 127. In FIG. 4B, a
cool fluid flows through cavity 403, and thereby cools nozzle tip
127. Fluid enters and exits cavity 403 through tubes 405 and 406,
respectively. In FIG. 4C, a cool fluid flows through tubes 407, and
thereby cools a fluid in a cavity 409, which in turn cools nozzle
tip 127.
[0082] In the examples shown in FIGS. 4A, 4B and 4C: (a) the fluid
may comprise any liquid or gas, including water or air; (b) the
fluid may be at a higher pressure than ambient air; (c) one or more
pumps may pump the fluid through, into or out of the tubes or
cavity; and (d) the fluid may recirculate, and in each circulation
cycle, one or more heat exchangers may remove heat from the fluid
before the fluid is sent near the nozzle tip again.
[0083] FIGS. 5A and 5B are cross-sectional views of valves, in an
illustrative implementation of this invention. The valves control
flow of molten glass 103 through the nozzle 125.
[0084] In FIG. 5A, the valve comprises a refractory rod 503
actuated by a motor 501 mounted on the crucible kiln lid. The rod
503 moves up and down in a direction parallel to vertical axis 505,
allowing or blocking flow of molten glass through the exit orifice
603 of nozzle 125. When the bottom tip 507 of rod 503 touches the
inside wall of the nozzle tip 127, exit orifice 603 of nozzle 125
is blocked, and no glass flows through exit orifice 603 of nozzle
125. When the tip 507 of the rod is raised, such that tip 507 does
not touch the inside wall of the nozzle tip 127, exit orifice 603
is not blocked, and molten glass flows through the exit orifice 603
of nozzle 125.
[0085] In FIG. 5B, the valve comprises refractory shears 511. When
open, the shears 511 surround, but do not intrude into, a region
immediately below the nozzle tip 127, thereby allowing molten glass
to flow through the exit orifice 603 of nozzle 125. As the shears
511 are closed, the shears 511 cut the molten glass filament
exiting the nozzle 125. When the shears 511 are closed, they block
the exit orifice 603 of nozzle 125 and prevent molten glass from
flowing through exit orifice 603. In some cases, the shears 511
comprise stainless steel or an Inconel.RTM. austenite
nickel-chromium-based superalloy, or comprise (or are coated with)
tungsten carbide. The shears are actuated by motor 517.
[0086] In each of FIGS. 5A and 5B: (a) the actuator (motor 501 or
motor 517) is controlled by a driver circuit, which is in turn
controlled by an Arduino.RTM. board and shield, which are
controlled by another computer; and (b) the g-code instructions
include instructions for controlling valve movements.
[0087] In some implementations of this inventions, one or more
disposable sheets of refractory material cover the nozzle tip,
except the nozzle orifice, in order to reduce fouling of the
nozzle. After solidified glass builds up on a disposable sheet, the
sheet is removed and replaced with a new disposable sheet. In some
cases, the refractory sheets comprise metal, such as stainless
steel, or an Inconel.RTM. austenite nickel-chromium-based
superalloy, or tungsten carbide.
[0088] FIG. 6A is a cross-sectional view of a disposable metal
sheet 601 that is positioned adjacent to nozzle tip 127, in an
illustrative implementation of this invention. FIG. 6B is a
cross-sectional view of two disposable metal sheets 611, 615 that
are positioned adjacent to nozzle tip 127, in an illustrative
implementation of this invention. In both FIGS. 6A and 6B,
fasteners (e.g., 605) hold the disposable sheet(s) stationary
relative to the nozzle tip 127. In some cases, the fasteners (e.g.,
605) comprise refractory clips or refractory magnets.
[0089] In the example shown in FIG. 6A, a single disposable sheet
(e.g., stainless steel, Inconel.RTM., or tungsten carbide) 601 is
press-formed to follow the shape of nozzle tip 127. A hole is cut
in sheet 601 that corresponds to the nozzle orifice 603 to allow
glass flow. A tab is introduced during press-forming to allow easy
sheet removal through the use of pliers.
[0090] In the example shown in FIG. 6B, two or more disposable
sheets are attached to the nozzle tip 127. After glass gets stuck
to the lowest sheet, the lowest sheet is removed by pliers, thus
uncovering the upper clean one. Tabs positioned in different areas
allow removal of one sheet at a time.
[0091] FIG. 7 is a cross-sectional view of two insulation skirts
701 703, in an illustrative implementation of this invention. In
FIG. 7, the insulation skirts 701, 703 assure that the annealing
chamber is always kept closed on the top. A lower, static
insulation skirt 701 is mounted on top of the annealing chamber.
The upper insulation skirt 703 is attached to moveable carriage
219. The moveable carriage 219 is attached to and moves with the
crucible kiln 107. The upper insulation skirt 219 is dimensioned to
completely cover the top of the annealing chamber throughout the
entire travel range of carriage 219 (and the printer head attached
to carriage 219). In some cases, the insulation skirts 701, 703
comprise two ceramic fiber boards (e.g., Duraboard.RTM.).
[0092] In some implementations, it is advantageous to immobilize
the print head (including nozzle 125, crucible 105, crucible kiln
107, and nozzle kiln 109). For example, immobilizing the print head
allows the crucible to be larger and heavier and to contain more
glass.
[0093] FIG. 8A is a cross-sectional view of an alternative
implementation of this invention, in which the print head is
stationary. In the example shown in FIG. 8A, the print head
(including nozzle 125, crucible 105, crucible kiln 107, and nozzle
kiln 109) is stationary relative to the walls of the annealing kiln
111. A build platform 808 is attached to robotic arm 801. The
robotic arm 801 moves with multiple degrees of freedom. For
example, in some cases, the robotic arm 801 moves with three, four,
five, six or more degrees of freedom. In FIG. 8A, one or more
motors 809 actuate, via robotic arm 801, motion of build platform
808 relative to nozzle 127; and (b) this motion controls the
vertical z position and horizontal x, y position of build platform
808 and thus controls where glass exiting the nozzle 127 is
deposited. The one or more motors 809 are each controlled by a
driver circuit, which is in turn controlled by one or more
computers.
