`
`;
`
` FOREIGN PATENT DOCUMENTS
`US 2011/0282482 Al——Nov. 17, 2011
`EP
`1262305
`/2006
`JP
`2001-270096
`10/2001
`OTHER PUBLICATIONS
`
`65
`
`51)
`
`Prior Publication Data
`
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`
`
`
`US 9,156,204 B2
`(10) Patent No:
`a2) United States Patent
`Knighton
`(45) Date of Patent:
`Oct. 13, 2015
`
`
`US009156204B2
`
`54) HYBRID SCANNER FABRICATOR
`
`75)
`
`73)
`
`a
`
`:
`.
`Inventor: Mark S. Knighton, Santa Monica, CA
`(US)
`
`Assignee: Synerdyne Corporation, Santa Monica,
`CA (US)
`“
`:
`:
`‘
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`USS.C. 154(b) by 249 days.
`
`eos
`Notice:
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`> Auboera
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`Int. Cl.
`BOSC 19/00
`BOSB 7/06
`BOSC LIAO
`B29C 67/00
`(52) U.S.CL
`CPG: saves sees semererrensas B29C 67/0055 (2013.01)
`(58) Field of Classification Search
`USPC onsen 118/308, 309, 313-315, 666, 667, 712,
`118/713, 665, 697, 698; 425/375, 135, 145,
`425/162, 166, 150, 131.1, 60
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`References Cited
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`
`Synerdyne Corporation, PCT Search Report and Written Opinion
`mailed Feb. 8, 2012; PCT/US201 1/035260.
`(Continued)
`
`Primary Examiner — Yewebdar Tadesse
`(74) Attorney, Agent, or Firm — Blakely Sokoloff Taylor &
`Zafman LLP
`
`ABSTRACT
`(57)
`A system and methodto fabricate three dimensional objects.
`A set of fabricationtools includeat least a coarse deposition
`head and a fine additive head, a fine subtractive head or both
`employed concurrently within a single housing. A scanner
`may also be used within the housing to perform interleaved
`scanning ofthepartial fabrication during the fabrication. The
`process may be adjusted based on the scanresults.
`
`7 Claims, 4 Drawing Sheets
`
`(56)
`
`U.S. PATENT DOCUMENTS
`
`3,013,925 A
`4,589,830 A
`4,752,352 A
`5,260,009 A
`5,303,141 A
`5,398,193 A *
`
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`deAngelis oo... 700/119
`
`
`
`
`COARSE
`SUBTRACTIVE
`HEAD
`NOZZLE
`
`
`
`
`
`
`
`30
`SCANNER
`
`XYZ SERVO TABLE
`
`
`
`1
`
`Shenzhen Tuozhu 1005
`
`1
`
`Shenzhen Tuozhu 1005
`
`

`

`US 9,156,204 B2
`
`Page 2
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`(56)
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`Synerdyne Corporation, et al., PCT Search Report mailed Apr. 9,
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`2012; PCT/US2011/051839.
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`ynerdyne Corporation, International Preliminary Report on Patent-
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`9 pages.
`
`
`
`
`
`* cited by examiner
`
`2
`
`

`

`US. Patent
`
`Oct. 13, 2015
`
`Sheet 1 of 4
`
`US 9,156,204 B2
`
`
`
`SALLOVYLENS
`
`de
`
`
`
`S1aVLiOANASZAK
`
`YANNVOS
`
`3
`
`

`

`US. Patent
`
`Oct. 13, 2015
`
`Sheet 2 of 4
`
`US 9,156,204 B2
`
`YOLOW
`
`VIHA
`
`ASHVOO
`
`QVWSH
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`NVOSGe
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`ONISOLINOW
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`
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`
`
`4
`
`
`

`

`U.S. Patent
`
`Oct. 13,2015
`
`Sheet 3 of 4
`
`US 9,156,204 B2
`
`START
`
`ORIENT COARSE NOZZLE
`FOR DEPOSITION
`
`2
`
`2
`
`304
` DEPOSIT MATERIAL
`
`FROM COURSE NOZZLE
`
` INTERLEAVE
`
`
`SCAN?
`
`SCAN
`OBJECT
`
`308
`
`
`
`310
`
`
`
`
` DETAILING
`REQUIRED?
`
`ANALYZE
`SCAN
`
`SUBTRACTIVE HEAD
`
`314
`
`
`
`DETAILING
`CAN BE
`
`
`DEFERRED?
`
`
`YES
`
`
`NO
`
`DETAIL OBJECT WITH FINE
`RESOLUTION ADDITIVE OR
`
`316
`4
`
`NO
`
`318 FABRICATION
`
`
`COMPLETE?
`
`
`YES
`END
`
`FIG. 3
`
`5
`
`

