US 5,184,306 A · Automated high-precision fabrication of objects of complex and unique geometry

Abstract

The present invention provides a method and apparatus for the automated reproduction of three dimensional objects of complex and unique geometry. A computer acquires data describing an object and its surroundings, constructs a computer-based three dimensional model of the object from that data, superimposes an ideal geometry on the computer-based model, alters the ideal geometry to fit the form and function required of the reproduction, and then guides a milling machine in the fabrication of the reproduction. In contrast to the prior art, the present invention does not require human intervention in the reproduction process. The present invention provides two preferred embodiments for the automated high precison reproduction of objects of complex and unique geometry. Both embodiments can machine reproductions solely from generic forms stored in the computer, thus eliminating the need for scanning. Alternatively, the reproductions may be machined solely from scanned data, without resort to generic forms stored in the computer.

Claims52

Dependent claims

A method of machining a reproduction of a 3-dimensional object such that the reproduction substantially duplicates all surfaces of said object, comprising:

(a) retrieving at least one generic form of said object from a computer, said generic form comprised of at least one set of coordinates residing on a plurality of scan lines;
(b) using a computer, automatically identifying feature coordinates in said set of coordinates to emphasize features on said generic form;
(c) generating a plurality of parametric curves extending through said feature coordinates;
(d) generating a parting line through said scan lines to divide said generic form into a plurality of regions to avoid undercuts and associated interferences during machining;
(e) generating a plurality of contour lines between coordinates on adjacent said scan lines, said coordinates including said feature coordinates;
(f) fixturing a material to be shaped into the reproduction of said object such that said material may be machined;
and
(g) transmitting a plurality of tool paths computed from said contour lines from the computer to a machine tool such that said machine tool is directed to machine the reproduction of said object.

5 more elements

An apparatus for machining a reproduction of a 3-dimensional object such that the reproduction substantially duplicates all surfaces of said object, comprising:

(a) at least one computer;
(b) at least one machine tool operatively connected to said computer;
(c) means for scanning said object and recording into the computer at least one set of coordinates;
(d) means for automatically identifying feature coordinates in said set of coordinates to emphasize features on said object;
(e) means for generating a plurality of parametric curves extending through said feature coordinates;
(f) means for computing a plurality of surface patches in the computer from said set of coordinates, said coordinates including said feature coordinates;
(g) means for generating a parting line through said surface patches in the computer to divide said object into a plurality of regions to avoid undercuts and associated interferences during machining;
(h) means for fixturing a material to be shaped into the reproduction of said object such that said material may be machined sequentially by said machine tool through alternate orientation of said material in accordance with said regions;
and
(i) means for transmitting a plurality tool paths corresponding to said surface patches from the computer to said machine tool such that said machine tool is directed to machine the reproduction of said object.

7 more elements

Dependencies are inferred from the claim text.

Automated high-precision fabrication of objects of complex and unique geometry

Life of this patent

Automated high-precision fabrication of objects of complex and unique geometry

Life of this patent

Abstract

Claims52