[0094] In FIG. 8A, the robotic arm 801 enters annealing kiln 111
through an opening 821 in the walls 115 of annealing kiln 111.
Insulation 803 reduces the amount of heat that exits through this
opening 821. In some cases, insulation 803 comprises an insulation
skirt or an insulated bellows. Also, a refractory door 805 with
door handle 807 provides access to the interior of annealing
chamber 111. The door 805 is sufficiently wide that a user may open
the door and remove the fabricated glass object after it cools.
[0095] FIG. 8B is a cross-sectional view of an apparatus 890 in
which an actuator causes build platform 858 to rotate, in an
illustrative implementation of this invention. This apparatus 890
is sometimes referred to herein as a "polar printer". In the polar
printer 890 shown in FIG. 8B: (a) motor 851 actuates build platform
857 to rotate about the build platform's center line 863; (b) motor
861, via a lead screw, actuates carriage 869 to move parallel to
linear axis "r" 865; and (c) motor 853, via a lead screw, actuates
build platform 857 to move vertically (up or down).
[0096] Thus, in FIG. 8B, polar printer 890 causes motion in 3
coordinates: r (radial distance), .theta. (angle) and z (height).
The print head (including nozzle 125, crucible 105, crucible kiln
107, and nozzle kiln 109) moves in the r dimension. The build
platform 857 moves up and down (z) in a direction parallel to
vertical axis 867. The build platform 857 also rotates (.theta.)
around its center line 863. The center line 863 of build platform
857 is perpendicular to the top surface of build platform 857 and
intersects the center of build platform 857. The center line 863 of
build platform 857 is co-located with the longitudinal axis of rod
856.
[0097] In FIG. 8B, polar printer 890 limits the movement of the
print head to only one dimension, the so-called "r" dimension.
This, in turn, allows bigger crucible kilns.
[0098] In FIG. 8B, motors 853, 861 are part of stepper motor-lead
screw systems that actuate r and z movements. Motor 851 actuates 0
movement (i.e., rotation) of build platform 857 via a series of
gears and components, as follows: motor 851 causes gear 855 to
rotate, which in turn causes gear 854 to rotate. This in turn
causes z motor 853 (which is mounted on gear 854) to rotate. This
in turn causes rod 856 and build platform 857 to rotate about
center line 863.
[0099] In FIG. 8B, motor 861 actuates the print head (including
nozzle 125, crucible 105, crucible kiln 107, and nozzle kiln 109)
to move along the r-axis. The print head rests on bearings that
travel along rails 871, 873.
[0100] In FIG. 8B, motors 851, 853, 861 are each controlled by a
driver circuit, which is in turn controlled by one or more
computers.
[0101] FIG. 9 is a block diagram showing hardware components that
interface with, or are controlled by, one or more computers, in an
illustrative implementation of this invention.
[0102] In the example shown in FIG. 9, a computer 900 receives
input from a human user, and provides output (in human-perceptible
form) to a human user, via one or more I/O devices (e.g., 902, 903,
941). For example, in some cases, I/O devices 902, 903, 941
comprise a computer monitor, keyboard and mouse, respectively. The
computer 900 stores data in an electronic memory device 901, and
accesses/reads data that is stored in memory device 901.
[0103] In the example shown in FIG. 9, the computer controls one or
more microcontrollers 904. For example, in some cases, the
microcontrollers 904 comprise an Arduino.RTM. PCB (printed circuit
board) and one or more Arduino.RTM. shield PCBs, including a shield
for controlling motors. In some cases: (a) the computer 900 takes
as input, a CAD (computer-aided-design) file; (b) the CAD file
includes a digital 3D model of a target object (i.e., the 3D glass
object to be fabricated); (c); the computer "slices", layer by
layer, the digital model; (d) the computer 900 outputs g-code
instructions for each layer, and (e) the g-code instructions are
transmitted to the microcontrollers 904 and control the selective
deposition of glass in layers, in order to manufacture the target
object.
[0104] In FIG. 9, the microcontrollers 904 control actuation in x,
y and z directions, as follows: Microcontrollers 904 control an
x-driver circuit 905, y-driver circuit 906 and z-driver circuit
907. The x-driver circuit 905 receives sensor data from x end stop
sensor 908 and controls x-motor 909, thereby controlling actuation
along an x-axis. The y-driver circuit 906 receives sensor data from
y end stop sensor 910 and controls y motor 911, thereby controlling
actuation along a y-axis. The z-driver circuit 907 receives sensor
data from z end stop sensor 912 and controls z-motor 913, thereby
controlling actuation along a z-axis.
[0105] In FIG. 9, controllers 914, 917, 920 perform PID control of
heating elements of the crucible kiln, nozzle kiln and annealing
kiln, respectively. For example, in some cases, controllers 914,
917, 920 each comprise a PLC (programmable logic controller) or
other digital controller. Controller 914 receives sensor data from
crucible kiln temperature sensor 916 and controls crucible kiln
heating elements 915. Controller 917 receives sensor data from
nozzle kiln temperature sensor 919 and controls nozzle kiln heating
elements 918. Controller 920 receives sensor data from annealing
kiln temperature sensor 922 and controls annealing kiln heating
elements 921. In some cases, the temperature sensors 916, 919, 922
comprise thermocouples.
[0106] In some cases, valve driver circuit 923 controls a valve
motor 924. The valve motor 924 actuates a valve. For example, in
some cases, valve motor 924 opens and shuts a pair of shears 511,
as shown in FIG. 5B. In some cases, valve motor 924 raises or
lowers rod 503, as shown in FIG. 5A.
[0107] In some cases, a plunger driver circuit 925 controls a
plunger motor 926. The plunger motor 926 actuates a plunger (e.g.,
1103) that creates pressure to actively extrude molten glass, as
shown in FIG. 11A.
[0108] In some cases, an air driver circuit 927 controls an air
pump 929. The air pump 929 pumps compressed air that is used to
created pressure to actively extrude molten glass, as shown in FIG.