`

`DEPOSITION ZONE
`
`safesyesaepson
`
`Yi
`
`FIG. 4
`
`6
`
`

`

`US 9,156,204 B2
`
`1
`HYBRID SCANNER FABRICATOR
`
`FIELD
`
`The invention relates to a method and apparatusfor fabri-
`cating three dimensional objects. More specifically, embodi-
`ments of the invention relate to a hybrid applicator having
`coarse and fine fabrication capabilities and, in some cases,
`interleaved scanning.
`
`BACKGROUND
`
`Various three dimensionalprinters exist which can be used
`to fabricate a three dimensional object from a digital model.
`Typically, such printers spray downa seriesoffine dots of a
`plastic material perpendicularly to a build surface. The dot
`size is selected to permit creation ofthe minimumfeature size
`desired. As a result, when larger than the minimum feature
`size is desired, many more dots must be accumulatedto create
`the feature. Additionally, a sacrificial material must be used to
`support anyfeatures that are not perpendicularly supported
`by the build surface. As a result, the build process tends to be
`quite slow.
`fabrication systems
`Other existing three dimensional
`employa gel, which is extruded and cured to form a three
`dimensional object. However, this system has manyofissues
`described above and additionally suffers from sagging and
`deformation during cure.
`Additionally, anomalies or inconsistencies within the build
`process camnotbe identified, while the process is occurring.
`Thus, it is only after the time is consumedfor the complete
`fabrication that the finished product may reveal the build was
`unsuccessful. Thus, an entire additional build process must be
`undertaken to create a new object. A morereliable and faster
`apparatus and system for forming three dimensional objects
`from a digital representation is desirable.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`
`
`The embodimentsofthe invention areillustrated by way of
`example and not by wayof limitation
`in the figures of the
`accompanying drawings in which like references indicate
`similar elements. It should be noted that references to an
`embodimentof the invention in this disclosure are not neces-
`sarily to the same embodiment, and they mean at least one.
`FIG. 1 is a schematic diagram of a system of one embodi-
`ment ofthe invention.
`
`FIG.2 is a schematic diagram of a control subsystem for
`one embodimentofthe invention.
`FIG. 3 is a flow diagram of operation according to one
`embodimentof the invention.
`FIG.41s a schematic diagram showing oriented deposition
`according to one embodimentofthe invention.
`
`DETAILED DESCRIPTION
`
`FIG. 1 is a schematic diagram of a system of one embodi-
`mentof the invention. Within the housing 100, a plurality of
`fabrication tools 108 is disposed. Fabrication tools 108 may
`be disposed as a single head or individual independently
`moveable heads. In one embodiment, a coarse print nozzle
`1021s provided to deposit a fabrication material within a work
`space 110 at a granularity of greater than 0.030 square inches
`per deposition. As used herein, granularity greater than x
`meansthat each deposition occupiesan area greater than x.A
`work surface (also referred to as a build surface) 112 provides
`a support for the fabrication of a three dimensional target
`
`2
`object 114. In one embodiment,a plurality of servos move the
`work surface 112 relative to the fabrication tools 108 in x,y.
`z androtational directions responsive to computercontrol.
`In some embodiments, because the coarse nozzle 102 may
`deposit volumes ofmaterial that will not cool quickly enough
`under ambientconditions, an active cooling arm 120 may be
`used to provide active localized cooling to material deposit by
`coarse nozzle 102. In some embodiments, coarse nozzle 102
`mayalso be oriented to a different angular orientations 122
`relative to the work surface 112. This is discussed in more
`detail with reference to FIG. 4 below. In some embodiments
`the cross section of the nozzle 102 may also be changed so
`that a single deposition may have a different shape than a
`subsequentorprior deposition.
`Insome embodiments, also included within the fabrication
`tools 108 is a fine nozzle 104 to deposit smaller amounts of
`material than the coarse nozzle. This permits detailing of an
`object created by the coarse nozzle 102 so that large features
`can be rapidly built with the coarse nozzle 102 and small
`features added with the fine nozzle 104. In one embodiment.
`fine nozzle 104 deposits material with granularity less than
`0.015 square inches per deposition. As used herein, a granu-
`larity of less than x meansa deposited spot occupies an area
`less than x. Also included within the fabrication tools 108, in
`one embodimentofthe invention, is a subtractive head 106.
`which can subtractivelydetail the object 114. In one embodi-
`ment, subtractive head 106 is a computer controlled milling
`bit. In some embodiments, performing the subtractive detail-
`ing before addition of a subsequent layer, access to detail
`desired features can be assured.
`In one embodimentofthe invention, a three dimensional
`scanner 130 is provided within the housing 100 to scan the
`object 114 during fabrication. This permits the fabrication
`processto be adjusted responsiveto identification ofvariance
`in the fabricated object 114 from the intended object as
`reflected in the digital model sourcing the data for the fabri-
`cation. In some embodiments, a scanner 130 mayuse laser
`ranging to create the three dimensional modelofthe work in
`process 114, Other scanning methods are also within the
`scope and contemplation ofthe invention.
`In some embodiments, the intermediate scanned model
`may be analyzed to determine whethercorrective measures
`may be deferred until later in the fabrication process where
`such deferral would improvetheefficiency ofthe fabrication.
`For example,ifdetailing with fine nozzle 104 may bedeferred
`because it will still be possible to create that detail at a later
`point, then the analysis from the intermediate scan may cause
`the deferral ofthat detailing. However, where that aspect may
`or will no longer be accessible after further fabricationsteps,
`the corrective action or detailing action must be taken before
`such subsequent fabrication actions obscure the area to be
`detailed.
`In some embodiments, such as shownin FIG.1. the fabri-
`cation tools 108 and scanner 130 remain fixed and the work
`surface 112 is movedto effect the relative motion between the
`point object and the tool 108 and scanner 130. In other
`embodiments, the tools 108 and scanning 130 move more
`while the target object remainsfixed. Additionally, while and
`embodiment with a coarse nozzle and a fine nozzle is
`
`described and shown, a system employing a range ofmultiple
`nozzles is within the contemplation of the invention.
`FIG. 2 is a schematic diagram of a control subsystem for
`one embodimentof the invention. A controller 200 interacts
`
`witha pluralityof drivers 208, a three dimensional scan head
`204, and monitoring software 202. Controller 200 uses a
`digital model of an object to be fabricated to instruct the
`drivers 208.
`
`20
`
`25
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`30
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`40
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`
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`
`7
`
`

