AQUAAIAACA TATYAA
`
`US 20060160250A1
`
`as) United States
`a2) Patent Application Publication (1) Pub. No.: US 2006/0160250 Al
`Bonassaret al.
`(43) Pub. Date:
`Jul. 20, 2006
`
`(54) MODULAR FABRICATION SYSTEMS AND
`METHODS
`
`Related U.S. Application Data
`
`(75)
`
`Inventors: Lawrence Bonassar, Ithaca, NY (US):
`Hod Lipson, Ithaca, NY (US); Daniel
`L. Cohen, Ithaca, NY (US); Evan
`Malone, Ithaca, NY (US)
`
`Coiiaapoaians Wadia!
`Michael L. Goldman
`Nixon Peabody LLP
`1300 Clinton Square
`P.O. Box 31051
`Rochester, NY 14603 (US)
`:
`(73) Assignee: Cornell Research Foundation,Inc., Ith-
`aca, NY
`
`(21) Appl. No.:
`
`11/201,057
`
`(22)
`
`Filed:
`
`Aug. 10, 2005
`
`(60)
`
`Provisional application No. 60/600,529,filed on Aug.
`11, 2004. Provisional application No. 60/704,299,
`filed on Aug. 1, 2005.
`Publication Claisification
`
`(51)
`
`Int. Cl.
`HOIL 21/00
`(2006.01)
`(92) WiSeCk semercientaanvanniiens 438/1; 438/5
`(57)
`ABSTRACT
`.
`.
`.
`Thepresent inventionrelates to an article fabrication system
`having a plurality of material deposition tools containing
`one or more materials useful in fabricating the article, and a
`material deposition device havinga tool interface for receiv-
`ing one of the material deposition tools. A system controller
`is operably connected to the material deposition device to
`control operation of the material deposition device. Also
`disclosed is a method of fabricating an article using the
`systemofthe invention and a method of fabricating a living
`three-dimensional structure.
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`~~ 104 106
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`Shenzhen Tuozhu 1010
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`MODULAR FABRICATION SYSTEMS AND
`METHODS
`
`{0001] This application claims thepriority benefit of the
`provisional patent application entitled, “Modular Fabrica-
`tion Systems and Methods,”filed Aug. 1, 2005, with express
`mail certificate number EV652971121US and U.S. Provi-
`sional Patent Application Ser. No. 60/600,529,filed Aug.11,
`2004, which are hereby incorporated by reference in their
`entirety.
`
`FIELD OF THE INVENTION
`
`[0002] The present invention relates generally to anarticle
`fabrication system, a method of fabricating an article, and a
`method of fabricating a living three-dimensional structure.
`
`BACKGROUND OF THE INVENTION
`
`{0003] Solid freeform fabrication (“SFF”) is the name
`given to a class of manufacturing methods which allow the
`fabrication of three-dimensional structures directly from
`computer-aided design (“CAD”) data. SFF processes are
`generally additive, in that material is selectively deposited to
`construct the product rather than removed from a block or
`billet. Most SFF processes are also layered, meaningthat a
`geometrical description ofthe product to be produced is cut
`by a set ofparallel surfaces (planar or curved), and the
`intersections ofthe product and each surlace referred to as
`slices or layers—are fabricated sequentially. Together, these
`two properties mean that SFP processes are subject to very
`different constraints than traditional material removal-based
`
`manufacturing. Nearly arbitrary product geometries are
`achievable, no tooling is required, mating parts and fully
`assembled mechanisms can be fabricated in a single step,
`and multiple materials can be combined, allowing function-
`ally graded material properties. New features, parts, and
`even assembled components can be “grown” directly on
`already completed objects, suggesting the possibility of
`using SFFfor the repair and physical adaptation of existing
`products. On the other hand, a deposition process must be
`developed and tuned for each material, geometry is limited
`by the ability of the deposited material to support itself and
`by the (often poor) resolution and accuracy ofthe process,
`and multiple material and process interactions must be
`understood.