11B. Alternatively, air pump 929 pumps compressed air that is
pumped through an air blowing tube, such as air blowing tube 1303
shown in FIG. 13. In this alternative case (with an air blowing
tube), air driver circuit 927 also controls air tube motor 928.
This motor 928 actuates an air blowing tube (e.g., 1303), moving
the tube up and down and thus closer to or further away from the
nozzle tip.
[0109] In some cases, a feeder driver circuit 930 controls a feeder
motor 931. The feeder motor 931 actuates a feeder mechanism for
feeding materials into crucible 105. For example, in some cases,
the feeder mechanism loads one or more of the following materials
into the crucible 105: glass nuggets, glass ingots, glass powder, a
glass rod or filament, or raw materials for manufacturing
glass.
[0110] In some cases, instructions for one or more movements of a
plunger, valve or tube are embedded in g-codes that are generated
by computer 900.
[0111] In the example shown in FIG. 9, controllers 914, 917, 920
and drivers 923, 925, 927, 930 are connected by communication links
to microcontrollers 904, and interface with, or are controlled by,
microcontrollers 904. Alternatively, in some cases, one or more of
controllers 914, 917, 920 and drivers 925, 927, 930 are connected
by communication links to computer 900, and interface with, or are
controlled by, computer 900. Alternatively, in some cases, one or
more of controllers 914, 917, 920 and drivers 925, 927, 930 are
connected by communication links to neither the computer 900 nor
the microcontrollers 904.
[0112] In FIG. 9, the lines between electronic devices symbolize
wired or wireless communication links.
[0113] FIG. 10A is a flowchart that shows steps in a method for
additive manufacture of glass, in an illustrative implementation of
this invention. The method shown in FIG. 10A includes the following
steps: A computer takes a CAD file as input and generates g-code
instructions for additive fabrication (e.g., uses a slicer
algorithm to generate g-codes) (Step 1001). One or more
microcontrollers (e.g. one or more Arduino.RTM. boards) take the
g-codes as an input and control at least (1) x, y movement of a
crucible kiln and a nozzle, and (2) z movement of a build platform
(Step 1002). Glass (e.g., glass nuggets, powder, or rod) is fed
into a crucible. Alternatively, raw materials for glass are fed
into the crucible (Step 1003). A crucible kiln heats the crucible,
causing glass (or raw materials for glass) in the crucible to melt
(Step 1004). Bubbles are removed in a fining step. In some cases,
fining agents are added to facilitate fining (Step 1005). Molten
glass flows into the nozzle and is heated by a nozzle kiln (Step
1006). Molten glass flows out of nozzle and is selectively
deposited to form a 3D object. In some cases, the deposition of
glass is layer-by-layer. In addition, in some cases, glass is
dribbled over an edge such that it descends to a lower layer than
the current layer (Step 1007). An annealing chamber heats the 3D
object, such that the temperature of the 3D object is maintained at
or above a target temperature while the 3D object is being built by
deposition of molten glass. After the deposition of glass is
complete, the temperature in the annealing chamber is slowly
lowered, such that the glass anneals (Step 1008). In some cases,
the glass is polished or undergoes other post-annealing steps (Step
1009).
[0114] FIG. 10B is a flowchart that shows steps in another method
for additive manufacture of glass, in an illustrative
implementation of this invention. The method shown in FIG. 10B
includes the following steps: Generate a CAD file (Step 1051).
Convert the CAD file to spiral g-code (Step 1053). Melt and fine
glass in a crucible (Step 1055). Heat the crucible nozzle and
annealing chamber, e.g., to 1850.degree. F. and 900.degree. F.,
respectively (Step 1057). Send g-code instructions to the printer.
In accordance with the g-code instructions, move the carriage (on
which the print head is mounted) in x, y directions, and move the
build platform in a z direction. In some cases, move a plunger or
valve (Step 1059). The print head deposits molten glass layer by
layer (Step 1061). Optionally, refill the crucible with molten
glass (e.g., by loading solid glass nuggets into the crucible and
then melting the nuggets) (Step 1063). Anneal the glass, by slowly
lowering the temperature of the glass (Step 1065). Perform
post-processing steps, including removing the printed 3D glass
object from the annealing chamber and, in some cases, polishing the
exterior of the glass (Step 1067).
[0115] In some implementations of this invention, the extrusion of
molten glass through the nozzle is actuated only by gravitational
force, and the rate of extrusion is controlled by factors such as
the temperature and material composition of the glass.
[0116] However, in some implementations, it is advantageous to
actively exert pressure against the molten glass, in order to
increase the extrusion rate for a given temperature or material
composition of glass. Furthermore, by varying the pressure exerted
against the molten glass, the rate of extrusion of the molten glass
may be controlled, while (in some cases) holding other factors
(such as temperature or material composition of glass)
constant.
[0117] FIG. 11A is a cross-sectional view of an apparatus, in which
a plunger exerts pressure that actively extrudes molten glass
through a nozzle, in an illustrative implementation of this
invention. In FIG. 11A, a refractory plunger 1103 pushes molten
glass 103 in the crucible 105 into the nozzle 125 at a controlled
rate. In some cases, the plunger is actuated via lead screw 1101 by
plunger motor 926. Alternatively, in some cases: (a) plunger 1103
is pneumatically actuated by compressed air pumped by air pump 929;
and (b) the air pump 929 pumps air at a constant or variable flow
rate or at a constant or variable pressure. In some cases, the
plunger motor 926 or air pump 929 is affixed to the top lid of the
crucible kiln and is controlled by one or more computers. For
example, in some cases, the plunger motor 926 is controlled by
driver circuit 925 that is in turn controlled by microcontrollers
904 (such as an Arduino.RTM. board and shield), which are in turn
controlled by a computer (e.g., 900); and (b) the computer 900
outputs g-codes that include instructions for the movement of the
plunger 1103.
