U.S. patent application number 14/805420 was filed with the patent office on 2015-11-12 for systems for additive manufacturing processes incorporating active deposition.
This patent application is currently assigned to MetaMason, Inc.. The applicant listed for this patent is MetaMason, Inc.. Invention is credited to Leslie Oliver Karpas, Aaron M. Ryan.
Application Number | 20150321420 14/805420 |
Document ID | / |
Family ID | 53754099 |
Filed Date | 2015-11-12 |
United States Patent
Application |
20150321420 |
Kind Code |
A1 |
Karpas; Leslie Oliver ; et
al. |
November 12, 2015 |
Systems for Additive Manufacturing Processes Incorporating Active
Deposition
Abstract
Systems and methods in accordance with embodiments of the
invention implement additive manufacturing processes whereby the
constituent material of an object to be fabricated is manipulated
prior to, or during, the respective deposition process such that
different portions of the deposited constituent material can be
made to possess different material properties. In one embodiment,
an additive manufacturing apparatus includes: a nozzle configured
to accommodate the extrusion of a constituent material through it
and deposit the constituent material onto a surface in accordance
with an additive manufacturing process to build up an object to be
fabricated; and a subassembly configured to manipulate the material
properties of some portion of the constituent material such that
different portions of the deposited constituent material can be
made to possess different material properties; where the
subassembly is configured to begin said manipulation prior to, or
concurrently with, its deposition onto a surface.
Inventors: |
Karpas; Leslie Oliver;
(Pasadena, CA) ; Ryan; Aaron M.; (Los Angeles,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MetaMason, Inc. |
Pasadena |
CA |
US |
|
|
Assignee: |
MetaMason, Inc.
|
Family ID: |
53754099 |
Appl. No.: |
14/805420 |
Filed: |
July 21, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14321046 |
Jul 1, 2014 |
9102099 |
|
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14805420 |
|
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61936263 |
Feb 5, 2014 |
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Current U.S.
Class: |
425/3 ;
425/131.1; 425/174.4 |
Current CPC
Class: |
B29C 64/209 20170801;
B33Y 30/00 20141201; G06F 30/00 20200101; B33Y 40/00 20141201; B29C
64/118 20170801 |
International
Class: |
B29C 67/00 20060101
B29C067/00 |
Claims
1. An additive manufacturing apparatus comprising: a nozzle
configured to accommodate the extrusion of a constituent material
through the nozzle and deposit the constituent material onto a
surface in accordance with an additive manufacturing process to
build up an object to be fabricated; and at least one subassembly
configured to manipulate the material properties of at least some
portion of the constituent material such that different portions of
the deposited constituent material can be made to possess different
material properties; wherein the at least one subassembly is
configured to begin the manipulation of the material properties of
the at least some portion of the constituent material prior to, or
concurrently with, its deposition onto a surface.
2. The additive manufacturing apparatus of claim 1, wherein the
subassembly is configured to begin the manipulation of the material
properties of the at least some portion of the constituent material
after it is extruded through the nozzle.
3. The additive manufacturing apparatus of claim 2, wherein the
subassembly comprises at least one of: an electromagnetic wave
source configured to subject at least some portion of the
constituent material to electromagnetic waves to begin the
manipulation of its material properties; a magnetizing source
configured to begin the magnetization of the at least some portion
of the constituent material; a source of gas configured to subject
the at least some portion of the constituent material to the gas
that begins the manipulation of its material properties; a
vibrating apparatus configured to vibrate the at least some portion
of the constituent material to thereby begin the manipulation of
its material properties; and a heating source configured to heat
the at least some portion of the constituent material to thereby
begin the manipulation of its material properties.
4. The additive manufacturing apparatus of claim 3 further
comprising a spatial-orientation mechanism configured to orient the
subassembly relative to the nozzle.
5. The additive manufacturing apparatus of claim 3, wherein the
subassembly comprises at least one electromagnetic wave source.
6. The additive manufacturing apparatus of claim 5 wherein the
electromagnetic wave source is coupled to the nozzle.
7. The additive manufacturing apparatus of claim 5, wherein the
electromagnetic wave source is independent of the nozzle, such that
the nozzle can move independently of the electromagnetic wave
source during the buildup of an object to be fabricated.
8. The additive manufacturing apparatus of claim 7, wherein the
subassembly further comprises fiber optic cables configured to
transmit electromagnetic waves generated by the electromagnetic
wave source to constituent material that is extruded through the
nozzle.
9. The additive manufacturing apparatus of claim 7, wherein the
subassembly further comprises optics for focusing electromagnetic
waves generated by the electromagnetic wave source onto constituent
material that is extruded through the nozzle.
10. The additive manufacturing apparatus of claim 2, wherein the at
least one subassembly is at least two subassemblies.
11. The additive manufacturing apparatus of claim 10, wherein: the
at least two subassemblies are disposed about the perimeter of the
nozzle; and each of the at least two subassemblies is configured to
begin the manipulation of the material properties in the same
manner on different respective portions of constituent material
that is extruded through the nozzle.
12. The additive manufacturing apparatus of claim 10, wherein each
of the subassemblies is configured to begin the manipulation of the
material properties on constituent material that is extruded
through the nozzle in a manner differently than the other
respective subassembly.
13. The additive manufacturing apparatus of claim 1, wherein: the
nozzle is configured to accommodate the extrusion of a constituent
material that comprises at least two component materials; and the
subassembly is configured to begin the manipulation of the material
properties of at least some portion of the constituent material by
manipulating the composition of the cross-section of the
constituent material as it is extruded through the nozzle.
14. The additive manufacturing apparatus of claim 13, wherein the
subassembly is configured to manipulate the spatial positioning of
a first component material relative to a second component material
within a given cross-section of the constituent material as it is
deposited on a surface.
15. The additive manufacturing apparatus of claim 14, wherein the
subassembly comprises a channel that is configured to transmit the
first component material for aggregation with the second component
material to form the constituent material.
16. The additive manufacturing apparatus of claim 15, wherein the
subassembly is configured to cause the aggregation of the first
component material and the second component material prior to, or
at the time of, the extrusion of the constituent material through
the nozzle.
17. The additive manufacturing apparatus of claim 15, further
comprising a spatial orienting mechanism configured to spatially
orient the channel to thereby control the aggregation of the first
component material and the second component material.
18. The additive manufacturing apparatus of claim 15, further
comprising at least a second channel disposed proximate the first
channel and configured to transmit the second component material,
and a rotating mechanism for translating the first channel and
second channel in a circular path such that the respective
component materials that outflow from the respective channels can
be controllably intertwined to thereby form the constituent
material.
19. The additive manufacturing apparatus of claim 1, wherein the
subassembly comprises a shutter assembly configured to control the
dimensions of the cross-section of constituent material that is
extruded through the nozzle.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The current application is a divisional of U.S. application
Ser. No. 14/321,046 filed Jul. 1, 2014, which claims priority to
U.S. Provisional Patent Application No. 61/936,263, filed Feb. 5,
2014, the disclosures of which are hereby incorporated by
reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to additive
manufacturing apparatuses and techniques for additive
manufacturing.