`
`[0004] SFF has traditionally focused on printing passive
`mechanical parts or products in a single material. and the
`emphasis of research has been on developing new deposition
`processes (U.S. Pat. No. 5,121,329 to Crump; U.S. Pat. No.
`5,134,569 to Masters; U.S. Pat. No, 5,204,055 to Sachs et.
`al.; and U.S. Pat. No. 5,126,529 to Weiss et. al.), on
`improving the quality, resolution, and surface finish of
`fabricated products, and on broadening the range ofsingle
`materials which can be employed by a given SFF process,
`including biocompatible polymers and other biomaterials
`(Pfister et al., “Biofunctional Rapid Prototyping for Tissue-
`engineering Applications: 3D Bioplotting Versus 3D Print-
`ing,’Journal ofpolymer Science Part A: Polymer Chemistry
`42:624-638 (2004); Landers et al., “Desktop Manufacturing
`of Complex Objects, Prototypes and Biomedical Scaffolds
`by Means of Computer-assisted Design Combined with
`Computer-guided 3D Plotting of Polymers and Reactive
`Oligomers,”Macromolecular Materials and Engineering
`282:17-21 (2000)), and living cells (Roth et al., “Inkjet
`
`Printing for High-throughput Cell Patterning, Biomaterials
`25:3707-3715 (2004)). These improvements have allowed
`freeform fabrication to become a viable means of manutfac-
`turing finished functional parts, rather than only prototypes.
`
`[0005] More recently, the greater utility of freeform fab-
`ricated products having multiple materials has been recog-
`nized, prompting reexamination and novel research into
`processes which can fabricate using multiple materials (U.S.
`Pat, No. 5,260,009 to Penn), and which can thereby produce
`complex articles with a variety of functionality, including
`functionally graded materials (Ouyang et al., “Rapid Proto-
`typing and Characterization of a WC—(NiSiB Alloy) Cer-
`amet/Tool Steel Functionally Graded Material (FGM) Syn-
`thesized by Laser Cladding,” Columbus, Ohio, USA:
`TMS—Miner. Metals & Mater. Soc. (2002); Smurov etal.
`“Laser-assisted Direct Manufacturing of Functionally
`Graded 3D Objects by Coaxial Powder Injection,”*Praceed-
`ings of the SPIE—The International Society for Optical
`Engineering 5399:27 (2004)), electronics, MEMS(Fuller et
`al., “Ink-jet Printed Nanoparticle Microelectromechanical
`Systems,Journal of Microelectromechanical Systems
`11:54-60 (2002). living tissue constructs (Mironov etal.,
`“Organ Printing: Computer-aided Jet-based 3D Tissue Engi-
`neering.” Trends in Biotechnology 21:157-161 (2003)), and
`compositions of living and nonliving materials (Sun et al.,
`“Multinozzle Biopolymer Deposition for Tissue Engineer-
`ing Application.” 6'* International Conference on Tissue
`Engineering, Orlando, Fla. (Oct. 10-13, 2003); International
`Patent Application No. PCT/US2004/015316 to Sunetal.;
`and U.S. Pat. No, 6,905,738 to Ringeisenet al.), All of these
`systems still depend upon a small fixed set of deposition
`process technologies, and are therefore limited to the mate-
`rials which can be adaptedto those processes, by the effects
`ofthose particular processes on the materials, and by the
`fabrication rates and resolutions of those processes.
