Manufacturing system using topology optimization design software, novel three-dimensional printing mechanisms and structural composite materials

A process for making a three-dimensional object, comprising:

• a. providing a deposition means for releasing and laying material for forming the object onto the stage or onto a object during the accretive manufacture of the object;
• b. providing an articulable positioning means for holding and manipulating the location and orientation of the stage or the object thereon in three-dimensional space;
• c. providing an articulable positioning means for holding and manipulating the location and orientation of the deposition means in three-dimensional space for controlling where the material is laid;
• d. sensing the one or more of the location and orientation of the stage, the articulable positioning means for the stage, the object surfaces, the deposition means, the articulable positioning means for the deposition means, and the material laid, measured in realtime;
• and
• e. controlling the location and orientation of;
• the stage, and then the object surfaces;
• the articulable positioning means for the stage and the articulable positioning means for the deposition means;
• the deposition means and the material laid by the deposition means during operation, including the discharge of material by the deposition means;
• and any subsequent change in the material laid by the deposition means during operation.

An apparatus for making a three-dimensional object, comprising:

• a. a stage for supporting the object during operation, on which the object is made, to which the object may be attached or grasped during operation;
• b. articulable positioning means adapted for engagement with the stage, the positioning means operative for holding and manipulating the location and orientation of the stage and object thereon in three-dimensional space during manufacture of the object;
• c. deposition means having at one end a discharge outlet operative for releasing and laying material for forming the object onto the stage or onto the object during the accretive manufacture of the object;
• d. a material source containing material used to form the object, the material source in fluid flow communication with the deposition means at another end of the deposition means remote from the discharge outlet;
• e. articulable positioning means adapted for engagement with the deposition means, the positioning means operative for holding and manipulating the deposition means in three-dimensional space for controlling where the material is laid;
• f. sensing means for sensing the location and orientation of one or more of the stage, the articulable positioning means for the stage, the object surfaces, the deposition means, the articulable positioning means for the deposition means, and the material laid, measured in real time;
• and
• g. control systems for controlling one or more of:
• i. location and orientation of the stage, and then the object surfaces during operation;
• ii. location and orientation of the articulable positioning means for the stage and the articulable positioning means for the deposition means;
• and
• iii. location and orientation of the deposition means and the material laid by the deposition means during operation, including the discharge of material by the deposition means and any subsequent change in the material laid by the deposition means;
• and
• h. a first software program operable for inputting properties of the material and initial defined load parameters, to provide a model of material deposition for accretive manufacturing.