System and method for computer automated manufacture with reduced object shape distortion

A system for producing a three-dimensional object from a three-dimensional design generated on a computer machine having improved dimensional accuracy, said object having at least a portion which includes a hollow interior, said system comprising:

• means for generating control signals specifying coordinate points of said three-dimensional object;
• a source of object material from which said object is formed;
• control means receiving said control signals for controlling a reaction of said object material at said coordinate points to form said object in three dimensions form said object material in response to said first control signals;
• a source of support material;
• dispensing means disposed in spaced proximity relative to said object for depositing said support material from said dispensing means to said object being formed;
• and
• support control means for controlling said dispensing means to form a three-dimensional structural support environment physically supporting said object including said hollow interior in situ as said object is being formed, said structural support environment including plural webs supporting said object at plural support points and wherein said webs include tapered edges contacting said object facilitating separation of said web and object.

A method for producing a three-dimensional object which ash been designed on a computer machine of the type which comprises generating control signals specifying three-dimensional coordinate points of said object in a prescribed coordinate system, said method comprising the steps of:

• providing a source of object material from which said object is formed;
• directing quantities of said object material to said three-dimensional coordinate points in response to said control signals to form said object by building said object material upon itself by dispensing a strand of object material in a fluent state in response to said control signals and treating said material after dispensing in controlled relation to said dispensing of said material and subjecting said material to a transition to a fixed physical state in which said material is set in a form of a three-dimensional object;
• providing a source of support material, dispensing and directing said support material from above a plane in which said object is being formed toward said object, independently but in controlled relation to said object material;
• and
• simultaneously forming a three-dimensional support structure from said support material which physically supports said object in situ during formation of said object.

A process for automatically manufacturing a three-dimensional object which has been designed on a computer machine comprising:

• generating control signals specifying the coordinate points of said three dimensional design generated by said computer machine;
• dispensing a strand of material in a fluent physical state in response to said control signals;
• treating said strand of material generally simultaneously as it is dispensed in controlled relation to said dispensing of said fluid material to cause said material to undergo a transition to a fixed, physical state in which said material is set in a form of said three dimensional object;
• and
• simultaneously forming a three-dimensional structural support environment which physically supports said object in situ during formation of said object to reduce warpage and dimensional distortion of said object.

A system for producing a three-dimensional object from a three-dimensional design generated on a computer machine having improved dimensional accuracy comprising:

• means for generating control signals specifying the three-dimensional coordinate points of said object in a prescribed coordinate system;
• a source of object material from which said object is formed;
• at least one working head for directing said object material from said working head to said coordinate points;
• control means for controlling said working head to direct said object material to said three-dimensional coordinate points in response to said control signals to form said object;
• a source of support material;
• support material dispensing means disposed in spaced proximity above said object being formed for dispensing said support material about said object so as to form a three-dimensional structural support environment constructed about said object as said object is being formed for physically supporting said object during formation;
• and
• wherein one of said working head and said support material dispensing means includes means for dispensing material as mass particles while the other of said working head and said support material dispensing means includes means for dispensing material as a fluent strand.