Apparatus and method for making three-dimensional articles using bursts of droplets

Claim 1

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising: a platform; a build material dispenser positioned adjacent said platform for dispensing build material in a plurality of droplets; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article based upon the article defining data, said processor comprising burst control means for operating said dispenser to dispense a series of bursts of build material toward a series of respective target positions to construct a continuous portion of the article as said dispenser is continuously advanced along the predetermined path of travel, each burst being defined by a plurality of successive droplets dispensed in relatively rapid succession to each other as compared to a last droplet in one burst and an initial droplet in a next succeeding burst so that the build material of the plurality of successive droplets of a burst combines at a respective target position.

Claim 2

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising: a platform; a build material dispenser positioned adjacent said platform for dispensing build material in a plurality of droplets; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article based upon the article defining data, said processor comprising burst control means for operating said dispenser to dispense a series of bursts of build material toward a series of respective target positions to construct a continuous portion of the article as said dispenser is continuously advanced along the predetermined path of travel, each burst being defined by a plurality of successive droplets dispensed in relatively rapid succession to each other as compared to a last droplet in one burst and an initial droplet in a next succeeding burst so that the build material of the plurality of successive droplets of a burst combines at a respective target position.

Claim 21

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising: a platform; a build material dispenser positioned adjacent said platform for dispensing build material in a plurality of droplets; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article based upon the article defining data, said processor comprising burst control means for operating said dispenser to dispense a series of bursts of build material toward a series of respective target positions to construct a continuous portion of the article as said dispenser is continuously advanced along the predetermined path of travel, each burst being defined by a plurality of successive droplets dispensed in relatively rapid succession to each other as compared to a last droplet in one burst and an initial droplet in a next succeeding burst so that the build material of the plurality of successive droplets of a burst combines at a respective target position; said processor further comprising means for operating said dispenser to dispense predetermined ones of said series of bursts with at least one of a different number of droplets and with a different spacing between adjacent bursts along the predetermined path of travel to thereby construct a continuous portion of the article with a relatively uniform thickness.

Claim 22

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising: a platform; a build material dispenser positioned adjacent said platform for dispensing build material in a plurality of droplets; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article based upon the article defining data, said processor comprising burst control means for operating said dispenser to dispense a series of bursts of build material toward a series of respective target positions to construct a continuous portion of the article as said dispenser is continuously advanced along the predetermined path of travel, each burst being defined by a plurality of successive droplets dispensed in relatively rapid succession to each other as compared to a last droplet in one burst and an initial droplet in a next succeeding burst so that the build material of the plurality of successive droplets of a burst combines at a respective target position; said processor further comprising means for operating said dispenser to dispense predetermined ones of said series of bursts with at least one of a different number of droplets and with a different spacing between adjacent bursts along the predetermined path of travel to thereby construct a continuous portion of the article with a relatively uniform thickness.

Claim 26

An apparatus for making a three-dimensional article based upon article defining data, the article including first and second contiguous wall portions defining a corner, said apparatus comprising: a platform; a build material dispenser positioned adjacent said platform for dispensing build material in a plurality of droplets; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article in successive layers based upon the article defining data, said processor comprising corner forming means for constructing the corner in successive layers each of first and second segments corresponding to the first and second wall portions so that respective corner points are provided by the first segment in a first layer and by the second segment in a second layer.

Claim 27

An apparatus for making a three-dimensional article based upon article defining data, the article including first and second contiguous wall portions defining a corner, said apparatus comprising: a platform; a build material dispenser positioned adjacent said platform for dispensing build material in a plurality of droplets; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article in successive layers based upon the article defining data, said processor comprising corner forming means for constructing the corner in successive layers each of first and second segments corresponding to the first and second wall portions so that respective corner points are provided by the first segment in a first layer and by the second segment in a second layer.

Claim 34

An apparatus for making a three-dimensional article based upon article defining data, the article including diverging first and second contiguous wall portions defining an over corner, said apparatus comprising: a platform; a build material dispenser positioned adjacent said platform for dispensing build material in a plurality of droplets; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article in successive layers based upon the article defining data, said processor comprising over corner forming means for constructing the over corner in successive layers each of first and second segments corresponding to the first and second wall portions and while providing respective corner points by at least one drop of build material dispensed from said dispenser along an axis defined by successive corner points at the over corner.

