Bpm Technology, Inc.

Herbert E Menhennett

Robert B Brown

Charles F Kirschman

William Berdell Barlage, Iii

John Larsen

Michael T Nowak

Jon N Leonard

James Richard Asbury

Manual M Ferreira

A method and apparatus for forming a three-dimensional article includes dispensing build material and thermally normalizing predetermined portions thereof at predetermined intervals during construction of the article. The thermal energy may be provided by a heated body advanced adjacent to or in contact with the surface portions. Thermal energy may also be supplied by a radiation source. The thermal normalization may be performed after a predetermined number of successive layers are dispensed. Related methods are also disclosed.

Apparatus and method for thermal normalization in three-dimensional

A three-dimensional article making apparatus includes a build material dispenser for dispensing build material based upon the article defining data, and a deviation sensor for sensing a deviation during construction of the article. The apparatus may operate the build material dispensing means to adjust or recover for a sensed deviation during construction of the article. A portion of dispensed build material may be removed responsive to a sensed deviation. In addition, the deviation sensor may be operated a plurality of times during construction of the article, and a portion of dispensed build material may be removed down to a previous desired article portion. The deviation sensor may be provided by article formation deviation sensor, a build material dispenser sensor, an article defining data deviation sensor, and/or a build rate deviation sensor. The article deviation sensor may cooperate with a heated electrically conductive body used to periodically dimensionally normalize the article. Method aspects of the invention are also disclosed.

Apparatus and method including deviation sensing and recovery features

A three-dimensional article making apparatus includes a build material dispenser positioned adjacent a platform for ejecting a plurality of droplets of build material; and dispenser positioners for relatively positioning the dispenser in five degrees of freedom with respect to the platform. Accordingly, the dispenser may be rotated and flipped to permit construction of a cantilevered portion of an article without requiring support material. The dispenser positioners include a Z-direction positioner for positioning the dispenser vertically relative to the platform, an X-Y positioner for positioning the dispenser in an X-Y planar direction relative to the platform, a flip angle positioner for rotatably positioning the dispenser relative to a generally horizontal axis, and a phi angle positioner for rotatably positioning the dispenser relative to a generally vertical axis. A processor is operatively connected to the dispenser and the dispenser positioners for advancing the dispenser along a predetermined path of travel while operating or firing the dispenser to construct the three-dimensional article in successive layers or portions based upon the article defining data. Method aspects of the invention are also disclosed.

Apparatus and method for dispensing build material to make a

An apparatus for making a three-dimensional article based upon article defining data may be used to make a mold for the article and molding the article from the mold. Alternately, the apparatus may be used to make articles having filled or solid portions. The apparatus preferably includes a base, a processor for defining a mold skin for producing a mold for the three-dimensional article, and a build material dispenser for dispensing build material responsive to the processor to construct the mold skin extending outwardly from the base and defining at least one cavity. Solidifiable fill material is introduced into the cavity to form solid mold portions. The solid mold portions may be separated from the mold skin, and injection molding, for example, used to mold the three-dimensional article. The base preferably includes a thin plastic layer which is penetrable to permit introduction of the solidifiable fill material into the cavity.

Process of and apparatus for making a three-dimensional article

An apparatus includes a processor for controlling a build material dispenser and a dispenser positioner to construct a three-dimensional article in successive layers based upon article defining data, and wherein the processor operates the dispenser to dispense a series of bursts of build material at a series of respective target positions as the dispenser is advanced along a predetermined path of travel. Each burst is defined by a plurality of droplets dispensed in relatively rapid succession so that the build material thereof combines at a respective target position. The build material dispenser is preferably a jet including a piezoelectric actuator for ejecting a droplet of build material responsive to a corresponding firing signal. Accordingly, the processor generates a predetermined number of firing signals for the piezoelectric actuator corresponding to a desired number of droplets in each burst. Method aspects of the invention are also disclosed.

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Easley, SC, United States of America

Herbert E Menhennett