BACKGROUND
[0003] `Additive manufacturing,` or `3D Printing,` is a term that
typically describes a manufacturing process whereby a 3D model of
an object to be fabricated is provided to an apparatus (e.g. a 3D
printer), which then autonomously fabricates the object by
gradually depositing, or otherwise forming, the constituent
material in the shape of the object to be fabricated. For example,
in many instances, successive layers of material that represent
cross-sections of the object are deposited or otherwise formed;
generally, the deposited layers of material fuse (or otherwise
solidify) to form the final object. Because of their relative
versatility, additive manufacturing techniques have generated much
interest.
SUMMARY OF THE INVENTION
[0004] Systems and methods in accordance with embodiments of the
invention implement additive manufacturing processes whereby the
constituent material of an object to be fabricated is actively
manipulated prior to, or during, the deposition process such that
different portions of the deposited constituent material can be
made to possess different material properties. In one embodiment,
an additive manufacturing apparatus includes: a nozzle configured
to accommodate the extrusion of a constituent material through the
nozzle and deposit the constituent material onto a surface in
accordance with an additive manufacturing process to build up an
object to be fabricated; and at least one subassembly configured to
manipulate the material properties of at least some portion of the
constituent material such that different portions of the deposited
constituent material can be made to possess different material
properties; where the at least one subassembly is configured to
begin the manipulation of the material properties of the at least
some portion of the constituent material prior to, or concurrently
with, its deposition onto a surface.
[0005] In another embodiment, the subassembly is configured to
begin the manipulation of the material properties of the at least
some portion of the constituent material after it is extruded
through the nozzle.
[0006] In still another embodiment, the subassembly includes at
least one of: an electromagnetic wave source configured to subject
at least some portion of the constituent material to
electromagnetic waves to begin the manipulation of its material
properties; a magnetizing source configured to begin the
magnetization of the at least some portion of the constituent
material; a source of gas configured to subject the at least some
portion of the constituent material to the gas that begins the
manipulation of its material properties; a vibrating apparatus
configured to vibrate the at least some portion of the constituent
material to thereby begin the manipulation of its material
properties; and a heating source configured to heat the at least
some portion of the constituent material to thereby begin the
manipulation of its material properties.
[0007] In yet another embodiment, the additive manufacturing
apparatus further includes a spatial-orientation mechanism
configured to orient the subassembly relative to the nozzle.
[0008] In still yet another embodiment, the subassembly includes at
least one electromagnetic wave source.
[0009] In a further embodiment, the electromagnetic wave source is
coupled to the nozzle.
[0010] In a still further embodiment, the electromagnetic wave
source is independent of the nozzle, such that the nozzle can move
independently of the electromagnetic wave source during the buildup
of an object to be fabricated.
[0011] In a yet further embodiment, the subassembly further
includes fiber optic cables configured to transmit electromagnetic
waves generated by the electromagnetic wave source to constituent
material that is extruded through the nozzle.
[0012] In a still yet further embodiment, the subassembly further
includes optics for focusing electromagnetic waves generated by the
electromagnetic wave source onto constituent material that is
extruded through the nozzle.
[0013] In another embodiment, the at least one subassembly is at
least two subassemblies.
[0014] In still another embodiment, the at least two subassemblies
are disposed about the perimeter of the nozzle, and each of the at
least two subassemblies is configured to begin the manipulation of
the material properties in the same manner on different respective
portions of constituent material that is extruded through the
nozzle.
[0015] In yet another embodiment, each of the subassemblies is
configured to begin the manipulation of the material properties on
constituent material that is extruded through the nozzle in a
manner differently than the other respective subassembly.
[0016] In still yet another embodiment, the nozzle is configured to
accommodate the extrusion of a constituent material that includes
at least two component materials, and the subassembly is configured
to begin the manipulation of the material properties of at least
some portion of the constituent material by manipulating the
composition of the cross-section of the constituent material as it
is extruded through the nozzle.
[0017] In a further embodiment, the subassembly is configured to
manipulate the spatial positioning of a first component material
relative to a second component material within a given
cross-section of the constituent material as it is deposited on a
surface.
[0018] In a still further embodiment, the subassembly includes a
channel that is configured to transmit the first component material
for aggregation with the second component material to form the
constituent material.
[0019] In a yet further embodiment, the subassembly is configured
to cause the aggregation of the first component material and the
second component material prior to, or at the time of, the
extrusion of the constituent material through the nozzle.
[0020] In a still yet further embodiment, the additive
manufacturing apparatus further includes a spatial orienting
mechanism configured to spatially orient the channel to thereby
control the aggregation of the first component material and the
second component material.
[0021] In another embodiment, the additive manufacturing apparatus
further includes at least a second channel disposed proximate the
first channel and configured to transmit the second component
material, and a rotating mechanism for translating the first
channel and second channel in a circular path such that the
respective component materials that outflow from the respective
channels can be controllably intertwined to thereby form the
constituent material.
[0022] In still another embodiment, the subassembly includes a
shutter assembly configured to control the dimensions of the
cross-section of constituent material that is extruded through the
nozzle.
[0023] In a further embodiment, a method of fabricating an object
includes: progressively depositing constituent material onto a
surface to form the shape of the object to be fabricated in
accordance with an additive manufacturing process; and manipulating
the material properties of at least some portion of the constituent
material that is deposited onto a surface such that at least some
portion of the deposited constituent material possesses different
material properties than at least some other portion of the
deposited constituent material; where manipulating the material
properties of the at least some portion of the constituent material
begins prior to, or concurrently with, its deposition onto a
surface.
[0024] In a still further embodiment, progressively depositing the
constituent material onto a surface includes extruding the
constituent material through a nozzle, and manipulating the
material properties of the at least some portion of the constituent
material begins after the at least some portion of the constituent
material is extruded through the nozzle.
[0025] In a yet further embodiment, manipulating the material
properties of the at least some portion of the constituent material
includes one of: subjecting the at least some portion of the
constituent material to electromagnetic waves; magnetizing the at
least some portion of the constituent material; subjecting the at
least some portion of the constituent material to a gas; vibrating
the at least some portion of the constituent material; and heating
the at least some portion of the constituent material.
[0026] In a still yet further embodiment, manipulating the material
properties of the at least some portion of the constituent material
includes subjecting the at least some portion of the constituent
material to electromagnetic waves.
[0027] In another embodiment, subjecting the at least some portion
of the constituent material to electromagnetic waves includes using
fiber optic cables to transmit the electromagnetic waves from a
wave source to the at least some portion of the constituent
material.
[0028] In still another embodiment, subjecting the at least some
portion of the constituent material to electromagnetic waves
includes using optics to focus the electromagnetic waves onto the
at least some portion of the constituent material.
