Method and system for direct writing, editing and transmitting a three dimensional part and imaging systems therefor

Abstract

A method and apparatus for creating three dimensional solid forms in metals, ceramics, organics or any combination thereof is made possible using a computer controlled system to create local environmental conditions that favor deposition from a material stream, precursor gas, weld process or plasma. In order to increase control and accuracy, the material can also be placed while the target area is monitored by a broadband poly-spectral imaging system, which provides dimensional, geometrical, chemical composition, stress and temperature feedback to the computer controlling the process. The local environmental conditions in the deposition area are controlled for magnetic, electric, and acoustic fields as well as for temperature, pressure, flow dynamics, and atmospheric composition. Complex materials can be “written” to match a computer's file of a three dimensional shape with virtually any material composition, surface finish, and geometrical complexity. Discrete components, such as microspheres, optical, electronic or any other components or materials that do not lend themselves to the deposition process, can be inserted and the shape written around them to make them an integral part of the final form. While the system can “write” a three-dimensional shape it can also be used to “erase” some or all of a shape. The environmental conditions can also be changed so that material can be removed under computer controlled so that any corrections or final features can be created including such operations as final polishing or surface finishing. The digital files containing the three-dimensional image, environmental and compositional data can be sent to remote locations where the data can be used to write a new three dimensional object.