Apparatus and method for dispensing build material to make a three-dimensional article

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising:

• a platform;
• build material jetting means positioned adjacent said platform for ejecting a plurality of droplets of build material;
• jet positioning means for advancing said jetting means along a predetermined path of travel and controlling an orientation of said jetting means relative to said platform in three directions and rotatably positioning said jetting means about two axes thereby defining five degrees of freedom of movement for said jetting means relative to said platform to construct the article based upon the article defining data;
• and
• a supply of build material connected in fluid communication with said jetting means, the build material having predetermined characteristics for permitting successive ejected droplets to adhere to and solidify upon previously ejected and solidified build material defining a generally horizontal build direction angle to thereby permit construction of a cantilevered portion of the article;
• and
• a processor operatively connected to said jetting means and said jet positioning means, said processor further comprising means for positioning said jetting means to eject droplets at an angle of not greater than about 45.degree. from horizontal for the generally horizontal build direction angle while constructing the cantilevered portion of the article.

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising:

• a platform;
• a build material dispenser comprising a jet positioned adjacent said platform for dispensing a plurality of droplets of build material;
• dispenser positioning means for advancing said jet along a predetermined path of travel relative to said platform, said dispenser positioning means comprising means for relatively positioning and orienting said jet with respect to said platform in three directions and rotatably positioning said jet about two axes thereby defining five degrees of freedom of movement for said jet means relative to said platform;
• and
• a supply of meltable build material connected in fluid communication with said jet, the meltable build material having predetermined characteristics for permitting successive dispensed droplets to adhere to and solidify upon previously dispensed and solidified build material defining a generally horizontal build direction.

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising:

• a platform;
• a build material dispenser having an orifice and being positioned adjacent said platform for dispensing a plurality of droplets of build material from said orifice to construct the article based upon the article defining data;
• a reservoir for containing the build material in a liquid state;
• a conduit connected in fluid communication between said reservoir and said dispenser;
• and
• filling means operatively connected to said reservoir for generating a predetermined pressure waveform within said reservoir for filling said conduit and said dispenser when said conduit and said dispenser are empty of build material.

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising:

• a platform;
• a build material dispenser positioned adjacent said platform for dispensing a plurality of droplets of build material;
• dispenser positioning means for advancing said dispenser along a predetermined path of travel relative to said platform;
• a processor for operating said dispenser and said dispenser positioning means to construct the article based upon the article defining data, said processor further comprising test means for operating said dispenser and said dispenser positioning means to construct a test pattern of dispensed and solidified build material;
• and
• test and compensation means operatively connected to said processor for sensing the test pattern and for adjusting a control parameter responsive to the sensed test pattern.

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising:

• a platform;
• a build material dispenser positioned adjacent said platform for dispensing a plurality of droplets of build material;
• dispenser positioning means for advancing said dispenser along a predetermined path of travel relative to said platform;
• and
• a processor for operating said dispenser and said dispenser positioning means to construct the article based upon the article defining data, said processor comprising means for operating said dispenser and said dispenser positioning means to construct a layer of a wall portion of the article in a plurality of side-by-side segments of dispensed and solidified build material formed in a sequence from a first side of the wall portion to a second side thereof, said processor further comprising means for operating said dispenser and said dispenser positioning means to form a next successive layer of the wall portion of the article in a plurality of side-by side segments of dispensed and solidified build material formed in an opposite sequence from the second side of the wall portion to the first side thereof.

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising:

• a platform;
• a build material jet positioned adjacent said platform for ejecting a plurality of droplets of build material;
• and
• jet positioning means for advancing said jet along a predetermined path of travel relative to said platform to construct the article in successive layers;
• said jet having a predetermined configuration so that a lowermost portion thereof, when positioned to jet droplets at an angle not less than about than about 5.degree. from horizontal, does not intersect an imaginary plane defined by a horizontal layer of the article being constructed.

An apparatus for making a three-dimensional article based upon article defining data, said apparatus comprising:

• a platform;
• a build material dispensing positioned adjacent said platform for dispensing a plurality of droplets of build material;
• dispenser positioning means for relatively positioning said dispenser with respect to said platform;
• and
• a processor operatively connected to said dispenser and said dispenser positioning means for advancing said dispenser along a predetermined path of travel while operating said dispenser to construct the article based upon the article defining data, said processor further comprising release structure means for generating a release portion of the article comprising dispensed and solidified build material being separable to thereby facilitate removal of the article from said platform.