[0029] In yet another embodiment, the method of fabricating an
object further includes manipulating the material properties of at
least some portion of the constituent material that is deposited
onto a surface in at least another way.
[0030] In still yet another embodiment, the constituent material
includes at least two component materials; and manipulating the
material properties of the at least some portion of the constituent
material includes manipulating the composition of the cross-section
of the constituent material that is deposited onto a surface.
[0031] In a further embodiment, manipulating the composition of the
cross-section of the constituent material that is deposited onto a
surface includes varying the aggregation of a first component
material and at least a second component material.
[0032] In a still further embodiment, varying the aggregation of a
first component material and at least a second component material
includes intertwining the first component material and at least the
second component material as the constituent material is being
deposited onto a surface.
[0033] In a yet further embodiment, manipulating the material
properties of the at least some portion of the constituent material
includes varying the cross-section of the constituent material that
is deposited.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIGS. 1A-1C illustrate the advantages, relative to the prior
art, of treating a material as it is extruded in an additive
manufacturing process in accordance with embodiments of the
invention.
[0035] FIG. 2 illustrates a method of additively manufacturing an
object where constituent material is manipulated in the deposition
process in accordance with an embodiment of the invention.
[0036] FIGS. 3A-3C illustrate various treating methods that can be
imposed on materials as they are extruded in an additive
manufacturing process in accordance with embodiments of the
invention.
[0037] FIG. 4 illustrates an additive manufacturing apparatus that
includes an assembly that is configured to manipulate the material
properties of the constituent material, and is configured such that
it can maneuver around the nozzle in accordance with an embodiment
of the invention.
[0038] FIG. 5 illustrates an additive manufacturing apparatus
including a polar array of subassemblies that include
electromagnetic wave sources that can be used to manipulate the
material properties of the constituent material in accordance with
an embodiment of the invention.
[0039] FIG. 6 illustrates using fiber optics to transmit
electromagnetic waves to treat a material as it is extruded in
accordance with an embodiment of the invention.
[0040] FIG. 7 illustrates an additive manufacturing apparatus
whereby focusing elements are used to focus electromagnetic waves
onto a constituent material as it is extruded in accordance with an
embodiment of the invention.
[0041] FIGS. 8A-8B illustrates an additive manufacturing apparatus
including multiple subassemblies, each configured to treat the
constituent material in a unique way, in accordance with an
embodiment of the invention.
[0042] FIGS. 9A-9C illustrate a constituent material that includes
two aspects being uniformly subjected to a treatment that impacts
each aspect differently in accordance with embodiments of the
invention.
[0043] FIGS. 10A-100 illustrate a constituent material that
includes two aspects that define a C-shape being uniformly
subjected to a treatment that impacts each aspect differently in
accordance with embodiments of the invention
[0044] FIGS. 11A-11C illustrate implementing different treating
methods to customize the material properties of an object to be
fabricated in accordance with embodiments of the invention.
[0045] FIG. 12 illustrates a vase that includes varying levels of
translucency that has been fabricated using additive manufacturing
techniques in accordance with an embodiment of the invention.
[0046] FIG. 13 illustrates a pair of glasses that includes
constituent material having varying material properties that has
been fabricated using additive manufacturing techniques in
accordance with an embodiment of the invention.
[0047] FIG. 14 illustrates rotating a pair of component materials
as they are extruded from respective channels to form a constituent
material in accordance with embodiments of the invention.
[0048] FIGS. 15A-15B illustrate rotating three component materials
that are extruded from three respective channels to form a
constituent material in accordance with embodiments of the
invention.
[0049] FIGS. 16A-16B illustrate manipulating the extrusion of a
first component material within a second component material to form
a constituent material in accordance with embodiments of the
invention.
[0050] FIGS. 17A-17B illustrates controlling a shutter for
manipulating the aperture of the nozzle as it deposits material in
accordance with an embodiment of the invention.
[0051] FIGS. 18A-18F illustrate different cross-sections that can
be obtained by manipulating the nozzle aperture in accordance with
embodiments of the invention.
DETAILED DESCRIPTION
[0052] Turning now to the drawings, systems and methods for
implementing additive manufacturing processes incorporating active
deposition are illustrated. In many embodiments, a method of
additively manufacturing an object includes manipulating the
material properties of at least some portion of the constituent
material that is deposited in accordance with an additive
manufacturing process to form the object such that at least some
portion of the deposited constituent material possesses different
material properties than at least some other portion of the
deposited constituent material, where manipulation of the material
properties of the at least some portion of the constituent material
begins prior to, or concurrently with its deposition onto a
surface. In numerous embodiments, the method includes beginning the
manipulation of the at least some portion of the constituent
material after it has been extruded through the nozzle of an
additive manufacturing apparatus. In several embodiments,
electromagnetic waves are used to begin the manipulation of the at
least some portion of the constituent material. In a number of
embodiments, certain portions of the constituent material are
manipulated in one way and certain portions of the constituent
material are manipulated in another way. In many embodiments, the
composition of the cross-section of the constituent material is
manipulated prior to the deposition of at least some portion of the
constituent material onto a surface. In many embodiments, the
aggregation of two component materials to form the constituent
material is controlled such that the composition of portions of the
constituent material can be varied.
[0053] Since its inception, additive manufacturing, or `3D
Printing`, has generated much interest from manufacturing
communities because of the seemingly unlimited potential that these
fabrication techniques can offer. For example, these techniques
have been demonstrated to produce any of a variety of distinct and
intricate geometries, with the only input being the final shape of
the object to be formed. In many instances, a 3D rendering of an
object is provided electronically to a `3D Printer`, which then
fabricates the object. Many times, a 3D Printer is provided with a
CAD File, a 3D Model, or instructions (e.g. via G-code), and the 3D
Printer thereby fabricates the object. Importantly, as can be
inferred, these processing techniques can be used to avoid heritage
manufacturing techniques that can be far more resource intensive
and inefficient. The relative simplicity and versatility of this
process can pragmatically be used in any of a variety of scenarios
including for example to allow for rapid prototyping and/or to
fabricate components that are highly customized for particular
consumers. For example, shoes that are specifically adapted to fit
a particular individual can be additively manufactured. Indeed,
U.S. Provisional Patent Application No. 61/861,376 discloses the
manufacture of customized medical devices and apparel using
additive manufacturing techniques; U.S. Provisional Patent
Application No. 61/861,376 and its progeny are hereby incorporated
by reference. It should also be mentioned that the cost of 3D
printers has recently noticeably decreased, thereby making additive
manufacturing processes an even more viable fabrication
methodology.
[0054] Given the demonstrated efficacy and versatility of additive
manufacturing processes, their potential continues to be explored.