`In
`particular,
`the system of U.S. Pat. No. 6,905,738 to
`Ringeisen et al., requires that
`for every material
`to be
`deposited, a two material system be developed comprising
`the material
`to be transferred, and a compatible matrix
`material which is vaporized by the laser in order to propel
`the transfer material to the substrate. In addition,this system
`has only demonstrated fabrication of thin films of materi-
`als—its ability to deposit many layers of materials is not
`well established. The system and method of Sun et al.,
`“Multinozzle Biopolymer Deposition for Tissue Engineer-
`ing Application,” 6" International Conference on Tissue
`Engineering, Orlando, Fla. (Oct. 10-13, 2003) and Interna-
`tional Patent Application No. PCT/US2004/015316 to Sun
`et al.,
`is limited to a fixed set of four deposition processes
`and requires that the alginate materials be deposited into a
`bath ofliquid crosslinking agent—alimitationit shares with
`the work ofPfister et al., “Biofunctional Rapid Prototyping
`for Tissue-engineering Applications: 3D Bioplotting Versus
`3DPrinting, Journal ofPolymer Science Part A: Polymer
`Chemistry 42:624-638 (2004) and Landerset al., “Desktop
`Manufacturing of Complex Objects, Prototypes and Bio-
`medical Scaffolds by Means of Computer-assisted Design
`Combined with Computer-guided 3D Plotting of Polymers
`and Reactive Oligomers,”Macromolecular Materials and
`Engineering 282:17-21 (2000). In addition, none of these
`systems explicitly measures the properties of, and monitors
`and controls the conditions experienced by the fabrication
`materials,
`the fabrication substrate, and the article under
`construction before, during. and/or afier fabrication as an
`
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`US 2006/0160250 Al
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`intrinsic part of the fabrication process and manufacturing
`plan. The fabrication process is thus limited to the spatial
`control of material placement onrelatively simple, passive
`substrates. Temporal control of the evolution of material
`properties is therefore not possible, and complex substrates
`whose state must be controlled and monitored continuously
`are not readily accommodated. Fabricating into or onto
`substrates, such as living organisms or devices which must
`remain in operation continuously, is problematic.
`
`[0006] A major challenge in orthopaedic tissue engineer-
`ing is the generation of seeded implants with structures that
`mimic native tissue, both in terms of anatomic geometries
`and intratissue cell distributions, Previous studies have
`demonstrated that
`techniques such as injection molding
`(Chang etal., “Injection Molding of Chondrocyte/Alginate
`Constructs in the Shape of Facial Implants,"J. Biomed. Mat.
`Res, 55:503-511 (2001)) and casting (Hung et al., “Ana-
`tomically Shaped Osteochondral Constructs for Articular
`Cartilage Repair’J. Biomech. 36:1853-1864 (2003)) of
`hydrogels can generate cartilage tissue in complex geom-
`etries. Other studies have investigated methods to reproduce
`regionalvariationsinarticular cartilage constructs by depos-
`iting multiple layers of chondrocytes (Klein et al., “Tissue
`Engineering ofStratified Articular Cartilage from Chondro-
`cyte Subpopulations,”Osteoarthritis Cartilage 11:595-602
`(2003)) or chondrocyte-seeded gels (Kim et al., “Experi-
`mental Model for Cartilage Tissue Engineering to Regener-
`ate the Zonal Organization of Articular Cartilage,”Osteoar-
`thritis Cartilage 11:653-664 (2003)). However,
`there
`remains no viable strategy for rapidly producing implants
`with correct anatomic geometries and cell distributions.
`Recently, advances in SFF techniques have enabled the
`deposition of multilayered structures composed of multiple
`chemically active materials (Malone etal., “Freeform Fab-
`rication of 3D Zine-Air Batteries and Functional Electro-
`Mechanical Assemblies,”Rapid Prototyping Journal 10:58-
`69 (2004)). Applicants believe that this technology has the
`potential to be adapted to the fabrication ofliving tissue
`under conditions that preserve cell viability.
`
`[0007] The present invention is directed at overcoming
`disadvantages ofprior art approaches and satisfying the need
`to establish a robust and reliable SFP system and method.
`
`SUMMARY OF THE INVENTION
`
`[0008] One aspect of the present invention relates to an
`article fabrication system. The system has a plurality of
`material deposition tools containing one or more materials
`useful in fabricating the article. The system has a material
`deposition device having a tool interface for receiving the
`material deposition tools, the tool interface of the material
`deposition device being movable relative to a substrate to
`dispense material from the material deposition tool to the
`substrate. A system controller is operably connected to the
`material deposition device to control operation ofthe mate-
`rial deposition device.
`
`[0009] Another aspect ofthe present inventionrelates to a
`method of fabricating an article. This method involves
`providing the above-described article fabrication system.