[0118] FIG. 11B is a cross-sectional view of an apparatus, in which
air exerts pressure that actively extrudes molten glass through a
nozzle, in an illustrative implementation of this invention. In
FIG. 11B, air pump 929 pumps compressed air through tubes 1151,
1153 into a pressurized chamber inside the walls 1111 of the
crucible 105. The compressed air 1155 exerts pressure on the molten
glass 103, pushing the molten glass 103 through the nozzle 125 at a
controlled rate. The air pump 929 pumps air at a constant or
variable flow rate or at a constant or variable pressure.
[0119] FIGS. 12A, 12B, 12C, 12D, 12E and 12F each show material
being fed into a printer, in an illustrative implementation of this
invention. In FIGS. 12A, 12B, 12C, 12D, and 12F, materials are
inserted into crucible 105. In FIG. 12E, materials are inserted
into nozzle 125. In FIGS. 12A, 12B, 12C, 12D, 12E and 12F, the
materials being fed into the printer comprise, respectively: (a)
solid glass nuggets 1203, (b) glass powder or raw materials for
glass 1205, (c) a glass rod 1207, (d) a solid ingot 1208, (d) a
molten, bubble-free glass filament 1209 that has already been
melted and fined (e.g., by another kiln), and (e) molten,
bubble-free glass 1210 that has already been melted and fined by
another kiln. In the examples shown in FIGS. 12A, 12B, 12C, and
12F, the upper lid 113 of the crucible kiln includes a door 1201
through which the materials are inserted.
[0120] In some cases, the materials are inserted manually.
Alternatively, in some cases, a feeder motor 931 actuates a feeder
mechanism that feeds the materials into the crucible or nozzle. For
example, in some cases, the feeder mechanism comprises any material
handling system, including any vibrating feeder, rotary feeder,
rotary screw feeder, variable rate feeder, or volumetric
feeder.
[0121] In some cases, raw materials for glass 1205 are fed into
crucible 105. For example, in some cases, the raw materials
comprise a combination of materials selected from: oxides (e.g.,
SiO.sub.2, B.sub.2O.sub.3, or P.sub.2O.sub.3), silicate sands,
feldspars (e.g. albite, anorthite, aplite), borax, dolomite,
limestone, nepheline, kyanite, sand, soda ash, or recycled glass.
In some cases, the raw materials also include one or more (a)
fluxes to reduce melting temperature (e.g., Na.sub.2O, PbO, K2O,
Li.sub.2O), (b) property modifiers to control material properties
such as durability, expansion, or viscosity (e.g., CaO,
Al.sub.2O.sub.3,), (c) colorants, or (d) fining agents (such as
As-oxides, Sb-oxides, KNO.sub.3, NaNO.sub.3, NaCl, fluorides, or
sulfates).
[0122] In some cases, it is advantageous to quickly refill the
crucible or nozzle with already molten and fined glass, as shown in
FIGS. 12E and 12F, thereby skipping the time delay of melting and
fining the glass in the print head itself.
[0123] In some cases, it is advantageous for the printer (a) to
extrude a molten glass filament that surrounds an air-filled
cavity, where the cavity extends for at least a portion of the
length of the filament, or (b) to otherwise extrude blown glass. In
illustrative implementations, coaxial infiltration of air into a
molten glass filament facilitates hollow object fabrication.
[0124] FIG. 13 is a cross-sectional view of an apparatus, in which
an air tube blows air into molten glass, in an illustrative
implementation of this invention. The apparatus shown in FIG. 3
achieves coaxial air infiltration, as the molten glass is extruded
through a nozzle.
[0125] In the example shown in FIG. 13, air pump 929 pumps air 1301
through a refractory tube 1303 that extends into nozzle 125. Tube
1303 is hollow, so that air may flow through it. A motor 928
controls vertical position of the refractory tube 1303, by
actuating motion of the tube 1303 up and down. During air blowing,
the tip 1305 of refractory tube 1303 is positioned almost at the
tip 127 of nozzle 125. By varying tube height (i.e., how far the
tip 1305 of tube 1303 is above tip 127 of nozzle 125) and air
pressure, the thickness of the resulting elongated cavity of air
inside the extruded glass is controlled. In some cases, refractory
tube 1303 comprises quartz, mullite, or AZS
(alumina-zirconia-silica).
[0126] In illustrative implementations of this invention, the
printer produces optically transparent glass. In some
implementations, the production of optically transparent glass
includes one of more of the following features: (a) starting from
large (and, in some cases, pre-fined) glass chunks to limit bubble
amount; (b) fining glass for at least 2 hours (and in some cases,
between 3 or 4 hours) to reduce bubble content; (c) extruding
viscous molten glass, instead of sintering a powder; (d) depositing
a molten glass filament with no vertical offset between the top of
the layer of glass being deposited and the nozzle (instead of
positioning the nozzle above the layer being deposited, and thereby
causing the extruded filament to drop before reaching the level of
the layer being deposited); (e) annealing the extruded glass in an
annealing chamber; and (f) polishing the exterior surface
(including base and walls) of the 3D printed glass object, after
the glass cools to room temperature.
[0127] In illustrative implementations, the 3D printer selectively
deposits molten glass. This allows the 3D printer to create shapes
that cannot be fabricated by conventional glassblowing or by a
conventional manufacturing technique in which a parison is blow
molded.
[0128] FIGS. 14A, 14B, 14C and 14D show non-limiting examples of
glass objects printed by a 3D printer (e.g., objects 1400, 1410,
1420), in illustrative implementations of this invention. In the
example shown in FIG. 14A, a printed glass object 1400 is an
integral structure that has multiple, separate internal cavities
1401, 1402, 1403; and (b) each of the cavities has a volume of at
least 40 milliliters and is entirely enclosed by the glass. In the
example shown in FIG. 14B, the printed glass object 1410 includes
multiple layers (e.g., 1411, 1412, 1413) of optically transparent
glass. The layers (e.g., 1411, 1412, 1412) partially merge into
each other vertically. In the example shown in FIG. 14B, the layers
(e.g., 1411, 1412, 1413) are part of a single spiral filament, and
thus are also connected to each other along a path that follows the
long, spiral central axis of the spiral filament. The glass object
1410 also includes an elongated protuberance 1414 that is located
on an exterior surface of the structure, and comprises a solidified
drip of glass. The protuberance 1414 is elongated along an axis
1415 that is aligned vertically. In the example shown in FIG. 14C,
a printed glass object 1420 is a unitary structure that includes a
spiral filament 1421 of optically transparent glass. The spiral
filament 1421 forms multiple layers (e.g., 1422, 1423, 1424), one
layer on top of another. The layers partially merge into each
other. The spiral filament 1421 has an elongated cavity 1425 that
is entirely enclosed by the filament and extends for at least half
of a revolution of a spiral formed by the filament. FIG. 14D is a
cross-sectional view of cavity 1425.
