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US 6,441,338 B1Granted
Rapid manufacturing of steel rule dies and other 3-dimensional products, apparatus, process and products
OwnerJoshua E. Rabinovichinventor
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OwnerJoshua E. Rabinovichinventor
Estimating the term…
A model building apparatus includes a beam delivery module and a stage movable in the X, Y and Z directions. A feedstock holding mechanism for the model building apparatus enables the model building apparatus to corrugate the feedstock into a latticed layer. The feedstock holding mechanism includes a feeder housing a spool of feedstock and jaws having push-down arms and side-holding arms. Engaging and disengaging of the feedstock by the jaws while moving the table allows for forming a latticed layer of feedstock that is several times thicker than the thickness of the feedstock. Reducing the total number of layers that comprise the model significantly increases the speed of constructing models that do not require solid walls. The latticed layers may be formed in a continuous process without cutting the feedstock prior to adding a new layer of feedstock, thereby improving the quality of the lattice structure due to less cutting and starting of the feedstock. A fully automatic, computer-controlled process of steel rule die-making goes from CAD design to finished die in a minutes, allowing production of any 3-Dimensional steel rule die.
A model building apparatus comprising a first frame member, a second frame member slidably connected to the first frame member for moving the second frame member independently with respect to the first frame member, a vertical support connected to the second frame member, a rotary stage connected to the vertical support, a platform connected to the rotary stage, a beam source connected to the rotary stage, a focus head and a beam delivery nozzle mounted on the platform, a feedstock delivery module mounted on the platform, a feedstock storing spool mounted on the feedstock delivery module and feedstock stored on the spool, a feedstock nozzle connected to the feedstock delivery module for receiving feedstock from the spool and feeder and for extending feedstock from a tip of the nozzle, the tip of the nozzle being aligned with a beam projected from the beam source to the focus head and through the beam delivery nozzle, a 3-dimensionally movable stage positioned beneath the nozzle for receiving feedstock in a predetermined pattern according to relative movement of the stage for receiving the feedstock extending from the nozzle tip and for fusing the feedstock to a substrate or to a previously fused layer of the feedstock for constructing a model by depositing and fusing successive layers of the feedstock.
A steel rule die producing method comprising delivering feedstock to a substrate that is secured to a stage that is movable in three dimensions, securing an initial layer of the feedstock to the substrate, moving the stage for creating a pattern with the deposited feedstock, securing a subsequent layer of feedstock to a previous layer of feedstock, and repeating the securing of subsequent layers of feedstock by moving the stage in three dimensions until a desired height of the steel rule die is obtained.
A steel rule die producing method comprising delivering feedstock to a substrate that is secured to a stage that is movable in three dimensions, securing an initial layer of the feedstock to the substrate, moving the stage for creating a pattern with the deposited feedstock, securing a subsequent layer of feedstock to a previous layer of feedstock, and repeating the securing of subsequent layers of feedstock by moving the stage in three dimensions until a desired height of the steel rule die is obtained, wherein the delivering feedstock to a substrate further comprises delivering feedstock with a sharpened profile for use as a cutting blade and delivering feedstock with a creased profile for use as a creasing blade.
A steel rule die producing method comprising delivering feedstock to a substrate that is secured to a stage that is movable in three dimensions, securing an initial layer of the feedstock to the substrate, moving the stage for creating a pattern with the deposited feedstock, securing a subsequent layer of feedstock to a previous layer of feedstock, and repeating the securing of subsequent layers of feedstock by moving the stage in three dimensions until a desired height of the steel rule die is obtained, further comprising trimming the feedstock with a tool prior to delivering the feedstock to the substrate.
A steel rule die producing method comprising delivering feedstock to a substrate that is secured to a stage that is movable in three dimensions, securing an initial layer of the feedstock to the substrate, moving the stage for creating a pattern with the deposited feedstock, securing a subsequent layer of feedstock to a previous layer of feedstock, and repeating the securing of subsequent layers of feedstock by moving the stage in three dimensions until a desired height of the steel rule die is obtained, further comprising trimming the feedstock with a tool after delivering the feedstock to the substrate.
A three-dimensional model building method, comprising:
Dependencies are inferred from the claim text.