For example, while the operation of many current generation
additive manufacturing apparatuses is premised on the uniform
deposition of a material in the shape of the desired object such
that the material properties of the corresponding printed object
are largely homogenous throughout its structure, in many instances
it may be desirable to additively manufacture a multi-material
object. Accordingly, additive manufacturing apparatuses and
techniques have recently been developed that can selectively
deposit any of a plurality of different materials during the
buildup of a desired object such that the printed object can be
made up of a plurality of different materials. For example,
Stratasys is a 3D Printing Company that develops 3D printers that
can deposit any of a plurality of materials during the buildup of a
single printed object, i.e. the printed object can be printed to
include a plurality of distinct materials. For instance, the Objet
Connex line of printers developed by Stratasys is adept at such
`multi-material printing.` Incidentally, Stratasys also boasts of
its PolyJet Technology which allows 3D printing resolutions as fine
as 0.0006'' per layer of deposited material to be achieved. PolyJet
technology essentially involves depositing a plurality of drops of
liquid photopolymer onto a build tray, and instantly uniformly
curing the deposited drops with UV light.
[0055] Nonetheless, even with these laudable achievements, the
state of the art can further benefit from an ability to exercise
even greater control and customization during the build of an
object in accordance with an additive manufacturing process.
Accordingly, in many embodiments of the invention additive
manufacturing processes are implemented whereby the material
properties of the constituent material of an additively
manufactured object are controllably manipulated while the material
is being deposited. In the context of this application, the
constituent material can be understood to be the material that
forms the additively manufactured object. Thus, material that is
deposited in accordance with an additive manufacturing process can
become the constituent material of the additively manufactured
object. Hence, by controllably manipulating the material properties
of the constituent material while it is being deposited, different
portions of the additively manufactured object can be made to
possess different material properties and additively manufactured
objects can thereby be highly customized. For example, in many
embodiments, the material properties of the constituent material
are controlled by altering the constitution of the constituent
material. These processes are now discussed in greater detail
below.
Methods for Implementing Active Deposition in Additive
Manufacturing Processes
[0056] In many embodiments, additive manufacturing processes that
incorporate active deposition techniques are implemented. Active
deposition can be understood to regard actively controlling the
material properties of material that is deposited in conjunction
with an additive manufacturing process to build up an object such
that different portions of the additively manufactured structure
can be made to possess different material properties. Such
techniques can be extremely advantageous insofar as they can allow
the fabrication of highly customized structures, e.g. different
portions of the structure can have tailored material properties.
Additionally, active deposition techniques can also impact the
buildup of an object. For example, constituent material can be
treated as it is being deposited so that it rapidly becomes
sufficiently rigid such that the weight of an overhang portion will
not distort its geometry.
[0057] FIGS. 1A-1C depict some of the advantages that active
deposition techniques in accordance with embodiments of the
invention can confer in relation to prior art additive
manufacturing methods. In particular, FIG. 1A depicts the operation
of a conventional additive manufacturing apparatus 100 that
includes a nozzle head 102 that is seen depositing constituent
material 104 to build up an object 106. FIG. 1B depicts an additive
manufacturing apparatus 110 in accordance with embodiments of the
invention that includes a nozzle head 112 and an ultraviolet (UV)
electromagnetic wave source 114 that is configured to treat
material that is extruded through the nozzle head 112. The
apparatus is seen depositing material 116 to build up an object
118. Note that the object includes a relatively larger overhang
feature 119 than anything seen with respect to FIG. 1A--the
additive manufacture of this feature 119 is made possible as the UV
electromagnetic wave source 114 can rapidly cure the material 116
as it is being deposited, such that the deposited material 116 is
relatively more rigid so that its weight doesn't distort the
desired overhang geometry 119. Essentially, the constituent
material 116 is sensitive to UV electromagnetic wave exposure such
that UV electromagnetic waves initiate the rapid hardening of the
constituent material.
[0058] FIG. 1C depicts yet another advantage that can be realized
with active deposition techniques. In particular, FIG. 1C depicts
an additive manufacturing apparatus 120 in accordance with
embodiments of the invention that includes a nozzle head 122 and a
magnetizing source 124. The apparatus 120 is seen depositing
material 126 to build up an object 128. Notably, the magnetizing
source 124 can selectively impart magnetic polarities onto the
additively manufactured object 128. In this way, the fabricated
object can be highly customized, as it can be specifically
determined which regions of the fabricated object are to possess
magnetic properties, and to what extent.
[0059] The above-described non-limiting examples illustrate some of
the advantages that the incorporation of active deposition in
additive manufacturing techniques can provide. In many embodiments,
additive manufacturing processes include active deposition that is
characterized by the selective treatment of certain of the
constituent material that is deposited. FIG. 2 illustrates a method
of additively manufacturing an object that includes selectively
manipulating the material properties of the constituent material
during its deposition in accordance with embodiments of the
invention. In particular, the method 200 includes depositing 202
constituent material onto a surface to form the shape of an object
to be fabricated in accordance with an additive manufacturing
process. Constituent material can be deposited 202 in accordance
with any of a variety of additive manufacturing processes. For
example, in many embodiments, constituent material is deposited 202
in accordance with a fused deposition modeling additive
manufacturing process. Fused deposition modeling essentially
regards depositing constituent material, usually in the form of a
plastic filament or a metallic wire, into the shape of the desired
object. Typically, the constituent material is extruded through a
nozzle and thereby deposited. In a number of embodiments,
constituent material is deposited 202 in accordance with a laser
engineered net shaping (LENS) process. In LENS additive
manufacturing, a feedstock metallic powder is provided to a build
head that heats and deposits the feedstock metal into the shape of
the structure to be formed. In several embodiments, constituent
material is deposited in accordance with an electron beam freeform
fabrication (EBF.sup.3) additive manufacturing process. EBF.sup.3
additive manufacturing processes are similar to LENS additive
manufacturing processes, except that the feedstock metal is in the
form of wire, and an electron beam is typically used to heat the
wire.
[0060] In numerous embodiments, material is deposited 202 in
conjunction with a 6-axis 3d printing additive manufacturing
process. Whereas conventional 3d printing processes typically
employ a vertically oriented build head that causes the downward
deposition of constituent material, 6-axis 3d printing processes
employ a build head that has six degrees of freedom and can thereby
cause the deposition of the constituent material in any of a
variety of directions. As can be appreciated, 6-axis 3d printing
processes are more versatile than conventional additive
manufacturing processes.
[0061] The method 200 further includes manipulating 204 the
material properties of at least some portion of the constituent
material that is deposited onto a surface such that at least some
portion of the deposited constituent material possesses different
material properties than at least some other portion of the
deposited constituent material, where the manipulation begins prior
to, or concurrently with, its deposition onto a surface. The
material properties can be manipulated 204 in any suitable way in
accordance with embodiments of the invention. For instance, in some
embodiments, as discussed above with respect to FIG. 1C, the
magnetic properties of the constituent material are manipulated; in
this way, certain portions of the deposited constituent material
can have different magnetic properties relative to other portions
of the deposited constituent material. Accordingly, the magnetic
properties of the additively manufactured object can vary
throughout the geometry of the object, and the magnetic properties
can thereby be highly customized. For example, a screwdriver having
a magnetic tip portion can be additively manufactured using the
above described processes.