[0129] In FIGS. 7, 8A, 8B, 11A, 11B, 12A-12F, one or both of
temperature sensors 128, 141 are not shown, but are actually
present in apparatus shown in those Figures
[0130] Crucible and nozzle materials and shapes may be varied,
depending on the particular implementation of this invention. For
example, in some cases, a wide elongated crucible allows refilling
farther from the nozzle with less impact on pressure head and
consequently on flow rate.
[0131] In some implementations, the skirt insulation system (e.g.,
701, 703) is replaced by a bellow system.
[0132] In illustrative implementations of this invention, the glass
comprises a glass material, as that term is defined herein. Thus,
in illustrative implementations of this invention, glass material
is melted in a crucible 105, extruded through a nozzle 125, and
selectively deposited (layer-by-layer or otherwise) to form a 3D
object that comprises glass material.
[0133] In illustrative implementations of this invention, the glass
comprises an amorphous material, as that term is defined herein.
Thus, in illustrative implementations of this invention, an
amorphous material is melted in a crucible 105, extruded through a
nozzle 125, and selectively deposited (layer-by-layer or otherwise)
to form a 3D object that comprises amorphous material.
Field of Endeavor
[0134] The field of endeavor of this invention is additive
manufacturing of glass, by extrusion of molten glass through a
nozzle.
[0135] The inventors confronted at least the following two
problems: (1) how to additively manufacture a glass object by
selective deposition of molten glass by extrusion through a nozzle;
and (2) how to additively manufacture an optically transparent
glass object, by selective deposition of molten glass by extrusion
through a nozzle.
Computers
[0136] In exemplary implementations of this invention, one or more
electronic computers (e.g. 900, 904) are programmed and specially
adapted: (1) to control the operation of, or interface with,
hardware components of an apparatus for additive manufacture of
glass, including any heating elements, motors, actuators, valves,
thermocouples or other sensors; (2) to control movement of a print
head or build platform; (3) to control temperature in the interior
of a kiln, including a crucible kiln, nozzle kiln or annealing
kiln, (4) to perform any other calculation, computation, program,
algorithm, computer function or computer task described or implied
above; (5) to receive signals indicative of human input; (6) to
output signals for controlling transducers for outputting
information in human perceivable format; and (7) to process data,
to perform computations, to execute any algorithm or software, and
to control the read or write of data to and from memory devices.
The one or more computers may be in any position or positions
within or outside of the additive manufacturing apparatus. For
example, in some cases (a) at least one computer is housed in or
together with other components of the additive manufacturing
apparatus, and (b) at least one computer is remote from other
components of the additive manufacturing apparatus. The one or more
computers are connected to each other or to other components of the
additive manufacturing apparatus either: (a) wirelessly, (b) by
wired connection, or (c) by a combination of wired and wireless
links.
[0137] In exemplary implementations, one or more computers are
programmed to perform any and all calculations, computations,
programs, algorithms, computer functions and computer tasks
described or implied above. For example, in some cases: (a) a
machine-accessible medium has instructions encoded thereon that
specify steps in a software program; and (b) the computer accesses
the instructions encoded on the machine-accessible medium, in order
to determine steps to execute in the program. In exemplary
implementations, the machine-accessible medium comprises a tangible
non-transitory medium. In some cases, the machine-accessible medium
comprises (a) a memory unit or (b) an auxiliary memory storage
device. For example, in some cases, a control unit in a computer
fetches the instructions from memory.
[0138] In illustrative implementations, one or more computers
execute programs according to instructions encoded in one or more
tangible, non-transitory, computer-readable media. For example, in
some cases, these instructions comprise instructions for a computer
to perform any calculation, computation, program, algorithm,
computer function or computer task described or implied above. For
example, in some cases, instructions encoded in a tangible,
non-transitory, computer-accessible medium comprise instructions
for a computer to: (1) to control the operation of, or interface
with, hardware components of an apparatus for additive
manufacturing of glass, including any heating elements, motors,
actuators, valves, thermocouples or other sensors; (2) to control
movement of a print head or build platform; (3) to control
temperature in the interior of a kiln, including a crucible kiln,
nozzle kiln or annealing kiln, (4) to perform any other
calculation, computation, program, algorithm, computer function or
computer task described or implied above; (5) to receive signals
indicative of human input; (6) to output signals for controlling
transducers for outputting information in human perceivable format;
and (7) to process data, to perform computations, to execute any
algorithm or software, and to control the read or write of data to
and from memory devices.
Network Communication
[0139] In illustrative implementations of this invention, one or
more electronic devices (e.g., 900, 904, 914, 917, 920, 925, 927,
930) are configured for wireless or wired communication with other
electronic devices in a network.
[0140] In some cases, one or more of the following hardware
components are used for network communication: a computer bus, a
computer port, network connection, network interface device, host
adapter, wireless module, wireless card, signal processor, modem,
router, computer port, cables or wiring.
[0141] In some cases, one or more computers (e.g., 900, 904) are
programmed for communication over a network. For example, in some
cases, one or more computers are programmed for network
communication: (a) in accordance with the Internet Protocol Suite,
or (b) in accordance with any other industry standard for
communication, including any USB standard, ethernet standard (e.g.,
IEEE 802.3), token ring standard (e.g., IEEE 802.5), wireless
standard (including IEEE 802.11 (wi-fi), IEEE 802.15
(bluetoothhigbee), IEEE 802.16, IEEE 802.20 and including any
mobile phone standard, including GSM (global system for mobile
communications), UMTS (universal mobile telecommunication system),
CDMA (code division multiple access, including IS-95, IS-2000, and
WCDMA), or LTS (long term evolution)), or other IEEE communication
standard.
