Note: Descriptions are shown in the official language in which they were submitted.
CA 02204792 1997-0~-08
Apparatus and method for constructing and sculpting shapes
Inventor: Tomasz Duczmal
March 29 1997.
Field of invention
This invention relates to a process and apparatus for constructing and or sculpting 3 dimensional structures
without usmg a solid partem. More particularly, the process uses a computer software to create a
mathematical ~ ,. . ' of a designed structure. Once design of a structure exists as set of XYZ
coordmates, the computer program controls a robot which operates a dispensing or sculpting device.
The dispensing device may release a quickly solidifymg matenal through a nozzle device to construct a
layer of material. The computer directs the dispensing device to add consecutive layers of matenal to erect
the ~ -~d.l ' shape.
Alternatively, a sculpting tool, using either mechanical machining or heat, sculpts a previously formed solid
into a p,. ' ' ' shape.
Background of the invention
As readers skilled in the art will recognize, this invention has a wide range of application. The following
example of ~,~,..~.. ~ " ,, ' '~ " ,, a boat shape is for illustrative purposes only, and does not suggest that
the invention is restricted to this application. In addition, plastic material such a polyurethane, also is used
only for the purpose of illustration. Other materials, such as molten metals, organic or inorganic compound
may be used.
Details of the dispensing or sculpting device may vary; however, the essence of the imvention and the
underlying methodology remains constant:
1. The 3 dimensional structure is created rn the computer memory and is directly translated to a physical
object through a sequential 3D building and/or sculpting process.
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The designer of a boat creates a mental image of the finished product. He imagines a shape of the hull,
construction details and other criteria. Typically, the next step is to puts this vision on paper in the form of
2D projections of the 3D structure. He may use a CAD program to assist the design process. In the next
step, he typically transfers this design onto flat buildmg materials, such as wood or sheet of metal. The 2D
pieces are than fitted together to approximate 3D shape of his design. The process is very labor intensive
and slow. Additionally, after assembling the 3D shape from 2D pieces, labour intensive shaping operations
are required to achieve the desired shape. A similar process is required for other structures such as storage
tanxs, bath tubs, etc.
Therefore, an important addition to the art would occur if a method and apparatus are developed that can
effectively transfer a 3D image of a structure from digital ~ fl~lll into a physical object in one
.~, process without an unnecessaTy 2D phase.
Brief cl~scli~,tion of the drawings
Fig. Ia Ib; sequence of boat building using the described process and apparatus;
Fig 2. Illustration of a dispensing device which illustrates the capability to control width of a wall, height,
and direction of released beads of solidifying material
Fig 3. Illustration of applying simultaneous ,, ~ r I ' usmg rnterwoven fibers.
Fig 4. A schematic diagram of software to control the process to erecting a structure.
Fig 5. Illustration of calculation steps which converts a 3D structure as represented in computer memory, to
series of volume pixels (voxels) allowing construction of an arbitrary shape in one continous process.
Fig 6. Illustration of a sequence of sculpturing using invention.
Fig 7. Illustration of the header arrangement which will create coupling groove for the adjacent layers.
Fig 8. Illustration of the header arrangement with movable wall of the dispenser to ~acilitate tilting o~ the
adjacent layers.
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Detailed ~hs."i~,tion of preferred e.nL ' .:
Fig I a and b illustrate an example of possible arrangement facilitating a boat construction. The support
structure I and 2 enables movement of platform 3 along X axis. Movement is controlled by a step motor
Mx (fig 4).. Platform 3 support's carriage 4 that is controlled by step motor My (fig4). Carriage 4 holds
arm 5 that is controlled by step motor Mz (fig4). This arrangement allows movement of a lower tip of the
arm 5 withrn a space S confined by structure I and 2. To the lower tip of the arm 5 is attached header 6 (fig
2a) using gimbaled joint allowing rotation of the header along axis alpha, beta, gamma. Tipping angle of
the header 6 is controlled by step motors Malpha, Mbeta, Mgamma. Header is constructed from one
stationary plate 8 with semicylinder 9 and plunger 10 (fig 2b), and movable plate 11. Position of disk 11
along plunger 10 is controlled by step motor Md and defines a width of space 12. Such arrangements
define an enclosed space 12 that is continuously filled with polyurethane through the feed port 13. The
velocity of the header movement is synchronizes with the volume of the polyurethane released into the
space 12. The curing time is adjusted to the resident time of the polyurethane inside the header. The
strength of the material required af er passing the confining space 12 shall be sufficient to maintain its
shape. As the header passes over given line in the space S it releases a bead B (fig 2a) of polyurethane and
reproduces layer by layer the shape of the structure from its digitaH~ D~.l~Liu-- (fig Ib). The width d is
deflned by position of plate 11, the height the bead by pitching along axis beta, the direction by yaw along
axis gamma and the position of the bead is controlled by tilt along axis alpha. All those movements
together with XYZ position are synchronized with the material follow F controlled by flow controller Cf.
