Abstract: Disclosed are methods and apparatus for fabricating a three-dimensional object in accordance with a computer-generated definition of the object that is stored within a memory. A method includes the steps of (a) evaluating the stored definition of the object to locate any un-supported features of the object; in response to locating an un-supported feature, (b) defining a support structure for the un-supported feature; (c) generating a fabrication tool movement list expressive of movements required by a fabrication tool to fabricate the object and any defined support structures; and (d) translating the fabrication tool in accordance with the generated fabrication tool movement list to fabricate the object and any defined support structures.

Abstract: Apparatus and method for fabricating a three-dimensional object in accordance with a CAD-generated specification of the object. A closed-loop extrusion system (10) includes a nozzle (12) for extruding a material, such as a hot melt adhesive; apparatus (14, 18, 46) for controllably positioning the nozzle in accordance with the specification; and a sensor (60) for generating a feedback signal that is indicative of at least one characteristic of a most recently extruded portion of the material. Visual and non-visual feedback sensors may be employed, including optical sensors, infrared emission sensors, and proximity detection sensors. The specification of the object is converted to a bit-mapped representation thereof to improve accuracy relative to vector-based representations. Methods for determining a need for supporting structures and anti-aliasing features and for integrating the structures and features into the object specification are also disclosed.

Abstract: Cumulative translational sweeps are used to shape geometric objects in a computer model, and they permit display of the resulting changes in shape in the object modelled, and control of processes involving the object modelled. If the geometric object is polyhedral, the cumulative translational sweeps, by creating additional facets, effect selective rounding along model edges and around model vertices. This permits computer modelling of the growth of layers, encompassing in addition to flat surface growth, growth with rounding around corners and over obstacles. Such growth occurs in the manufacture of semiconductors. Modelling a change in a solid structure in stages of growth (or shrinking) and of rounding, as might take place during processing of integrated circuits is achieved by controlled sweep sequences that sweep the structure a finite number of times in accordance with a rayset and stipulated parameters of shape, balance, convexity/concavity, degree of faceting, and memory limitation.