[0142] In some cases, one or more electronic devices in the
additive manufacturing apparatus include a wireless communication
module for wireless communication with other electronic devices in
a network. Each wireless communication module includes (a) one or
more antennas, (b) one or more wireless transceivers, transmitters
or receivers, and (c) signal processing circuitry. The wireless
communication module receives and transmits data in accordance with
one or more wireless standards.
Definitions:
[0143] The terms "a" and "an", when modifying a noun, do not imply
that only one of the noun exists.
[0144] "Amorphous material" means a material that (a) has a
non-crystalline atomic structure when solid and (b) exhibits a
glass transition when cooling toward the amorphous material's glass
transition temperature. As used herein, an "amorphous material"
remains an amorphous material, regardless of temperature (e.g.,
above or below glass transition temperature) or phase (e.g., solid
or liquid).
[0145] The term "comprise" (and grammatical variations thereof)
shall be construed as if followed by "without limitation". If A
comprises B, then A includes B and may include other things.
[0146] The term "computer" includes any computational device that
performs logical and arithmetic operations. For example, in some
cases, a "computer" comprises an electronic computational device,
such as an integrated circuit, a microprocessor, a mobile computing
device, a laptop computer, a tablet computer, a personal computer,
or a mainframe computer. In some cases, a "computer" comprises: (a)
a central processing unit, (b) an ALU (arithmetic logic unit), (c)
a memory unit, and (d) a control unit that controls actions of
other components of the computer so that encoded steps of a program
are executed in a sequence. In some cases, a "computer" also
includes peripheral units including an auxiliary memory storage
device (e.g., a disk drive or flash memory), or includes signal
processing circuitry. However, a human is not a "computer", as that
term is used herein.
[0147] "Contain" shall be construed as if followed by "without
limitation". If A contains B, then A contains B and may contain
other things. To "contain" does not require total enclosure. For
example, a container "contains" a fluid within a cavity formed by
the container's walls, even if hole in a container wall creates an
orifice connecting the cavity and the external environment.
[0148] "Defined Term" means a term or phrase that is set forth in
quotation marks in this Definitions section.
[0149] For an event to occur "during" a time period, it is not
necessary that the event occur throughout the entire time period.
For example, an event that occurs during only a portion of a given
time period occurs "during" the given time period.
[0150] The term "e.g." means for example.
[0151] The fact that an "example" or multiple examples of something
are given does not imply that they are the only instances of that
thing. An example (or a group of examples) is merely a
non-exhaustive and non-limiting illustration.
[0152] An "exit orifice" of a nozzle means an orifice through which
a fluid or other material exits the nozzle.
[0153] A non-limiting example of "extrusion" is flow of molten
glass through a nozzle, which flow is actuated only by
gravitational force.
[0154] Unless the context clearly indicates otherwise: (1) a phrase
that includes "a first" thing and "a second" thing does not imply
an order of the two things (or that there are only two of the
things); and (2) such a phrase is simply a way of identifying the
two things, respectively, so that they each may be referred to
later with specificity (e.g., by referring to "the first" thing and
"the second" thing later). For example, unless the context clearly
indicates otherwise, if an equation has a first term and a second
term, then the equation may (or may not) have more than two terms,
and the first term may occur before or after the second term in the
equation. A phrase that includes a "third" thing, a "fourth" thing
and so on shall be construed in like manner.
[0155] "Fluid" means a gas or a liquid.
[0156] The term "for instance" means for example.
[0157] "Glass material" means a material that comprises, when
solid: (a) silicate glass, (b) borate glass, (c) phosphate glass,
(d) fluoride glass, or (e) chalcogenide glass. As used herein,
"glass material" remains glass material, regardless of temperature
(e.g., above or below glass transition temperature) or phase (e.g.,
solid or liquid).
[0158] Non-limiting examples of a "heating element" include a
resistive heating element and an inductive heater.
[0159] "Herein" means in this document, including text,
specification, claims, abstract, and drawings.
[0160] The term "hole" means a hole, cavity, gap, opening or
orifice.
[0161] The terms "horizontal" and "vertical" shall be construed
broadly. For example, in some cases, the terms "horizontal" and
"vertical" refer to two arbitrarily chosen coordinate axes in a
Euclidian two dimensional space, regardless of whether the
"vertical" axis is aligned with the orientation of the local
gravitational field.
[0162] As used herein: (1) "implementation" means an implementation
of this invention; (2) "embodiment" means an embodiment of this
invention; (3) "case" means an implementation of this invention;
and (4) "use scenario" means a use scenario of this invention.
[0163] The term "include" (and grammatical variations thereof)
shall be construed as if followed by "without limitation".
[0164] "I/O device" means an input/output device. For example, an
I/O device includes any device for (a) receiving input from a
human, (b) providing output to a human, or (c) both. For example,
an I/O device includes a user interface, graphical user interface,
keyboard, mouse, touch screen, microphone, handheld controller,
display screen, speaker, or projector for projecting a visual
display. Also, for example, an I/O device includes any device
(e.g., button, dial, knob, slider or haptic transducer) for
receiving input from, or providing output to, a human.
[0165] A non-limiting example of "layer-by-layer" deposition is to
deposit flat, separate layers, one on top of another. A
non-limiting example of "layer-by-layer" deposition is to deposit a
filament in a spiral as shown in FIG. 14C, where layers 1422, 1423
and 1424 are all portions of the same filament 1421, and layer 1422
rests on top of layer 1423, which in turn rests on top of layer
1424. Another non-limiting example of "layer-by-layer" deposition
is to deposit a filament such that the filament bends in a
non-spiral shape, such that a first portion of the filament rests
on a second portion of the filament, and the second portion of the
filament rests on a third portion of the filament.