The information comes sequentially from the digital l~ ,ll of a 3D structure.
In another aspect of the invention, the trailing edge of the semicylinder 9 is shaped into trapezoidal grove
G I and the similar grove G2 is located on the leading edge of header as illustrated on fig 7a. The
polyurethane released into space 12, fills all gaps, and shrinkage of the compound during curing adds
strength to the bonding of the adjacent layers. The grove G2 is not neccessary if G I is a male type as shown
on fig 8a and fig8b.
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Jet another aspect of the invention is illustrated on fig 8. To facilitate tilting consecutive layers as shown on
fig 8b, the plate 8 has a movable part 8a, which facilitates adjustments of the distance d (fig 8a)
Fig 5. Illustrates a mathematical steps necessary to perform construction process using this invention. The
wall of constructed boat B is represented as set of coordinates. The position of planes P are established at
the intenal D(flg Sa). This planes cuts a layers of boat B as illustrated on fig 5b., and software calculates a
coordinates of volume pixels (voxels) its alpha, beta and gamma angles, width and volume. Calculated data
are than put into a matrix of vectors vi as illustrated below.
vO=[O, O, O, O, O, O, dref, volref ]
vl=[delta xl, delta yl, delta zl, delta alphal, delta betal, delta gammal, delta dl, delta voll]
vi=[ delta xi, delta yi, delta zi, delta alphai, delta betai, delta gammai, delta di, delta voli]
This matrix is than sequentially fed into the drivers of stepper motors (fig4), which in turn moves the arm of
the manipulator into position and releases fast solidifying compound at this location. The process of
passing a voxel data is synchronized with material flow and together with high resolution of a voxels it
causes a contrnuos movement of the manipulator and smooth dispensing of a compound (figSc).
Described above apparatus and method allows to build ven, complicated structures effectively and precisely
in one continuous process.
If a strength of the finished structure is an issue than simultaneous fiber ~ ' can be introduced as
illustrated on fig 3. After even, pass of the header and buildup of the next layer a threads of carbon fiber or
glass fiber or any I ~ ~ flber can be interwoven on top of this layer. Even threads (illustrated as
2,4,6 etc. on fig 3) goes across to tbe other side of the shape being constructed and odd threads goes to the
opposite side. The new layer is now wrapped by fibers and strength of the fiber is added to the structure.
~ with header movement a thread A is added to increase strength in longitudinal direction. A
chopped fiberglass can be added to the compound being released into space 12 (fig 2b).
A logical extension of the technology illustrated above is to use the computer logic to control a machbning
or sculptrng device to shape the desrred object from a block of material. A typical example would be to use
CA 02204792 1997-0~-08
a heated electrical wire or knife to machine a l,..,d~; ' ' shape from a block of expanded Styrofoam as
illustrated on fig 6b. To the lower tip of the manipulator arm 5 is attached heated wire bracket (fig 6b) using
gimbaled joint allowing rotation of the frame along axis alpha, beta, gamma. Tipping angle of the bracket
is controlled by step motors Malpha, Mbeta, Mgamma. The width d is defined by position of the vertical
part of the bracket, the height of the bead is established by pitching along axis alpha, the direction by yawn
along axis gamma amd the position of the bead is controlled by tilt along axis beta. All those movements
together with XYZ position of the mamipulator arm comes sequentially from the digital ~ ,.. of a
3D structure.
Fig 6a. Illustrates a mathematical steps necessary to perform construction process using this invention. In
the first step it is neccessary to substract shape S from block B. Block B represents a piece of compound
being used. The result of substraction is the shape S' which is now devided, ' " '.y along planes P.
The position of planes P are established at the interval D. This planes defines a layers of a shape S' as
illustrated on fig 6b., and software calculates a coordinates of volume pixels (voxels) its alpha, beta and
gamma angles, width and volume. Calculated data are than put into a matrix of vectors vi as illustrated
below.
v0=[0, 0, 0, 0, 0, 0, dref, ]
vl=[delta xl, delta yl, delta zl, delta alphal, delta betal, delta gammal, delta dl, ]
vi=[delta xi, delta yi, delta_zi, delta alphai, delta betai, delta gammai, delta di, ]
This matrix is than sequentially fed into the drivers of stepper motors (fig4), which in turn moves the arm of
the manipulator into position and heated wire "sculpts" the compound at this location. The process of
passing a voxel data causes a continuos movement of the manipulator and smooth cutout of a compound
(fig 6b). Once all matrix is processed the shape S is left in the form as designed.
Described above apparatus and method allows to build very complicated structures effectively and precisely
in one continuous process.