`Material
`is dispensed from the material deposition tools,
`when mounted on the tool interface of the material deposi-
`tion device, in amounts andat positions on the substrate in
`response to instructions fromthe system controller, whereby
`an article is fabricated on the substrate.
`
`[0010] A further aspect of the present invention relates to
`a methodoffabricating a living three-dimensional structure.
`This method involves providing a data set representing a
`living three-dimensional structure to be fabricated. One or
`more compositions including a composition having a hydro-
`gel with seeded cells is provided, The one or more compo-
`sitions are dispensed in a pattern in accordance withthe data
`set suitable to fabricate the living three-dimensional struc-
`ture.
`
`[0011] Yet another aspect ofthe present invention relates
`to an article fabrication system. The system has a material
`deposition too] containing one or more materials useful in
`fabricating the article. The system has a material deposition
`device having a tool
`interface for receiving the material
`deposition tool, the tool interface of the material deposition
`device being movable relative to a substrate to dispense
`material from the material deposition tool to the substrate.
`The system has an enclosure defining a receptacle for
`enclosing the substrate in a confined environment segregated
`from other components ofthe system and capable of receiv-
`ing material dispensed from the material deposition tool. A
`system controller is operably connected to the material
`deposition device to control operation of the material depo-
`sition device.
`
`(0012] Yeta further aspect of the present invention relates
`to anarticle fabrication system. The system has a material
`deposition tool containing one or more materials useful in
`fabricating the article. The system has a material deposition
`device having a tool
`interface for receiving said material
`deposition tool, the tool interface of the material deposition
`device being movable relative to a substrate to dispense
`material from the material deposition tool to the substrate.
`The system has one or more sensors positioned to detect
`non-geometric properties of material dispensed to the sub-
`strate. A system controller is operably connected to the
`sensors to control detection of material properties and to the
`material deposition device to control the material deposition
`device.
`
`(0013] The present invention relates to an article fabrica-
`tion system having multiple interchangeable material depo-
`sition tools and one or more modules capable of receiving
`material dispensed from material deposition tools. The
`deposition tools may contain interchangeable cartridges
`containing, materials useful
`in fabricating the article. The
`tools and/or the cartridges may also contain apparatus for
`monitoring and conditioning the material for deposition. The
`substrate modules are useful in fabricating the article, and
`mayalso contain apparatus for monitoring and conditioning
`the deposited materials,
`
`[0014] The system may also have a device to automati-
`cally switch tools andtheir cartridges and substrate modules,
`or these may be fixed in the system. A system controlleris
`operably connected to the material tools, cartridges, sub-
`strate modules, transfer devices, and positioning systems.
`The system has provision for monitoring and controlling the
`environmental conditions under which fabrication takes
`place, for monitoring and correcting fabrication errors dur-
`ing the course of fabrication, and for monitoring and con-
`trolling the properties of the article being fabricated during
`the course of fabrication. The combined capabilities ofthe
`system,
`the deposition tools, and the substrate modules
`allow monitoring and control of the conditions experienced
`
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`by all of the materials and by the article being fabricated,
`before. during, and/or after the fabrication process. This
`extends the freeform fabrication process to include con-
`trolled evolution of material properties as well as controlled
`deposition of multiple materials, allowing not just geomet-
`ric, but spatio-temporal control over the properties ofthe
`composite article being fabricated. These extended capabili-
`ties are especially important when fabricating integrated
`systems comprising multiple active materials, such as elec-
`trochemical devices and living tissue constructs. This is also
`the case when depositing constructsinto sensitive substrates,
`such as living organisms or sensing devices, the health and
`function of which must be maintained throughout the fab-
`rication process.
`
`[0015] The present invention’s modular system architec-
`ture and multi-level control scheme give it distinct advan-
`tages over other systems. The modular systemarchitecture
`enables the system ofthe present invention to adapt to high
`throughput applications,
`in which material changes and
`substrate changes must be eflicient and, in some cases, in
`which automation would be beneficial. The modular design
`also enables the system to adapt
`to a broad range of
`applications. For example, the same general system design
`could be used for in vitro as well as in vivo fabrication.