Claim 35

An apparatus for making a three-dimensional article based upon article defining data, the article including diverging first and second contiguous wall portions defining an over corner, said apparatus comprising: a platform; a build material dispenser positioned adjacent said platform for dispensing build material in a plurality of droplets; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article in successive layers based upon the article defining data, said processor comprising over corner forming means for constructing the over corner in successive layers each of first and second segments corresponding to the first and second wall portions and while providing respective corner points by at least one drop of build material dispensed from said dispenser along an axis defined by successive corner points at the over corner.

Claim 42

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising: a platform; a plurality of build material jets positioned adjacent said platform for ejecting build material in a plurality of droplets, said plurality of jets being directed to have a common target position; jet positioning means for advancing said plurality of jets along a predetermined path of travel with respect to said platform, said jet positioning means comprising means for relatively positioning said plurality of jets along three directions and rotating said plurality of jets about two axes with respect to said platform thereby defining five degrees of freedom of movement for said plurality of jets relative to said platform; and a processor for controlling said plurality of jets and said jet positioning means to construct the article based upon the article defining data, said processor comprising control means for operating said plurality of jets to eject respective droplets substantially simultaneously from said plurality of jets.

Claim 43

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising: a platform; a plurality of build material jets positioned adjacent said platform for ejecting build material in a plurality of droplets, said plurality of jets being directed to have a common target position; jet positioning means for advancing said plurality of jets along a predetermined path of travel with respect to said platform, said jet positioning means comprising means for relatively positioning said plurality of jets along three directions and rotating said plurality of jets about two axes with respect to said platform thereby defining five degrees of freedom of movement for said plurality of jets relative to said platform; and a processor for controlling said plurality of jets and said jet positioning means to construct the article based upon the article defining data, said processor comprising control means for operating said plurality of jets to eject respective droplets substantially simultaneously from said plurality of jets.

Claim 45

A method for making a three-dimensional article based upon article defining data using an apparatus of a type including a platform, and a build material dispenser positioned adjacent the platform for dispensing build material in a plurality of droplets, said method comprising the steps of: advancing the dispenser along a predetermined path of travel with respect to the platform; and operating the dispenser to dispense a series of bursts of build material at a series of respective target positions to construct a continuous portion of the article as the dispenser is continuously advanced along the predetermined path of travel to thereby construct the article based upon the article defining data, each burst being defined by a plurality of successive droplets dispensed in relatively rapid succession to each other as compared to a last droplet in one burst and an initial droplet in a next succeeding burst so that the build material of the plurality of successive droplets of a burst combines at a respective target position.

Claim 46

A method for making a three-dimensional article based upon article defining data using an apparatus of a type including a platform, and a build material dispenser positioned adjacent the platform for dispensing build material in a plurality of droplets, said method comprising the steps of: advancing the dispenser along a predetermined path of travel with respect to the platform; and operating the dispenser to dispense a series of bursts of build material at a series of respective target positions to construct a continuous portion of the article as the dispenser is continuously advanced along the predetermined path of travel to thereby construct the article based upon the article defining data, each burst being defined by a plurality of successive droplets dispensed in relatively rapid succession to each other as compared to a last droplet in one burst and an initial droplet in a next succeeding burst so that the build material of the plurality of successive droplets of a burst combines at a respective target position.

Claim 57

A method for making a three-dimensional article based upon article defining data using an apparatus of a type including a platform, and a build material dispenser positioned adjacent the platform for dispensing build material in a plurality of droplets, the article including first and second contiguous wall portions defining a corner, said method comprising the steps of: advancing the dispenser along a predetermined path of travel with respect to the platform; operating the dispenser to construct the article in successive layers based upon the article defining data; and constructing the corner in successive layers each of first and second segments corresponding to the first and second wall portions so that respective corner points are provided by the first segment in a first layer and by the second segment in a second layer.