[0062] In a number of embodiments, manipulating 204 the material
properties of the constituent material includes manipulating the
cross section of the constituent material (e.g. the cross section
being judged as it is deposited onto a surface) such that the
deposited constituent material in one portion of the additively
manufactured object embodies a different cross section than another
portion. In general, the constituent material can be manipulated in
any of a variety of ways in accordance with embodiments of the
invention--embodiments of the invention are not limited to
manipulating the magnetic properties or the cross section of the
material.
[0063] Moreover, any of a variety of techniques can be used to
manipulate the material in accordance with embodiments of the
invention. FIGS. 3A-3C depict some examples of techniques that can
be used to manipulate the materials properties of the constituent
material in accordance with embodiments of the invention. In
particular, FIG. 3A depicts a portion of an additive manufacturing
apparatus that includes a subassembly 304 that subjects constituent
material 306, as it is extruded through the nozzle 302 during the
deposition process, with a vapor that initiates a material
transformation of the constituent material 306 as it is being
deposited. Note that although the constituent material is being
treated prior to its deposition onto the surface, the completion of
any transformation may not happen until after the constituent
material has been deposited. For example, the subassembly 304 might
initiate a relatively slow reaction that does not complete until
after the constituent material 306 has been deposited. While FIG.
3A depicts subjecting the constituent material 306 with a vapor,
any similar process can be implemented in accordance with
embodiments of the invention. For example, in some embodiments, a
subassembly is configured to coat the constituent material (e.g.
with color) as it is being deposited. The coating of the
constituent material as it is being deposited adds a thin layer of
material to the periphery of the constituent material and thereby
alters the material properties of the constituent material. With
this technique, different portions of the additively manufactured
structure can be, for example, colored differently during the
deposition process.
[0064] FIG. 3B depicts a portion of an additive manufacturing
apparatus that includes a subassembly 314 that is configured to
vibrate constituent material 316 as it is extruded through a nozzle
312. The vibration of the constituent material 316 can, for
example, initiate work hardening that can alter the material
properties of the constituent material 316.
[0065] Similarly, FIG. 3C depicts a portion of an additive
manufacturing apparatus that includes a subassembly 324 that is
configured to heat constituent material 326 as it exits a nozzle
head 322. The heating, for example, can manipulate the material
properties insofar as constituent material that is heated can be
annealed.
[0066] Importantly, as can be appreciated, any combination of the
above-described subassemblies can be incorporated to manipulate the
material properties of the constituent material in accordance with
embodiments of the invention. Indeed, more generally, any
combination of any of a variety subassemblies that can manipulate
the material properties of the constituent material in any of a
variety of ways can be incorporated in accordance with embodiments
of the invention. For example, in some embodiments, the deposited
constituent material is manipulated by a subassembly that imposes a
heat treatment on the constituent material, a subassembly that
imposes an electromagnetic treatment on the constituent material,
and/or a subassembly that imposes a magnetic treatment on the
constituent material. In some embodiments, a single subassembly is
capable of manipulating the constituent material in a plurality of
ways. For example, in some embodiments, a single subassembly can
impose a magnetic treatment, an electromagnetic treatment, and/or a
heat treatment on the constituent material. In general, the
constituent material can be manipulated in any number of ways in
accordance with embodiments of the invention.
[0067] In a number of embodiments, additive manufacturing
apparatuses that are configured to incorporate active deposition
techniques include subassemblies that can be moved relative to the
deposited constituent material. For example, in many embodiments, a
subassembly can maneuver around and about constituent material as
it is extruded through an additive manufacturing nozzle head. In
this way, cylindrical portions of the extruded material, for
example, do not have to be treated uniformly; instead, the
subassembly can maneuver so as to treat only certain portions of
the constituent material that is extruded onto a surface. FIG. 4
illustrates an additive manufacturing apparatus that includes a
subassembly that can maneuver relative to constituent material that
is extruded through a nozzle. In particular, the additive
manufacturing apparatus includes a nozzle 402 and a subassembly 404
that can maneuver with respect to constituent material 406 that is
extruded through the nozzle 402. As can be appreciated, the
subassembly 404 can manipulate the properties of the constituent
material 406 in any suitable way, including in any of the
above-described ways, in accordance with embodiments of the
invention. The illustration depicts that the subassembly 404 can
maneuver with sufficient precision such that only certain portions
408 (as opposed to an entire portion of the extruded section) of
the constituent material 406 have been treated. Thus, only those
treated portions will possess the transformed material properties.
In essence, the material properties of the constituent material can
be custom-tailored with even greater precision.
[0068] Accordingly, it can be seen how the incorporation of active
deposition techniques in accordance with embodiments of the
invention can allow the manufacture of highly customized objects.
While several techniques are shown for manipulating the material
properties, it should be clear that the material can be manipulated
in any suitable way in accordance with embodiments of the
invention. In many embodiments, the manipulation of material
properties is achieved by subjecting the constituent material to
electromagnetic waves that initiate the transformation of the
material properties, and this is now discussed in greater detail
below.
Using Electromagnetic Waves to Initiate the Transformation of
Material Properties
[0069] In many embodiments, electromagnetic waves are used to
initiate the transformation of materials properties of portions of
the constituent material. For example, in numerous embodiments,
either infrared rays or ultraviolet rays are used to initiate the
transformation of materials properties of a constituent material as
it is extruded through the nozzle. Of course, the constituent
material can be exposed to any suitable electromagnetic waves that
initiate the transformation of its material properties. As can be
appreciated, the constituent material that is to be deposited must
be sensitive to the particular applied electromagnetic wave, and
the effect of the electromagnetic radiation exposure on the
material properties should be known. For example, in some
embodiments, the constituent material is exposed to electromagnetic
radiation of a particular wavelength that alters the mechanical
properties of the constituent material. In several embodiments,
exposure to electromagnetic radiation of a particular wavelength
alters the opacity of the material. For example, the constituent
material can include a pigment that is sensitive to the applied
electromagnetic radiation such that the opacity of the constituent
material can be tuned. Of course, the constituent material can be
sensitive to the application of electromagnetic radiation in any of
a variety of ways, and this sensitivity can be utilized to
controllably tune the material properties in accordance with
embodiments of the invention.