`
`[0016] The multi-level sensing, actuation, control, and
`intelligence enables the system to log and/or control the
`spatio-temporal state of numerous properties ofboth mate-
`rials and articles being fabricated prior, during, and after
`fabrication (for example, from the start of the fabrication
`process through incubation). These material and article
`properties include but are notlimited to temperature, humid-
`ity, light, vibration, pressure, mechanical loading. and shape.
`Spatio-temporal control of numerous properties is important
`when fabricating integrated systems with active materials
`such as electromechanical devices, self-assembling struc-
`tures, and living tissue constructs.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG.1 isa perspective view ofa fabrication system
`[0017]
`in accordance with the present invention.
`
`[0018] FIG. 2 is a perspective view of a material deposi-
`tion device and the tool rack of the system in accordance
`with the present invention in which the tool rack is con-
`nected to the material deposition device.
`
`(0019] FIG. 3 is a front view of a material deposition
`device of a system in accordance with the present invention
`without a material deposition tool attached at
`the tool
`interface.
`
`[0020] FIG. 4 is a front view ofa material deposition tool
`in accordance with the present invention, which is a car-
`tridge holding tool capable of receiving a modular material
`cartridge.
`
`[0021] FIG. 5 is a front view of a material deposition
`device in accordance with the present invention fitted at a
`tool
`interface with a cartridge holding tool capable of
`receiving a modular material cartridge.
`
`FIG.6 is a front view ofa cartridge holding tool in
`[0022]
`which a modular material cartridge carrying a syringe is
`positioned in the cartridge chamber.
`
`[0023] FIG. 7 is a front view of a material deposition
`device of a system in accordance with the present invention
`fitted at the tool interface with a cartridge holding tool in
`which a modular material cartridge carrying a syringe is
`positioned in the cartridge chamber.
`[0024] FIGS, 8A-D are perspective views of a cartridge
`holding tool and material modular syringe cartridge that fits
`into the cartridge holding tool. FIGS. 8A-B illustrate per-
`spective, exploded views ofthe parts of a syringe which fit
`into the syringe cartridge. FIG, 8C illustrates a perspective,
`exploded view of how the syringe fits into the syringe
`cartridge. FIG. 8D illustrates a perspective view of the
`cartridge holding tool fitted with the syringe cartridge.
`
`FIG.9 is a perspective view of a transfer device in
`[0025]
`accordance with the present invention.
`
`[0026] FIG. 10 is a perspective view ofa fabrication
`system in accordance with the present invention in which the
`transfer device is in contact with a material deposition tool
`located on a tool rack. Also shown is the electronic wiring
`of a fabrication system that connects to an external com-
`puter.
`
`[0027] FIG. 11 is a perspective view of a fabrication
`system in accordance with the present invention in which a
`transfer device is replacing a material cartridge in a cartridge
`socket of a material deposition tool connected to a tool
`interlace.
`
`(0028] FIG. 12 is a back view of a material deposition
`device in accordance with the present invention showing a
`sensor attached to the back ofthe tool interface. The sensor
`detects properties of the substrate, of the article being
`fabricated, and of the materials being deposited,
`[0029] FIG. 13 is a perspective view ofa tip calibration
`sensor positioned on a substrate of a material deposition
`device. The tip calibration sensor enables the system con-
`troller to be awareofthe precise location ofa reference point
`onthe tool or tools attached to the tool interface relative to
`the tool interface.
`
`[0030] FIG. 14A isa front view ofa module in accordance
`with the present invention which is attachable to the sub-
`strate. A plan view (FIG, 14B) and a side view (FIG. 14C)
`of the substrate module are also shown.
`
`[0031] FIG. 15 is a perspective view of a module in
`accordance with the presentinvention depictinga receptacle
`into which material from a material deposition device is
`dispensed and examples offixture points, interfaces, and
`sensing and actuation ports which may be included in the
`module.
`
`[0032] FIG. 16 is a perspective view of a module in
`accordance with the present invention in which a receptacle
`is enclosed,
`
`[0033] FIG. 17 is an exploded perspective view of a
`module in accordance with the present invention.