[0166] As used herein: (a) to say that a glass material is "molten"
means that the temperature of the glass material is above the glass
transition temperature of the glass material; (b) to say that an
amorphous material is "molten" means that the temperature of the
amorphous material is above the glass transition temperature of the
amorphous material; and (c) to say that glass is "molten" means
that the temperature of the glass is above the glass transition
temperature of the glass. As used herein: (a) to say that a glass
material "melts" means that the glass material undergoes a glass
transition as the temperature of the glass material increases; (b)
to say that an amorphous material "melts" means that the amorphous
material undergoes a glass transition as the temperature of the
amorphous material increases; and (c) to say that glass "melts"
means that the glass undergoes a glass transition as the
temperature of the glass increases.
[0167] As used herein, "nozzle" means any orifice through which
material (such as molten glass, gas, liquid, fluid, or solid)
passes. A nozzle may have any shape. For example, in some cases, a
nozzle may have a shape that does not accelerate material the as
the material exits the nozzle.
[0168] To say that glass material is "optically transparent" means
that the glass material is transparent to light in the visible
light spectrum. To say that amorphous material is "optically
transparent" means that the amorphous material is transparent to
light in the visible light spectrum. To say that glass is
"optically transparent" means that the glass is transparent to
light in the visible light spectrum.
[0169] The term "or" is inclusive, not exclusive. For example A or
B is true if A is true, or B is true, or both A or B are true.
Also, for example, a calculation of A or B means a calculation of
A, or a calculation of B, or a calculation of A and B.
[0170] A parenthesis is simply to make text easier to read, by
indicating a grouping of words. A parenthesis does not mean that
the parenthetical material is optional or may be ignored.
[0171] To say that a nozzle "selectively deposits" material does
not have any implication regarding whether the rate of flow of the
material varies over time.
[0172] As used herein, the term "set" does not include a group with
no elements. Mentioning a first set and a second set does not, in
and of itself, create any implication regarding whether or not the
first and second sets overlap (that is, intersect).
[0173] Non-limiting examples of "silicate glass" include fused
quartz glass, soda-lime-silica glass, sodium borosilicate glass
(including Pyrex.RTM. glass), lead-oxide glass, and aluminosilicate
glass.
[0174] "Some" means one or more.
[0175] As used herein, a "subset" of a set consists of less than
all of the elements of the set.
[0176] "Substantially" means at least ten percent. For example: (a)
112 is substantially larger than 100; and (b) 108 is not
substantially larger than 100.
[0177] The term "such as" means for example.
[0178] To say that a machine-readable medium is "transitory" means
that the medium is a transitory signal, such as an electromagnetic
wave.
[0179] Except to the extent that the context clearly requires
otherwise, if steps in a method are described herein, then the
method includes variations in which: (1) steps in the method occur
in any order or sequence, including any order or sequence different
than that described; (2) any step or steps in the method occurs
more than once; (3) different steps, out of the steps in the
method, occur a different number of times during the method, (4)
any combination of steps in the method is done in parallel or
serially; (5) any step or steps in the method is performed
iteratively; (6) a given step in the method is applied to the same
thing each time that the given step occurs or is applied to
different things each time that the given step occurs; or (7) the
method includes other steps, in addition to the steps
described.
[0180] This Definitions section shall, in all cases, control over
and override any other definition of the Defined Terms. For
example, the definitions of Defined Terms set forth in this
Definitions section override common usage or any external
dictionary. If a given term is explicitly or implicitly defined in
this document, then that definition shall be controlling, and shall
override any definition of the given term arising from any source
(e.g., a dictionary or common usage) that is external to this
document. If this document provides clarification regarding the
meaning of a particular term, then that clarification shall, to the
extent applicable, override any definition of the given term
arising from any source (e.g., a dictionary or common usage) that
is external to this document. To the extent that any term or phrase
is defined or clarified herein, such definition or clarification
applies to any grammatical variation of such term or phrase, taking
into account the difference in grammatical form. For example, the
grammatical variations include noun, verb, participle, adjective,
and possessive forms, and different declensions, and different
tenses. In each case described in this paragraph, Applicant is
acting as Applicant's own lexicographer.
Variations:
[0181] This invention may be implemented in many different ways.
Here are some non-limiting examples:
[0182] In one aspect, this invention is a method that comprises, in
combination: (a) heating of glass material such that the glass
material becomes or remains molten; and (b) deposition of the
molten glass material, in which the molten glass material is
extruded through a nozzle to form an object; wherein during at
least part of the deposition, (i) the object being formed rests on
a build platform, (ii) the molten glass material is deposited
layer-by-layer; and (iii) one or more computers control where in
each layer the molten glass material is deposited, by controlling a
set of actuators that actuate movement of one or both of the nozzle
and build platform. In some cases, at least one actuator, out of
the set of actuators, directly or indirectly actuates the nozzle to
move along at least one horizontal axis. In some cases: (a) the
heating occurs in a kiln; (b) during the deposition, a first
actuator, out of the set of actuators, actuates the kiln and the
nozzle to move along a first horizontal axis; and (c) during the
deposition, a second actuator, out of the set of actuators,
actuates the kiln and the nozzle to move along a second horizontal
axis, the first and second horizontal axes being perpendicular to
each other. In some cases, during the deposition: (a) a first
actuator, out of the set of actuators, actuates the nozzle to move
along a horizontal axis; and (b) a second actuator, out of the set
of actuators, actuates the build platform to rotate. In some cases:
(a) during the deposition, the build platform is positioned inside
an annealing kiln; and (b) after the deposition, the annealing kiln
anneals extruded glass material. In some cases, extrusion of the
molten glass material through the nozzle is actuated by
gravitational force and is not actuated by any other net mechanical
force. In some cases, during the deposition: (a) the nozzle is
stationary relative to a wall of the annealing kiln; and (b) at
least one actuator, out of the set of actuators, actuates the build
platform to cause the build platform to move relative to the nozzle
and the wall. In some cases: (a) an exit portion of the nozzle
surrounds or is adjacent to an exit orifice of the nozzle; (b) the
method further comprises cooling the exit portion of the nozzle by
causing fluid to flow through a region that adjoins the exit
portion; and (c) the fluid is cooler than molten glass material
exiting the exit orifice. Each of the cases described above in this
paragraph is an example of the method described in the first
sentence of this paragraph, and is also an example of an embodiment
of this invention that may be combined with other embodiments of
this invention.
