Crucible and spindle for a variable size drop deposition system

Abstract

An apparatus for forming three-dimensional objects includes a crucible (1) for holding a molten material; a conically-shaped orifice (1a) having a fixed outlet diameter (do) at the bottom of the crucible through which a jet (50) of the molten material flows towards the substrate; and an oscillating mechanical member (5) for breaking the flow of molten material into the molten material drops (60). The oscillating mechanical member further includes a conically-shaped head (5a) for cooperating with the orifice (1a) and for varying the effective size of the orifice. The conically-shaped head includes a slanted radial portion (5c) and a tip portion (5b) extending through the orifice. The effective diameter (deff) of the jet is defined by the relationship deff=[d02−(d0−δ tan θ)2]1 / 2, wherein δ represents the amount of the tip portion extending through the orifice, and θ represents a slant angle corresponding to the slanted radial portion of the conically-shaped head.

Description

FIELD OF THE INVENTION [0001] The present invention relates to an apparatus for manufacturing a three-dimensional object. More specifically, the present invention relates to an improved crucible and spindle design for a drop deposition system. BACKGROUND OF INVENTION [0002] Manufacturing processes utilizing deposition techniques have been developed for rapid prototyping of three-dimensional parts and tooling. For example, in U.S. Pat. Nos. 5,301,863, 5,301,415, 5,207,371 and 5,286,573 to Prinz et al., conventional systems and methods are disclosed for manufacturing three-dimensional objects by forming using thermal spray or weld deposition techniques to deposit material layers on a work surface. See also U.S. Pat. No. 5,266,098 to Chun et al. [0003] Drop generators have also been developed and applied to the rapid prototyping of three-dimensional objects. See P. F. Jacobs, Rapid Prototyping and Manufacturing, ch. 16 (Society of Manufacturing Engineers 1992). In a conventional drop g...

AI Technical Summary

Benefits of technology

The present invention provides an apparatus for manufacturing a three-dimensional object using a continuously variable diameter liquid jet to create variable drop sizes. The apparatus includes a crucible and spindle apparatus with an improved design that overcomes the limitations of conventional drop deposition systems. The crucible holds a reservoir of molten material, and an orifice with a fixed diameter is provided in the bottom of the crucible through which a jet of the molten material flows towards the substrate. An oscillating mechanical member with a conically-shaped head is provided for varying the effective size of the orifice and breaking the flow of molten material into the molten material drops. The conically-shaped head has a slanted radial portion and a tip portion extending through the orifice, and the effective diameter of the orifice is defined by the equation deff=[d02−(d0−δ tan θ)2]1 / 2. The technical effects of the invention include improved precision and accuracy in the creation of three-dimensional objects using a liquid jet deposition method.

Problems solved by technology

The manufacturing capabilities of conventional drop generators, however, remain limited by the relatively small range of possible drop sizes.

Despite the variability of external oscillation, the possible range of drop sizes from a conventional drop generator is limited by the fixed injector diameter, which is typically less than one millimeter.

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