`[0034] FIG. 18 is a perspective view of a fabrication
`system in accordance with the present invention in which a
`module is attached to a substrate.
`
`[0035] FIG. 19 is a perspective view of a fabrication
`system in accordance with the present inventionin whicha
`module having an enclosed receptacle is attached to a
`substrate.
`
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`Jul. 20, 2006
`
`FIGS. 20A-B are photographs showingthe results
`[0036]
`of viability tests in which both live (FIG. 20A) and dead
`(FIG. 20B) cells were detected in printed gels.
`
`[0037] FIG. 21Ais a stereolithography (“STL”) image of
`a bovine meniscus generated by a CT scan. FIG. 21B is a
`photograph ofthe printed meniscus-shaped gel using the
`fabrication system and method of the present invention.
`
`[0038] FIG. 22 is a photograph ofa 1-millimeter thick,
`autoclavable, clear plastic bag used to enclose the substrate
`in a sterile environment.
`
`[0039] FIG. 23 is a photograph of a plastic bag containing
`a printed sample which has been transferred to a sterilized
`hood for removal of a fabricated article.
`
`FIGS. 24.4-L are photographsofprinted gels using
`[0040]
`the fabrication system method of the present
`invention
`compared to images generated by CT scans.
`
`[0041] FIG. 25A-B are photographs of microscope views
`during viability tests using fluorescence microscopyfiltered
`to illuminate living cells (FIG. 25A) andfiltered to illumi-
`nate dead cells (FIG. 25B).
`
`[0042] FIG. 26A is a CAD model image generated from
`a CT sean of a meniscus-shaped pieceof cartilage used in
`fabricating the article shown in FIG, 26B. FIG, 26B is a
`photographofa fabricated article produced by a fabrication
`system in accordance with the present invention.
`
`[0043] FIG. 27A is a CAD model image generated from
`a CT scan of a meniscus-shaped piece of cartilage used in
`fabricating the article shown in FIG, 27B. FIG. 27B is a
`photograph of a fabricated article produced by a fabrication
`system in accordance with the present invention.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`
`[0044] One aspect of the present invention relates to an
`article fabrication system. The system has a plurality of
`material deposition tools containing one or more materials
`useful in fabricating the article. The system has a material
`deposition device having a tool interface for receiving the
`material deposition tools, the tool interface ofthe material
`deposition device being movable relative to a substrate to
`dispense material from the material deposition tool to the
`substrate. A system controller is operably connected to the
`material deposition device to control operation of the mate-
`rial deposition device.
`
`[0045] Another aspect of the present invention relates to
`an article fabrication system. The system has a material
`deposition tool containing one or more materials useful in
`fabricating the article. The system has a material deposition
`device having a tool interface for receiving the material
`depositiontool, the tool interface of the material deposition
`device being movable relative to a substrate to dispense
`material from the material deposition tool to the substrate.
`The system has an enclosure defining a receptacle for
`enclosing the substrate in a confined environment segregated
`from other components ofthe system and capableof receiv-
`ing material dispensed from the material deposition tool. A
`system controller is operably connected to the material
`deposition device to control operation of the material depo-
`sition device.
`
`[0046] A further aspect of the present invention relates to
`an article fabrication system. The system has a material
`deposition too] containing one or more materials useful in
`fabricating the article. The system has a material deposition
`device having a tool interface for receiving said material
`deposition tool, the tool interface of the material deposition
`device being movable relative to a substrate to dispense
`material from the material deposition tool to the substrate.
`The system has one or more sensors positioned to detect
`non-geometric properties of material dispensed to the sub-
`strate. A system controller is operably connected to the
`sensors to control detection of material properties and to the
`material deposition device to control the material deposition
`device.
`
`FIG.1 is a perspective view ofone embodimentof
`(0047]
`the systemofthe present invention. In the particular embodi-
`ment shown in FIG,1, tool rack 4 is connected to material
`deposition device 2. Located near material deposition device
`2 and tool rack 4 is transfer device 100, which is capable of
`making contact with material deposition tool 18 and moving
`material deposition tools 18 between material deposition
`device 2 and tool rack 4.