Claim 58

A method for making a three-dimensional article based upon article defining data using an apparatus of a type including a platform, and a build material dispenser positioned adjacent the platform for dispensing build material in a plurality of droplets, the article including first and second contiguous wall portions defining a corner, said method comprising the steps of: advancing the dispenser along a predetermined path of travel with respect to the platform; operating the dispenser to construct the article in successive layers based upon the article defining data; and constructing the corner in successive layers each of first and second segments corresponding to the first and second wall portions so that respective corner points are provided by the first segment in a first layer and by the second segment in a second layer.

Claim 60

A method for making a three-dimensional article based upon article defining data using an apparatus of a type including a platform, and a build material dispenser positioned adjacent the platform for dispensing build material in a plurality of droplets, the article including diverging first and second contiguous wall portions defining an over corner, said method comprising the steps of: advancing the dispenser along a predetermined path of travel with respect to the platform; operating the dispenser to construct the article in successive layers based upon the article defining data; and constructing the over corner in successive layers each of first and second segments corresponding to the first and second wall portions and while providing respective corner points by at least one drop of build material dispensed from the dispenser along an axis defined by successive corner points at the over corner.

Claim 61

A method for making a three-dimensional article based upon article defining data using an apparatus of a type including a platform, and a build material dispenser positioned adjacent the platform for dispensing build material in a plurality of droplets, the article including diverging first and second contiguous wall portions defining an over corner, said method comprising the steps of: advancing the dispenser along a predetermined path of travel with respect to the platform; operating the dispenser to construct the article in successive layers based upon the article defining data; and constructing the over corner in successive layers each of first and second segments corresponding to the first and second wall portions and while providing respective corner points by at least one drop of build material dispensed from the dispenser along an axis defined by successive corner points at the over corner.

Claim 63

A method for making a three-dimensional article based upon article defining data using an apparatus of a type including a platform, a plurality of build material jets positioned adjacent the platform and aligned for ejecting build material in a plurality of respective droplets toward a common target position, and jet positioning means for relatively positioning the plurality of jets along three directions and rotating the plurality of jets about two axes with respect to the platform thereby defining five degrees of freedom of movement for the plurality of jets relative to the platform, said method comprising the steps of: advancing the jets along a predetermined path of travel with respect to the platform and while positioning the jets along five degrees of freedom of movement relative to the platform; and operating the jets to eject respective droplets substantially simultaneously from the plurality of jets.

Claim 64

A method for making a three-dimensional article based upon article defining data using an apparatus of a type including a platform, a plurality of build material jets positioned adjacent the platform and aligned for ejecting build material in a plurality of respective droplets toward a common target position, and jet positioning means for relatively positioning the plurality of jets along three directions and rotating the plurality of jets about two axes with respect to the platform thereby defining five degrees of freedom of movement for the plurality of jets relative to the platform, said method comprising the steps of: advancing the jets along a predetermined path of travel with respect to the platform and while positioning the jets along five degrees of freedom of movement relative to the platform; and operating the jets to eject respective droplets substantially simultaneously from the plurality of jets.

Claim 66

An apparatus for making a three-dimensional article including first and second contiguous wall portions defining a corner based upon article defining data, said apparatus comprising: a platform; a build material dispenser positioned adjacent said platform for dispensing build material in a plurality of droplets; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article based upon the article defining data, said processor comprising burst control means for operating said dispenser to dispense a series of bursts of build material toward a series of respective target positions as said dispenser is advanced along the predetermined path of travel, each burst being defined by a plurality of droplets dispensed in relatively rapid succession so that the build material thereof combines at a respective target position, and means for constructing the corner in successive layers each of first and second segments corresponding to the first and second wall portions so that respective corner points are provided by the first segment in a first layer and by the second segment in a second layer.

Claim 67

An apparatus for making a three-dimensional article including first and second contiguous wall portions defining a corner based upon article defining data, said apparatus comprising: a platform; a build material dispenser positioned adjacent said platform for dispensing build material in a plurality of droplets; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article based upon the article defining data, said processor comprising burst control means for operating said dispenser to dispense a series of bursts of build material toward a series of respective target positions as said dispenser is advanced along the predetermined path of travel, each burst being defined by a plurality of droplets dispensed in relatively rapid succession so that the build material thereof combines at a respective target position, and means for constructing the corner in successive layers each of first and second segments corresponding to the first and second wall portions so that respective corner points are provided by the first segment in a first layer and by the second segment in a second layer.