[0070] FIG. 5 illustrates an additive manufacturing apparatus that
includes subassemblies that are configure to irradiate constituent
material as it is extruded through a nozzle, and thereby alter the
constituent material, in accordance with embodiments of the
invention. In particular, the additive manufacturing apparatus
includes a plurality of subassemblies 504 that are symmetrically
disposed about a nozzle 502; the plurality of subassemblies are
configured to irradiate the constituent material with
electromagnetic waves of a particular wavelength as it is extruded
through the nozzle 502, and thereby initiate a material
transformation. The symmetrical distribution of the subassemblies
506 around the perimeter of the deposited constituent material 506
allows selected portions of the deposited constituent material to
be irradiated. As can be appreciated, the constituent material can
be irradiated with electromagnetic waves of any suitable
wavelength. For example, the constituent material can be irradiated
with ultraviolet waves, infrared waves, X-ray waves, microwaves,
etc.
[0071] Although FIG. 5 depicts that the subassemblies 504 are
coupled to the nozzle head 502 and each subassembly 504 includes a
source of electromagnetic radiation, in many embodiments, the
electromagnetic wave source is decoupled from the nozzle head;
instead, the electromagnetic waves are delivered to the constituent
material using any of a variety of suitable techniques. For
example, in many embodiments, fiberoptic cables are used to deliver
electromagnetic waves to the constituent material as it is extruded
through the nozzle. FIG. 6 depicts an additive manufacturing
apparatus that utilizes fiber optic cables to deliver
electromagnetic waves to the constituent material as it is extruded
through the nozzle. In particular, the additive manufacturing
apparatus includes a nozzle 602 and a subassembly 604 that is used
to expose the constituent material 606 that is extruded through the
nozzle to electromagnetic radiation of a particular wavelength.
Notably, the subassembly includes fiber optic cables 608 that
transmit electromagnetic waves originating from a source (not
shown) to the subassembly 604. In this way, the source of
electromagnetic radiation is decoupled from the nozzle. Decoupling
the electromagnetic radiation source from the nozzle head can
confer a variety of benefits. For example, by decoupling the EM
source, the nozzle head thereby requires less power to maneuver
during the build up of an additively manufactured structure. This
can yield substantial power savings. Moreover, by decoupling the
electromagnetic radiation source from the additive manufacturing
apparatus, a single electromagnetic radiation source can source
multiple additive manufacturing apparatuses. Note that the use of
fiber optics can allow the electromagnetic wave source to be
separated from the body of the additive manufacturing apparatus by
any suitable distance. For example, the electromagnetic wave source
can be located in one part of a business complex, while the body of
the additive manufacturing apparatus can be located at a different
part of the business complex. While the use of fiber optics to
transmit electromagnetic radiation waves is illustrated, EM waves
can be transmitted using any suitable mechanism in accordance with
embodiments of the invention. For example, in many embodiments,
electromagnetic waves are transmitted over the air using any of a
variety of focusing elements that direct the waves toward the
constituent material as it is deposited through the nozzle. FIG. 7
depicts an additive manufacturing apparatus whereby electromagnetic
wave sources are decoupled from the nozzle head, and focusing
elements are used to deliver electromagnetic waves from the
electromagnetic wave sources to the constituent material that is
extruded through the nozzle. In particular, the additive
manufacturing apparatus 700 includes infrared wavelength sources
704 that are decoupled from the nozzle 702. The additive
manufacturing apparatus 700 further includes focusing elements 708
that are configured to project the infrared electromagnetic
radiation waves to the constituent material 706 that is extruded
through the nozzle. As before, the decoupling of the nozzle from
the electromagnetic wave source allows the nozzle 702 to be more
nimble, and can allow the additive manufacturing apparatus 700 to
draw less power during operation.
[0072] While the above description has listed a variety of ways in
which the material properties of a constituent material can be
controllably manipulated, in many embodiments, the materials
properties of the constituent material is varied in multiple ways
as it is being deposited. Thus for example, in many embodiments,
additive manufacturing apparatuses include a plurality of
subassemblies, each of which being able to controllably manipulate
select portions of the constituent material in a different way. For
instance, in some embodiments, an additive manufacturing apparatus
includes a first subassembly that is configured to controllably
expose a constituent material to infrared electromagnetic radiation
and thereby initiate a first material transformation, as well as a
second subassembly that is configured to controllably expose the
constituent material to ultraviolet electromagnetic radiation and
thereby initiate a second, different, material transformation.
Essentially, a first material property of the constituent material
can be a function of exposure to infrared radiation, and a second
material property of the constituent material can be a function of
exposure to ultraviolet radiation. In this way, multiple material
properties of the constituent material can be controllably tuned
during the deposition process. In several embodiments, an additive
manufacturing apparatus includes a single subassembly that can
controllably manipulate deposited constituent material in each of a
plurality of different ways. For instance, in some embodiments, an
additive manufacturing apparatus includes a subassembly that can
controllably expose a constituent material to infrared
electromagnetic radiation to initiate a first material
transformation, and can also controllably expose the constituent
material to an ultraviolet radiation to initiate a second material
transformation. As can be appreciated, the exposure of the
constituent material to infrared radiation and to ultraviolet
radiation need not be simultaneous. While, the above discussion has
focused on using electromagnetic radiation to initiate material
transformation, it should be clear that the constituent material
can be transformed using any suitable technique in accordance with
embodiments of the invention.
[0073] FIGS. 8A-8B illustrate an additive manufacturing apparatus
that includes a plurality of subassemblies, each of which being
configured to controllably tune a separate respective material
property of the constituent material. In particular, FIG. 8A
illustrates an additive manufacturing apparatus that includes a
first subassembly 814 that is configured to apply a first technique
to the constituent material, a second subassembly 816 that is
configured to apply a second technique to the constituent material,
and a third subassembly 818 configured to apply a third technique
to the constituent material as it is extruded through the nozzle
head 802. FIG. 8B depicts that the constituent material 806
includes aspects that are sensitive to the first technique 821 such
that the application of the first technique augments a first
material property of the constituent material; aspects that are
sensitive to the second technique 822 such that the application of
the second technique augments a second material property of the
constituent material; and aspects that are sensitive to the third
technique 823 such that the application of the third technique
augments a third material property of the constituent material.
Accordingly, each of the three material properties of the
constituent material can be controllably tuned using the techniques
that can be applied with the respective subassemblies 814, 816, and
818. For instance, the aspects of the constituent material 806 that
are sensitive to the first technique 821 can be a pigment, the
transparency of which is altered based on infrared radiation
exposure; the aspects of the constituent material 806 that are
sensitive to the second technique 822 can be a material that
hardens as a function of exposure to ultraviolet radiation; and the
aspects of the constituent material 806 that are sensitive to the
third technique can be a material that magnetizes as a function of
exposure to an applied magnetic field. Correspondingly, the first
technique can comprise exposing the constituent material 806 to
infrared radiation, the second technique can comprise exposing the
constituent material 806 to ultraviolet radiation, and the third
technique can comprise exposing the constituent material 806 to a
magnetic field. In general, embodiments of the invention include
constituent materials that comprise a plurality of aspects that are
each differently sensitive to any of a variety of applied
techniques, e.g. including, but not limited to, any of the
above-described techniques. Thus, for example a single feedstock
constituent material including a plurality of such aspects can be
fed into a respective additive manufacturing apparatus, and be
imbued with different, but customized, material properties during
the buildup of a desired object. Of course, it should be
appreciated that the constituent material can include any number of
aspects that are differently sensitive to applied techniques;
embodiments of the invention are not restricted to constituent
materials having exactly three such aspects. It should also be
appreciated that although FIGS. 8A-8B depict three subassemblies
that each treat a respective aspect of the constituent material, in
some embodiments, a single subassembly can apply different
techniques to treat the individual aspects of the constituent
material.
