Honeywell International Inc.

Rutgers, the State University of New Jersey

Alliedsignal Inc.

Stratasys, Inc.

Vikram Ramesh Jamalabad

Stephen C Danforth

Mukesh Agarwala

Ahmad Safari

Noshir Langrana

Charles J Gasdaska

Remco Van Weeren

Amit Bandyopadghyay

William R Priedeman, Jr

Richard A Burne

Milton Ortiz

Philip J Whalen

John P Pollinger

Jeffrey A Chard

Anna Loskiewicz-Buczak

Methods for improving the manufacture of objects made by layered manufacturing techniques through improved tool path generation. A vertex improvement aspect improves tool paths used to form vertices. Outer perimeter vertices can be improved by automatically creating an outer boundary reflecting the design intent to have material extending to the perimeter vertex. The outer boundary can be used as a contour tool path or as a limit to travel by raster tool paths. Boundary vertices within parts can be improved by extending more internal boundary vertices outward toward enclosing vertices, thereby eliminating some internal voids. Contour boundaries near outer perimeter corners can be better defined by extending outward a contour tool path toward the corners. Narrow regions between combinations of outer and/or inner perimeters can be filled through improved tool paths. Layer regions near inner voids can receive consistent filling through an improved raster tool path method. Sub-perimeter voids between raster bead pair turn-arounds and contour beads can be eliminated by automatically adjusting the raster tool path vertices toward the adjacent raster bead pair and/or contour bead.

Tool path planning process for component by layered manufacture

Methods for improving layered manufacturing techniques to improve an objects' surface properties and shorten manufacturing time for support structures. One aspect of the invention forms surfaces having reduced or no concavities between layers having improved crack resistance. One method deposits alternate, surface improvement material on each layer near the future location of the main material surface, followed by deposition of the main material, the edges of which conform to the previously deposited and solidified alternate material. In this method, the center of the main material layers can be concave rather than the interlayer regions. Another aspect of the invention provides removable structures to support the deposition of main material. The support structures provide support over main material cavities for depositing the material to form the cavity ceilings, while minimizing the time and material required to build the support structures. Minimized support structures include structures formed as columns supported by the cavity floor and angle braces to supported by the cavity walls. Some supports are supported by the side wall but not the floor, and other by the floor and not the side walls.

Procedures for rapid build and improved surface characteristics in layered manufacture

Limited range physical entities located in a topological space are dynamically grouped by partitioning the space into grids for different functional domains, a group being associated with each grid that corresponds to a unique functional domain and a unique topological space. A range of effectiveness for each entity is determined and compared with other groups. Each entity is then assigned to be a member of a particular group. The assigning step may comprise calculating a membership value for each entity, the membership value being equal to the ratio of the intersecting space to total space within a group.

Method for dynamically grouping limited range physical entities in a topological space

A fused deposition process is used to form three-dimensional solid objects from a mixture including a particulate composition dispersed in a binder. The article is formed by depositing the mixture in repeated layers of predefined thickness, with each layer solidifying before the next adjacent layer is dispensed. Following formation and a binder removal step, the article may be at least partially densified to achieve preselected properties. The process permits three-dimensional articles to be formed relatively quickly and inexpensively, without the need for molds or other tooling.

Solid freeform fabrication methods

A ceramic component is manufactured rapidly using a mold made directly from a solid freeform manufacturing process. Solid freeform fabrication, or rapid prototyping, procedures are used to generate molds of materials that are soluble or otherwise fugitive. A gel casting suspension containing ceramic and emulsifying agents is poured into the cavity of the mold and caused to set. The mold is then removed by dissolution or heat treatment, leaving intact the gelcast part. Conventional procedures are then utilized to densify the gelcast component to the required final component. Time consuming and expensive machine tooling procedures are virtually eliminated. Ceramic components are generated rapidly in a cost effective manner.

Gel cast molding with fugitive molds

Growing community of inventors

Somerville, NJ, United States of America

Vikram Ramesh Jamalabad