Methods and apparatus for rapidly prototyping three-dimensional objects from a plurality of layers

A method of producing a prototype of a three-dimensional object comprising a plurality of layers, the method comprising the steps of:

• generating a computer model of the three-dimensional object, wherein the computer model is comprised of a sequential plurality of slices, and wherein each slice is a mathematical representation of a corresponding sequential layer of the prototype;
• generating, from each respective sequential slice, a respective machine tool path for cutting a respective sequential layer from a respective sheet of thermoplastic material;
• cutting a first sequential layer having a peripheral edge and an exposed face from a first sheet of thermoplastic material along a respective machine tool path generated for the first sequential layer, wherein the first sequential layer has a thickness of between about 0.02 inches and about 0.25 inches;
• applying a solvent to a face of a second sheet of thermoplastic material;
• placing the second sheet of thermoplastic material in contacting face-to-face relation with the first sequential layer such that the solvent fuses the face of the second sheet of thermoplastic material with the exposed face of the first sequential layer;
• and
• cutting a second sequential layer having a peripheral edge and an exposed face from the second sheet of thermoplastic material along a respective machine tool path generated for the second sequential layer, wherein the second sequential layer has a thickness of between about 0.02 inches and about 0.25 inches.

An apparatus for producing a prototype of a three-dimensional object comprising a plurality of layers, the apparatus comprising:

• a data processing apparatus for generating a computer model of the three-dimensional object, wherein the computer model is comprised of a sequential plurality of slices, wherein each slice is a mathematical representation of a corresponding sequential layer of the prototype, and wherein the data processing apparatus comprises means for generating, from each respective sequential slice, a respective machine tool path for cutting a respective sequential layer from a respective sheet of material;
• means for cutting a first sequential layer having a peripheral edge and an exposed face from a first sheet of material along a respective machine tool path generated for the first sequential layer;
• means for applying a solvent to a face of a second sheet of material;
• means for placing the second sheet of material in contacting face-to-face relation with the first sequential layer such that the solvent fuses the face of the second sheet of material with the exposed face of the first sequential layer;
• and
• means for cutting a second sequential layer having a peripheral edge and an exposed face from the second sheet of material along a respective machine tool path generated for the second sequential layer.

A rapid prototyping system for rapidly producing a prototype of a three-dimensional object comprising a plurality of layers, the system comprising:

• a data processing system, comprising:
• means for generating a computer model of the three-dimensional object;
• means for slicing the computer model into a sequential plurality of slices, wherein each slice is a mathematical representation of a corresponding sequential layer of the prototype;
• and
• means for generating, from each respective sequential slice, a respective machine tool path for cutting a respective sequential layer from a respective sheet of material;
• a three-dimensional part generator in communication with the data processing system, comprising:
• means for removably securing a first sheet of material to a supporting structure;
• means for cutting a first sequential layer having a peripheral edge and an exposed face from the first sheet of material along a respective machine tool path generated for the first sequential layer;
• means for applying a solvent to a face of a second sheet of material;
• means for placing the second sheet of material in contacting face-to-face relation with the first sequential layer such that the solvent fuses the face of the second sheet of material with the exposed face of the first sequential layer;
• and
• means for cutting a second sequential layer having a peripheral edge and an exposed face from the second sheet of material along a respective machine tool path generated for the second sequential layer.