[0074] In many embodiments, a constituent material includes a
plurality of aspects such that when the constituent material is
uniformly subjected to a single treatment, at least two of the
plurality of aspects of the constituent material respond
differently to the treatment such that each of the at least two of
the plurality of aspects develop different material properties.
FIGS. 9A-9C depict a constituent material that comprises a
plurality of different aspects, such that when the constituent
material is subjected to a particular uniform treatment, each of
the aspects respond differently such that they each develop
different material properties. In particular, FIG. 9A depicts the
cross section of a constituent material 906 that includes two
aspects 921 and 922. FIG. 9A depicts that the constituent material
906 is being exposed to a treatment 916 that uniformly applied to
its cross section. FIG. 9B depicts that the uniform treatment 916
has acted to eliminate the portion of the constituent material that
was defined by the presence of the first aspect 921, and transmute
the material properties of the second aspect 922. Of course, the
uniform treatment 916 can impact the constituent material 906 in
any of a variety of ways in accordance with embodiments of the
invention. Thus, for example, FIG. 9C depicts that the uniform
treatment 916 has acted to transmute the material properties of
each of the aspects 921 and 922 in a different way.
[0075] Although FIG. 9 depicts aspects that are cylindrical in
nature, it should be clear that the aspects within the constituent
material can be of any suitable shape in accordance with
embodiments of the invention. Indeed, as will be discussed later,
the cross section of the constituent material can be of any
suitable shape in accordance with embodiments of the invention.
Thus, for example, FIGS. 10A-10C depict a constituent material that
includes aspects defining a C-shape. FIGS. 10A-10C are similar to
the illustrations seen in FIGS. 9A-9C, except that the constituent
material 1006, includes first and second aspects 1021, 1022 that
define a C-shape; as before, a uniform treatment 1016 is applied to
the constituent material 1006.
Fabrication Strategies Incorporating Active Deposition
[0076] In many embodiments, additive manufacturing processes
incorporate active deposition techniques are used to fabricate
structures that include varied material properties. For example, as
alluded to above, a constituent material may be sensitive to
particular wavelengths of electromagnetic radiation insofar as the
electromagnetic radiation exposure can controllably tune the
constituent material's mechanical properties.
[0077] FIGS. 11A-11C depict how active deposition techniques can be
used to dictate the mechanical properties of an additively
manufactured structure. In particular, FIG. 11A illustrates that
when a constituent material 1106 is exposed to infrared radiation
from an infrared radiation source 1114, the resulting structure
1108 has demonstrable pliability. FIG. 11B illustrates that when
the constituent material 1106 is exposed to ultraviolet radiation
from an ultraviolet radiation source 1116, the resulting structure
1128, has demonstrable rigidity. In essence, exposure to infrared
radiation causes the constituent material 1106 to develop
pliability, while exposure to ultraviolet radiation causes the
constituent material to develop rigidity. Accordingly, these
mechanical properties of the constituent material 1106 may be
controllably tuned while the constituent material 1106 is being
deposited.
[0078] Thus, FIG. 11C illustrates that the constituent material
1106 of the base of the additively manufactured structure 1138 has
been treated with ultraviolet radiation from an ultraviolet
radiation source 1116, while the upper portion of the additively
manufactured structure 1138 has been treated with infrared
radiation from an infrared radiation source 1114. Accordingly, the
base of the additively manufactured structure 1138 is developed to
have notable structural rigidity, whereas the upper portion of the
additively manufactured structure 1138 is developed to have notable
pliability.
[0079] Of course, while the tuning of the mechanical properties has
been discussed and illustrated, it should be clear that any of the
constituent material properties can be modified in accordance with
embodiments of the invention using any of a variety of treatments.
For example, FIG. 12 depicts an additively manufactured vase having
varied translucence in accordance with embodiments of the
invention. In particular, it is illustrated that the vase 1200 is
transparent in its upper portion 1202, semi-transparent in its
middle portion 1206, and not transparent at its base 1208. The vase
1200 was fabricated from a constituent material that included a
pigment that is sensitive to infrared radiation such that the
transparency of the constituent material is a function of its
exposure to infrared radiation. Thus, during the additive
manufacture of the vase, the different levels were exposed to
different levels of infrared radiation to controllably determine
the level of transparency, e.g. where greater transparency was
desired, the constituent material was subjected less infrared
radiation and vice versa.
[0080] For example, FIG. 13 depicts a pair of glasses that can be
fabricated using additive manufacturing processes that incorporate
active deposition in accordance with embodiments of the invention.
In particular, the pair of glasses 1300 defines three portions: the
skeleton of the frame 1304, the surface of the frame 1306, and the
lenses 1308. The constituent material is sensitive to ultraviolet
radiation as well as infrared radiation. In particular, exposure to
ultraviolet radiation causes the constituent material to develop
hardness while exposure to infrared radiation causes the material
to lose its translucency. Thus, when constituent material was
deposited to form the portions of the surface of the frame 1304,
the constituent material was subjected to infrared radiation and
not subjected to UV radiation so that the surface of the frame 1304
became soft and non-transparent. Conversely, when constituent
material was deposited to form the lens, the constituent material
was treated with 100% UV radiation and 0% infrared radiation so
that the deposited constituent material became hard and
transparent. When constituent material is deposited to form the
skeleton of the frame 1302, the constituent material was treated
with UV radiation at 100% so that the skeleton of the frame 1302 is
developed to be hard. The translucency of the skeleton of the frame
1302 does not impact the operation of the glasses, so it can be
exposed to any level of infrared radiation. While several examples
of structure having varied material properties are illustrated, it
should be emphasized that examples discussed are meant to be
illustrative and not exhaustive. Any of a variety of material
properties can be tuned during the deposition of the constituent
material in an additive manufacturing process in accordance with
embodiments of the invention. More generally, it should be
understood that the above-mentioned concepts are meant to be
versatile; thus, for example, any combination and any permutation
of the above-described techniques can be implemented in accordance
with embodiments of the invention. The above-described concepts are
meant to be illustrative and not exhaustive. Additionally, it
should also be appreciated that while the above-descriptions have
regarded additive manufacturing apparatuses that include
subassemblies that work in conjunction with the nozzle head, in
many embodiments, the subassemblies can operate independently of
the nozzle-head. For example, the subassemblies can be controlled
to treat already deposited constituent material. The subassemblies
may be used in this manner to refine the material properties of
already deposited constituent material in accordance with
embodiments of the invention.