Claim 68

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising: a platform; a build material dispenser positioned adjacent said platform for dispensing build material in a plurality of droplets; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform, said dispenser positioning means comprising means for relatively positioning said dispenser along three directions and rotating said dispenser about two axes with respect to said platform thereby defining five degrees of freedom of movement for said dispenser relative to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article based upon the article defining data, said processor comprising burst control means for operating said dispenser to dispense a series of bursts of build material toward a series of respective target positions as said dispenser is advanced along the predetermined path of travel, each burst being defined by a plurality of droplets dispensed in relatively rapid succession so that the build material thereof combines at a respective target position.

Claim 69

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising: a platform; a build material dispenser positioned adjacent said platform for dispensing build material in a plurality of droplets; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform, said dispenser positioning means comprising means for relatively positioning said dispenser along three directions and rotating said dispenser about two axes with respect to said platform thereby defining five degrees of freedom of movement for said dispenser relative to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article based upon the article defining data, said processor comprising burst control means for operating said dispenser to dispense a series of bursts of build material toward a series of respective target positions as said dispenser is advanced along the predetermined path of travel, each burst being defined by a plurality of droplets dispensed in relatively rapid succession so that the build material thereof combines at a respective target position.

Claim 70

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising: a platform; a build material jet positioned adjacent said platform for dispensing build material in a plurality of droplets, said jet comprising a housing and a piezoelectric actuator positioned within said housing for dispensing the plurality of droplets of build material therefrom; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article based upon the article defining data, said processor comprising burst control means for operating said dispenser to dispense a series of bursts of build material toward a series of respective target positions as said dispenser is advanced along the predetermined path of travel, each burst being defined by a plurality of droplets dispensed in relatively rapid succession so that the build material thereof combines at a respective target position.

Claim 71

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising: a platform; a build material jet positioned adjacent said platform for dispensing build material in a plurality of droplets, said jet comprising a housing and a piezoelectric actuator positioned within said housing for dispensing the plurality of droplets of build material therefrom; dispenser positioning means for advancing said dispenser along a predetermined path of travel with respect to said platform; and a processor for controlling said dispenser and said dispenser positioning means to construct the article based upon the article defining data, said processor comprising burst control means for operating said dispenser to dispense a series of bursts of build material toward a series of respective target positions as said dispenser is advanced along the predetermined path of travel, each burst being defined by a plurality of droplets dispensed in relatively rapid succession so that the build material thereof combines at a respective target position.

Claim 72

A method for making a three-dimensional article based upon article defining data using an apparatus of a type including a platform, a plurality of build material jets positioned adjacent the platform and aligned for ejecting build material in a plurality of respective droplets toward a common target position, and jet positioning means for relatively positioning the plurality of jets along three directions and rotating the plurality of jets about two axes with respect to the platform thereby defining five degrees of freedom of movement for the plurality of jets relative to the platform, said method comprising the steps of: advancing the jets along a predetermined path of travel with respect to the platform and while positioning the jets along five degrees of freedom of movement relative to the platform; and operating the dispenser to dispense a series of bursts of build material at a series of respective target positions as the dispenser is advanced along the predetermined path of travel to thereby construct the article based upon the article defining data, each burst being defined by a plurality of droplets dispensed in relatively rapid succession so that the build material thereof combines at a respective target position.

Claim 73

A method for making a three-dimensional article based upon article defining data using an apparatus of a type including a platform, a plurality of build material jets positioned adjacent the platform and aligned for ejecting build material in a plurality of respective droplets toward a common target position, and jet positioning means for relatively positioning the plurality of jets along three directions and rotating the plurality of jets about two axes with respect to the platform thereby defining five degrees of freedom of movement for the plurality of jets relative to the platform, said method comprising the steps of: advancing the jets along a predetermined path of travel with respect to the platform and while positioning the jets along five degrees of freedom of movement relative to the platform; and operating the dispenser to dispense a series of bursts of build material at a series of respective target positions as the dispenser is advanced along the predetermined path of travel to thereby construct the article based upon the article defining data, each burst being defined by a plurality of droplets dispensed in relatively rapid succession so that the build material thereof combines at a respective target position.