`
`(0048] Material deposition device 2 and tool rack 4 are
`again illustrated in perspective in FIG, 2, As shown,
`machine base 6 is the general supporting structure of mate-
`rial deposition device 2, Machine base 6 preferably has
`horizontal surface 90 which mayrest on the ground or on a
`flat surface, such as the top of a bench or a table, and two
`vertical surfaces 92-B connected to horizontal surface 90.
`
`In a preferred embodiment, machine base 6 is a large,
`precision granite structure, although other materials may be
`used in the construction of machine base 6 so long as the
`material is capable of dissipating vibration from the high
`acceleration motions that material deposition device 2 is
`capableof.
`
`[0049] Positioning system 8 is preferably a machine
`driven X-Y coordinate gantry supported by machine base 6.
`Positioning system 8 has two X-axis stages, includingfirst
`X-axis stage 10.4 and second X-axis stage 10B, preferably
`constructed of commercially available ballscrew stages.
`X-axis stages 10A-B rest on, and are attached to, vertical
`walls 92A-B of machine base 6. Positioning system 8 is
`preferably
`constructed of
`a
`commercially
`available
`ballscrew stage identical to X-axis stages 10A-B. Y-axis
`stage 12 is fixed, at opposite ends and perpendicular to,first
`X-axis stage LOA and second X-axis stage 10B and spans
`horizontal surface 90.
`
`[0050] Movementat positioning system 8 occurs as Y-axis
`stage 12 moves back and forth along X-axis stages 10A-B.
`This movement
`is driven by motors 404-B which,
`in a
`preferred embodiment, are high-performance brushless DC
`motors with optical encoders for displacement feedback.
`However, any motor which is capable of producing rela-
`tively high acceleration, good velocity regulation, and posi-
`tioning accuracy may be used to operate the movement of
`positioning system 8. In operation, motor 40A drives one
`end of Y-axis stage 12 along X-axis stage 10A while motor
`40B simultaneouslydrives the other end ofy-axis stage 12
`along X-axis stage 10B.
`
`(0051] Another moving componentofpositioning system
`8 is tool interface 20, which resides on Y-axis stage 12 and
`moves back and forth along Y-axis stage 12. Tool interface
`
`30
`
`30
`
`

`

`US 2006/0160250 Al
`
`Jul. 20, 2006
`
`20 is capable ofreceiving a material deposition tool, such as
`material deposition tool 18 illustrated in FIG. 2. As dis-
`cussed in greater detail below, material deposition tool 18
`may receive material cartridges, such as material cartridge
`26. Movement of tool interface 20 along Y-axis stage 12 is
`driven by motor 42, which is preferably a motor similarto,
`or identical to, motors 40A-B. With tool interface 20 being
`capable of moving back and forth along Y-axis stage 12 and
`Y-axis stage 12 being capable of moving back and forth
`along X-axis stages 10A-B, positioning system8 is capable
`of moving tool interface 20 in virtually any direction on a
`horizontal plane above horizontal surface 90.
`
`[0052] Abovehorizontal surface 90 of machine base 6 and
`below positioning system 8 is substrate 16, Substrate 16 is
`a build surface upon which material from material deposi-
`tion tool 18 is deposited. In a preferred embodiment, sub-
`strate 16 is equipped with calibration device 44, which may
`be fixed anywhere onsubstrate 16, but is preferably fixed to
`an outer edge or corner of substrate 16. Calibration device
`44 is described in greater detail below. Substrate 16 is
`preferably constructed of a precision-ground aluminum
`plate, but may be constructed of any material capable of
`ensuring planarity. Substrate 16 rests on support structure
`34, which holds substrate 16 in a horizontal position or,
`alternatively, may be adjusted to change the orientation(i.e.
`angle) of the surface plane of substrate 16 relative to
`positioning system 8. Support structure 34 is preferably of
`rigid construction.
`
`In the particular embodimentillustrated in FIG.2,
`[0053]
`support structure 34 is connected to Z-axis stage 14. Z-axis
`stage 14 is preferably a commercially available ballscrew
`stage, identical to X-axis stag