`

`US 9,156,204 B2
`
`3
`During fabrication controller 200 mayperiodically initiate
`ascan ofthe partial object using scan head 204, The resulting
`scan data may beprovided to the monitoring software module
`202, which may conduct an analysis. For example, monitor-
`ing software module 202 may perform comparisonofexisting
`source model relative to what has been built in the partial
`object. The comparison mayreflect a need to modify one or
`more aspects of the build, or do additional additive or sub-
`tractive detailing. An evaluation mayalso be undertakento
`determine whethersuch additional detailing maybe deferred.
`The deferral ofthe detailing should be undertaken where such
`deferral makes where such deferral makes the overall fabri-
`
`cation moreefficient. For example, where deferral of detail-
`ing reduces the number of movements the object must
`ndergo in the process. Deferral should generally not be
`ndertaken whenthereis no efficiency gain or where it mayor
`will not be possible to perform detailingat a later point during
`the process. Drivers 208 include servo driversto drive notions
`210, 212, 214, and 216 to drive therelative motion between
`he work surface (112 in FIG.1) andthe fabricationtools (108
`in FIG. 1). As shown, motor 210 controls x motor, motor 212
`controls y motion, motor 214 controls z motor and motor 216
`controls rotation. An additional driver drives motor 218,
`which controls the orientation and cross section ofthe coarse
`
`oot
`
`nozzle. Additionally drivers 208 to include drivers to drive
`fine head deposition 220 coarse deposition 222 and the mill
`motor 224.
`
`FIG. 3 is a flow diagram of operation according to one
`embodimentofthe invention. At block 302, the coarse nozzle
`is oriented for desired angular deposition relative to the
`underlying material. In some cases, the model nozzle may
`deposit perpendicularly achieving a flat deposition zone 302
`as shown in FIG.4. In othercases, the nozzle maybe oriented
`to deposit an angle6 relative to the perpendicular to achieve
`an angular deposition zone 404 in FIG. 4.
`At block 304, the systemdrives the coarse nozzle to deposit
`material in the orientation selected at block 302. At decision
`block 306, a determination is made whether a scan should be
`interleaved at this point in the fabrication process. If a scan
`shouldbeinterleaved the object is scanned at block 308 and
`the three dimensional model ofthe partial objectis created. At
`block 310, the scan ofthe partial object is analyzedrelativeto,
`for example, the model on which the fabrication is based to
`evaluate if changes should be madeto the fabrication process
`concurrently.
`For example, variations between the intended design
`reflected in the source model and what has actually been
`created maynecessitate additional detailing or changes in the
`calibration ofthe system. Additionally, determinationscan be
`made whetherdetailing can be deferredto the extent that such
`deferral will improve the efficiency ofthe fabrication process
`by, for example, reducing the numberof the relative move-
`mentof the fabrication headsandthe object.
`A determination is made at decision block 312 whether
`
`detailing is required. f detailing is required at decision block
`314, a determination is made whether to what extent the
`detailing can be deferred. If the detailing is required and
`cannotbe deferred, the object detailed with the fine resolution
`additive or subtractive head at block 316. If no detailing is
`required or after the detailing is complete at block 316, the
`decision is made at decision block 318 wherethe fabrication
`
`is complete. If the fabrication is not complete, the system
`returns for further deposition. Otherwisethe process ends.
`While embodiments ofthe invention are discussed above in
`
`the context of flow diagrams reflecting a particular linear
`order, this is for convenience only. In some cases, various
`operations may be performed in a different order than shown
`
`4
`or various operations may occur in parallel. It should also be
`recognized that some operations described with respect to
`one embodiment may be advantageously incorporated into
`another embodiment. Such incorporation is expressly con-
`templated.
