Multiaxis 3D printing of porous molds for molded fiber part manufacturing
AssigneeMiso Robotics, Inc.
InventorsJoshua Gouled Goldberg, Alexander John Garden
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Abstract
A method of making 3D printed porous mold or filters are disclosed in which the external surface of the mold/filter is formed by a single printed layer of material. Supporting layers are then laid down on the surface layer in way that creates a porous body that of substantially uniform porosity across the entire mold/filter surface. Use of such porous bodies as screens on molds for the manufacture of molded fiber parts are described as well as general uses as filters having 3D exterior surfaces.
Claims19
A porous mold for producing a molded fiber part comprising:
- a 3D porous body having at least a first body surface and a second body surface not coplanar with the first body surface;
- and
- a continuous, porous, fiber contact screen on the first body surface and the second body surface, the fiber contact screen containing a plurality of pores in fluid communication with the 3D porous body, the fiber contact screen created from a set of layers of material bonded together in a continuous fill pattern that, where adjacent to the first body surface, is orthogonal to the first body surface and where adjacent to the second body surface is orthogonal to the second body surface,
- wherein an exterior fiber contact surface of the fiber contact screen is formed by an orthogonally printed outermost layer that follows a contour of the 3D porous body,
- wherein each layer in the set of layers follows the contour of the 3D porous body, and
- wherein the fill pattern is orthogonal to the contour of the 3D porous body to achieve a substantially uniform porosity across the exterior fiber contact surface.
A computer-readable medium storing computer-readable instructions which, when acted upon by a 3D printer, cause the 3D printer to create a porous mold component, the porous mold component comprising:
- a continuous, porous, fiber contact screen to be assembled on a 3D porous body;
- the 3D porous body having at least a first body surface and a second body surface not coplanar with the first body surface;
- and
- the continuous, porous, fiber contact screen containing a plurality of pores in fluid communication with the 3D porous body, the fiber contact screen created from a set of layers of material bonded together in a continuous fill pattern that when assembled with the 3D porous body is orthogonal to the first body surface where adjacent to the first body surface and where adjacent to the second body surface is orthogonal to the second body surface,
- wherein an exterior fiber contact surface of the fiber contact screen is formed by an orthogonally printed outermost layer that follows a contour of the 3D porous body,
- wherein each layer in the set of layers follows the contour of the 3D porous body, and
- wherein the fill pattern is orthogonal to the contour of the 3D porous body to achieve a substantially uniform porosity across the exterior fiber contact surface.
A porous mold for producing a molded fiber part comprising:
- a 3D porous body having a plurality of external surfaces that are not coplanar;
- and
- a continuous, porous, fiber contact screen on the plurality of external surfaces, the fiber contact screen containing a plurality of pores in fluid communication with the 3D porous body, the fiber contact screen created from a set of layers of material bonded together in a continuous fill pattern that, where adjacent to the plurality of external surfaces, is orthogonal to the external surfaces,
- wherein an exterior fiber contact surface of the fiber contact screen is formed by an orthogonally printed outermost layer that follows a contour of the 3D porous body,
- wherein each layer in the set of layers follows the contour of the 3D porous body, and
- wherein the fill pattern is orthogonal to the contour of the 3D porous body to achieve a substantially uniform porosity across the exterior fiber contact surface.
A porous mold for producing a molded fiber part comprising:
- a 3D porous body;
- and
- a continuous, porous, fiber contact screen having a 3D external fiber contacting surface formed by a single 3D printed layer of material that follows a contour of the 3D porous body,
- wherein the fiber contact screen comprises a fill pattern that is orthogonal to the contour of the 3D porous body to achieve a substantially uniform porosity across the 3D external fiber contacting surface.
Dependencies are inferred from the claim text.