[0183] In another aspect, this invention is an apparatus
comprising, in combination: (a) a build platform; (b) one or more
heating elements for heating of glass material, such that the glass
material becomes or remains molten; (c) a nozzle for deposition of
the molten glass material, such that the molten glass material is
extruded through the nozzle to form an object that rests on the
build platform; (d) a set of actuators; and (e) one or more
computers for controlling the deposition, such that, during at
least a portion of the deposition (i) the molten glass material is
deposited layer-by-layer; and (ii) the one or more computers
control where in each layer the molten glass material is deposited,
by causing the set of actuators to actuate movement of one or both
of the nozzle and build platform. In some cases, at least one
actuator, out of the set of actuators, is configured to actuate the
nozzle to move along at least one horizontal axis. In some cases:
(a) a first actuator, out of the set of actuators, is configured to
actuate the nozzle and at least some of the heating elements to
move parallel to a first horizontal axis; and (b) a second
actuator, out of the set of actuators, is configured to actuate the
nozzle and at least some of the heating elements to move parallel
to a second horizontal axis, the first and second horizontal axes
being perpendicular to each other. In some cases: (a) a first
actuator, out of the set of actuators, is configured to actuate the
nozzle to move parallel to a horizontal axis; and (b) a second
actuator, out of the set of actuators, is configured to actuate the
build platform to rotate. In some cases: (a) the build platform is
positioned inside a kiln; and (b) the kiln is configured to anneal
extruded glass material. In some cases, the apparatus includes a
valve for controlling flow of molten glass material through the
nozzle. In some cases: (a) the nozzle is stationary relative to a
wall of the kiln; and (b) at least one actuator, out of the set of
actuators, is configured to actuate the build platform such that
the build platform moves relative to the nozzle and the wall. In
some cases: (a) an exit portion of the nozzle surrounds or is
adjacent to an exit orifice of the nozzle; and (b) the apparatus
further comprises one or more tubes or cavities adjacent to the
exit portion, which tubes or cavities are configured to cool the
exit portion when fluid cooler than the molten glass material flows
through the tubes or cavities. Each of the cases described above in
this paragraph is an example of the apparatus described in the
first sentence of this paragraph, and is also an example of an
embodiment of this invention that may be combined with other
embodiments of this invention.
[0184] In another aspect, this invention is an apparatus
comprising: (a) heating elements for heating glass material, such
that the glass material becomes or remains molten; (b) a nozzle for
extruding the molten glass material; (c) tubes or chambers that are
adjacent to a tip of the nozzle; (d) a pump for pumping fluid
through the tubes or chamber to cool the tip of the nozzle to a
temperature that is less than temperature of the molten glass
material; (e) a set of actuators; and (f) a set of computers that
is programmed to control the set of actuators such that the set of
actuators actuate movement of one or both of the nozzle and build
platform during the extruding, such that extruded molten glass
material forms an object in accordance with digital instructions
accessed or generated by at least one computer, out of the set of
computers. In some cases, the apparatus further comprises a kiln
for annealing the molten glass material. In some cases: (a) a first
actuator, out of the set of actuators, is configured to actuate the
nozzle and at least some of the heating elements to move parallel
to a first horizontal axis; and (b) a second actuator, out of the
set of actuators, is configured to actuate the nozzle and at least
some of the heating elements to move parallel to a second
horizontal axis, the first and second horizontal axes being
perpendicular to each other. In some cases: (a) a first actuator,
out of the set of actuators, is configured to actuate the nozzle to
move parallel to a horizontal axis; and (b) a second actuator, out
of the set of actuators, is configured to actuate the build
platform to rotate. Each of the cases described above in this
paragraph is an example of the apparatus described in the first
sentence of this paragraph, and is also an example of an embodiment
of this invention that may be combined with other embodiments of
this invention.
[0185] In another aspect, this invention comprises an article of
manufacture that comprises an integral structure, which integral
structure has multiple, separate internal cavities, such that each
of the cavities has a volume of at least 40 milliliters and is
entirely enclosed by the glass material. In some cases, the
integral structure includes layers of optically transparent glass
material, such that adjacent layers partially merge into each
other. In some cases, the integral structure further comprises an
elongated protuberance, which protuberance: (a) is located on an
exterior surface of the structure; and (b) comprises a solidified
drip of glass material. In some cases, the protuberance is
elongated along an axis that is aligned vertically. Each of the
cases described above in this paragraph is an example of the
article of manufacture described in the first sentence of this
paragraph, and is also an example of an embodiment of this
invention that may be combined with other embodiments of this
invention.
[0186] In another aspect, this invention comprises an article of
manufacture that comprises a unitary structure, wherein : (a) the
unitary structure includes a spiral filament of optically
transparent glass material; (b) the spiral filament forms multiple
layers, one layer on top of another, which layers are part of the
spiral filament and partially merge into each other vertically; and
(c) the spiral filament has an elongated cavity that is entirely
enclosed by the filament and extends for at least half of a
revolution of a spiral formed by the filament. The article of
manufacture described in the first sentence of this paragraph may
be combined with other embodiments of this invention.
[0187] The above description (including without limitation any
attached drawings and figures) describes illustrative
implementations of the invention. However, the invention may be
implemented in other ways. The methods and apparatus which are
described above are merely illustrative applications of the
principles of the invention. Other arrangements, methods,
modifications, and substitutions by one of ordinary skill in the
art are therefore also within the scope of the present invention.
Numerous modifications may be made by those skilled in the art
without departing from the scope of the invention. Also, this
invention includes without limitation each combination and
permutation of one or more of the abovementioned implementations,
embodiments and features.
* * * * *