`It should be appreciated that reference throughout this
`specification to “one embodiment” or “an embodiment”
`means that a particular feature, structure or characteristic
`described in connection with the embodimentis includedin at
`
`least one embodimentofthe present invention.Therefore,itis
`emphasized and should be appreciated that two or moreref-
`erences to “an embodiment” or “one embodiment” or “an
`
`alternative embodiment” in various portions of this specifi-
`cation are not necessarilyall referring to the same embodi-
`ment. Furthermore, the particular features, structures or char-
`acteristics may be combined as suitable in one or more
`embodiments ofthe invention.
`
`the invention has been
`In the foregoing specification,
`described with referenceto the specific embodimentsthereof.
`Tt will, however, be evident that various modifications and
`changes can be made thereto without departing from the
`broader spirit and scope of the invention asset forth in the
`appendedclaims. The specification and drawingsare, accord-
`ingly, to be regardedin an illustrative rather than a restrictive
`sense.
`Whatis claimedis:
`
`1. A three dimensional printing apparatus comprising:
`a structure defining a work area;
`an interface to receive digital data defining a geometryfor
`a three-dimensional object to be fabricated;
`at least two different additive nozzlesthat deposit different
`volumes ofmaterial per unit oftime at each nozzle’s spot
`of deposition, one nozzle depositing at least twice as
`muchastheother, the two nozzles including:
`a coarse additive nozzle that deposits a larger volume of
`material per unit of time within the workarea;
`a fine additive nozzle that deposits a smaller volume of
`material per unit of time at a spot within the work area;
`and
`a controller configured to select between the coarse addi-
`tive nozzle and the fine additive nozzle during a build
`process based onthedigital data defining the geometry,
`to cause large features internal to the three-dimensional
`object to be built with the coarse additive nozzle more
`rapidlythan is possible with the fine additive nozzle.
`2. The three dimensional printing apparatus of claim 1
`whereinthe fine additive nozzle comprises a nozzle having a
`spot deposit granularity less than 0.015 square inches at a
`point of deposition.
`3. The three dimensional printing apparatus of claim 1
`whereinthe coarse additive nozzle has a spot deposit granu-
`larity greater than 0.030 square inchesat a point ofdeposition.
`4. The three dimensional printing apparatus of claim 1
`further comprising:
`temperature control subsystemto actively cool a portion of
`the deposit of material more rapidly than an intrinsic
`cooling rate of the material.
`5. The three dimensional printing apparatus of claim 1
`further comprising:
`a three dimensional scanner coupled to the structure to
`capture three dimensional data about the three-dimen-
`sional object being fabricated; and
`a control subsystem that monitors scan head data and con-
`trols the coarse additive fine additive nozzles to adjust a
`fabrication process to improve at least one of the speed
`or accuracy of a fabrication of the three-dimensional
`object.
`
`
`
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`US 9,156,204 B2
`
`5
`6. A three dimensionalprinting apparatus comprising:
`a structure defining a work area;
`an interface to receive digital data defining a geometry for
`a three-dimensional object to be fabricated;
`a coarse nozzle to deposit material at a coarse granularity 5
`within the work area; and
`at least one of a fine granularity additive nozzle or a fine
`granularity subtractive headto detail the material depos-
`ited bythe coarse nozzle; and
`a control subsystem that includes a software module con-
`figured to determine whether access to detail will be
`possible after a subsequent layer of material is depos-
`ited, and whether the fabrication of the three-dimen-
`sional object will be moreefficient per unit oftime when
`the detailing is deferred to a point of later time in the 15
`fabrication.
`
`10
`
`7. The three dimensional printing apparatus of claim 6
`wherein the subtractive mechanism comprises:
`a computer-controlled milling bit.
`RR ROR
`
`20
`
`9
`
`