[0081] While the above illustrations and discussions have suggested
the transformation of the bulk inherent material properties of the
constituent material, in many embodiments, the material properties
are manipulated insofar as the cross-section of the extruded
constituent material is manipulated. These aspects are now
discussed in greater detail below.
Manipulating the Cross-Section of the Deposited Constituent
Material
[0082] In many embodiments, the constituent material is manipulated
insofar as its cross section as it is being deposited onto a
surface in accordance with a deposition process is manipulated. The
cross section of the material can be manipulated in any suitable
way in accordance with embodiments of the invention. For example,
the deposited constituent material can include a first component
material and a second component material that are intertwined while
the aggregate constituent material is being deposited.
[0083] FIG. 14 depicts that a constituent material 1406 is
manipulated by intertwining a first component material 1412 with a
second component material 1414 while the constituent material 1406
is being deposited in accordance with embodiments of the invention.
Although a constituent material 1406 having two component materials
1412, 1414 is depicted, it should be clear that a constituent
material having any number of component materials can be deposited
in accordance with embodiments of the invention. For example, FIGS.
15A-15B depict that a constituent material is manipulated by
intertwining first, second, and third component materials while the
constituent material is being deposited. The constituent material
can be an aggregate of any number of component materials in
accordance with embodiments of the invention.
[0084] The cross section of the deposited constituent material can
be altered in any suitable way in accordance with embodiments of
the invention, and is not just limited to intertwining component
materials. For example, in some embodiments, the first component
material is enveloped by the second component material. In many
embodiments, the spatial relationship between a first component
material and a second component material can be controllably varied
in any suitable way. FIGS. 16A-16B depict how a constituent
material includes a first component material disposed within a
second component material, where the location of the first
component material within the second component material can be
controllably varied. In particular, FIG. 16A depicts that the first
component 1612 material defines a spiraling path within a second
component material 1614. This can be achieved for example by
rotating the first component material 1612 within the second
component material 1614 in a circular path while the aggregate is
being deposited onto a surface. A controllable channel can be used
to cause this outcome. For example, FIG. 16B depicts a controllable
channel 1630 that emits the first component material 1612 within
the second component material 1614. The relative location of the
channel 1630 within the second component material 1614 can be
controlled that the emission of the first component material within
the second component material can be controlled; in this way the
constitution of the cross section of the constituent material can
be controlled.
[0085] These techniques can be advantageous in the additive
manufacture of any of a variety of structures in accordance with
embodiments of the invention. For example, in some embodiments, a
wire is additively manufactured whereby the first component
material is conductive, and the second conductive material is
insulating. Accordingly, the cross section of the constituent
material defines the cross section of the wire; where it is desired
that the wire include an exposed lead, the channel responsible for
emitting the conductive first component material can be controlled
to move to the periphery for the constituent material such that the
first conductive component material is exposed. Of course, it
should be understood that the above described techniques are not
limited to the fabrication of wires; indeed, in many embodiments,
these techniques are used to fabricate any of a variety of
structures.
[0086] The cross section of the constituent material can be
transformed in any suitable way in accordance with embodiments of
the invention, and is not limited to varying the spatial
relationship of component materials within the constituent
material. For example, as alluded to above, in some embodiments,
the deposited constituent material is coated with a colored
material prior to deposition--in this way, the cross section of the
constituent material is being manipulated insofar as a thin layer
of colored coating is being applied to the constituent material.
Indeed, the cross section of the component material can be modified
in any suitable way in accordance with embodiments of the
invention. In a number of embodiments, the geometry of the cross
section is transformed, and this aspect is now discussed below in
further detail.
Manipulating the Geometry of the Cross Section of the Constituent
Material in Accordance with Embodiments of the Invention
[0087] In many embodiments, the geometry of the cross section of
the constituent material is controllably manipulated during the
deposition process. The geometry can be varied in any number of
ways using any of a variety of techniques. For example, in some
embodiments, a shutter mechanism is adjoined to the nozzle to vary
the geometry of the extruded constituent material; the shutter
mechanism can controllably manipulate the geometry of the extruded
constituent material. FIGS. 17A-17B depict the operation of a
shutter assembly in accordance with embodiments of the invention.
In particular, FIG. 17A depicts that the shutter assembly 1720 is
adjoined to the nozzle 1702 and is in a first non-activated
position, where the constituent material 1706 is extruded into a
base geometry, while FIG. 17B depicts that the shutter assembly
1720 is in an activated position, where the geometry of the cross
section is in a second controlled position. Accordingly, any of a
variety of cross sections can be defined. For example, FIGS.
18A-18F depict a number of cross sections of deposited constituent
material that can be defined using shutter assemblies in accordance
with embodiments of the invention. In particular: FIG. 18A depicts
that a square cross section can be defined; FIG. 18B depicts that
an augmented triangular cross section can be defined; FIG. 18C
depicts that a six-pointed star can be defined; FIG. 18D depicts
that a triangular cross section can be defined; FIG. 18E depicts
that a trapezoid can be defined; and FIG. 18F depicts that a
circular cross section can be defined. While several illustrative
cross sections are illustrated and discussed, it should be clear
that any of a variety of cross section geometries can be
implemented in accordance with embodiments of the invention.
[0088] While the above discussion has regarded manipulating the
cross-section of the deposited constituent material prior to
extrusion, the constituent material can be manipulated prior to
extrusion using any of a variety of methods in accordance with
embodiments of the invention. For example, in some embodiments, the
nozzle head is fabricated from a material that is transparent to
certain electromagnetic wavelengths, e.g. infrared radiation;
simultaneously, the constituent material may be sensitive to
infrared radiation exposure. Thus, prior to extruding the
constituent material, the nozzle head may be exposed to infrared
radiation; because it is transparent to infrared radiation, the
material properties of the constituent material that is within the
nozzle head can be transmuted by the infrared radiation exposure.
In this way, the initiation of the transformation of the material
properties of the constituent material can begin prior to the
extrusion. Of course, it should be appreciated that although the
above example is discussed in connection with infrared radiation,
any suitable electromagnetic wavelength range may be implemented.
More generally, while several examples of manipulating the material
properties of constituent material are given, it should be
understood that the material properties of a constituent material
can be manipulated prior to extrusion in any suitable way in
accordance with embodiments of the invention. The discussed
examples are meant to be illustrative and not exhaustive.
[0089] In general, as can be inferred from the above discussion,
the above-mentioned concepts can be implemented in a variety of
arrangements in accordance with embodiments of the invention.
Accordingly, although the present invention has been described in
certain specific aspects, many additional modifications and
variations would be apparent to those skilled in the art. It is
therefore to be understood that the present invention may be
practiced otherwise than specifically described. Thus, embodiments
of the present invention should be considered in all respects as
illustrative and not restrictive.
* * * * *