Rapid Prototyping (e.g., Layer-by-layer, Material Deposition) Patents (Class 700/119)
  • Patent number: 7962238
    Abstract: The invention relates to a process or device for the production of a three-dimensional object by layer-wise solidification of a material which is solidifiable under the application of electromagnetic irradiation by means of mask illumination, wherein the mask is produced using an image forming unit having a prescribed resolution, which is formed from a constant number of image forming elements (pixels) being discrete and being arranged in a spatially mutually fixed manner. For the improvement of the resolution along the outer and inner contours of the sectional areas of the object to be generated layer-wise in the sub-pixel range, a multiple illumination per layer is performed, which consists of a series of multiple images that are mutually shifted in the sub-pixel range in the image/construction plane, wherein a separate mask/bitmap is produced for each shifted image.
    Type: Grant
    Filed: July 30, 2010
    Date of Patent: June 14, 2011
    Assignee: Envisiontec GmbH
    Inventors: Alexandr Shkolnik, Hendrik John, Ali El-Siblani
  • Patent number: 7957825
    Abstract: Fuselage sections of an aircraft are joined using splice elements that compensate for gaps caused by mismatches between mating surfaces on the fuselage sections. The fuselage sections are virtually assembled using computer models that are based on non-contact measurements of as-built fuselage sections. The virtually assembled fuselage sections are used to map the gaps between the mating surfaces. The mapped gaps are used to produce tool inserts having profiles that reflect the dimensions of the gaps. The tool inserts are used to manufacture splice elements having profiles that fill the gaps when the fuselage sections are assembled and joined, thereby eliminating the need for shims and spaces to fill the gaps.
    Type: Grant
    Filed: July 14, 2010
    Date of Patent: June 7, 2011
    Assignee: The Boeing Company
    Inventors: Bobby J. Marsh, Kinson D. VanScotter, Karen Malen-Hogle
  • Publication number: 20110118864
    Abstract: Apparatus for producing an object by sequentially forming thin layers of a construction material one on top of the other responsive to data defining the object, the apparatus comprising: a plurality of printing heads each having a surface formed with a plurality of output orifices and controllable to dispense the construction material through each orifice independently of the other orifices; a shuttle to which the printing heads are mounted; a support surface; and a controller adapted to control the shuttle to move back and forth over the support surface and as the shuttle moves to control the printing heads to dispense the construction material through each of their respective orifices responsive to the data to form a first layer on the support surface and thereafter, sequentially the other layers; wherein each printing head is dismountable from the shuttle and replaceable independently of the other printing heads.
    Type: Application
    Filed: January 26, 2011
    Publication date: May 19, 2011
    Applicant: Object Geometries Ltd.
    Inventors: Eliahu M. KRITCHMAN, Igal ZEYTOUN
  • Publication number: 20110111360
    Abstract: A process for determining 3-D data of at least one prepared jaw area, such as a prepared tooth stump, by mechanically scanning the jaw area and digitizing the measured values determined during the scanning. The jaw area is prepared with a dental instrument having positions which are optically measured during the preparation, and the 3-D data is determined from the positions of the dental instrument that are associated with the prepared jaw area.
    Type: Application
    Filed: April 2, 2009
    Publication date: May 12, 2011
    Applicant: DEGUDENT GMBH
    Inventors: Lothar Volkl, Stefan Fecher, Hartmut Brinkmann, Ralf Jaumann
  • Publication number: 20110091832
    Abstract: The present invention is directed to computer-implemented methods of making a transfer tray using rapid prototyping techniques, where the gingival edge of the tray is defined to intersect with at least one receptacle for receiving an orthodontic appliance. This tray configuration helps to minimize the travel distance of the tray when placing the tray over a patient's teeth, while also preserving a high degree of mechanical retention for retaining the appliance until such time that the appliance is bonded to the tooth. Other aspects of the tray and associated methods of bonding are directed to a frangible web that extends over the gingival portion of the receptacle and fractures to facilitate tray removal after bonding.
    Type: Application
    Filed: June 16, 2009
    Publication date: April 21, 2011
    Inventors: Sung Kim, Richard E. Raby
  • Patent number: 7930054
    Abstract: A system and method for toolpath creation is provided. The method includes exporting CAD defined 3-D geometry to a slicing module; slicing the 3-D geometry creating a set of 2-D patterns representing the 3-D geometry; generating vector code from the set of 2-D patterns; and translating the vector code to machine code.
    Type: Grant
    Filed: March 27, 2006
    Date of Patent: April 19, 2011
    Assignee: The Boeing Company
    Inventors: Victor B. Slaughter, Christopher S. Huskamp
  • Patent number: 7930058
    Abstract: Processing a wafer using a double side grinder having a pair of grinding wheels. Warp data is obtained by a warp measurement device for measuring warp of a wafer as ground by the double side grinder. The warp data is received and a nanotopography of the wafer is predicted based on the received warp data. A grinding parameter is determined based on the predicted nanotopography of the wafer. Operation of the double side grinder is adjusted based on the determined grinding parameter.
    Type: Grant
    Filed: December 31, 2007
    Date of Patent: April 19, 2011
    Assignee: MEMC Electronic Materials, Inc.
    Inventors: Sumeet S. Bhagavat, Roland R. Vandamme, Tomomi Komura, Tomohiko Kaneko, Takuto Kazama
  • Publication number: 20110087350
    Abstract: The present invention relates to a system and method of transforming an inconsistent 3D (three-dimensional) model of one or more 3D objects into a valid printable 3D model, said method comprising: (a) receiving an input model file and/or receiving modeler data, giving rise to an input 3D model having one or more parts; (b) analyzing said input 3D model and removing its one or more inconsistencies; (c) thickening the one or more parts of said 3D model, while preserving their functionality; and (d) unifying the union of interior volumes of said one or more parts, thereby removing self intersections and/or intersections between the two or more parts, giving rise to a valid printable 3D model.
    Type: Application
    Filed: October 8, 2009
    Publication date: April 14, 2011
    Applicant: 3D M.T.P. LTD
    Inventors: Effi FOGEL, Arik Maman ADLER, Zohar BASIL
  • Patent number: 7925374
    Abstract: A system for production of a dental crown (23, 24) includes identification equipment (2), modeling equipment (9), ordering equipment (6), and an automated production arrangement (16). The latter, as a function of one or more first information items, is arranged to effect production, by means of pressing or pressure-casting, of an integrated dental crown which is made up of two layers. The first layer comprises or consists of porcelain material, and the second layer consists of aluminum oxide, zirconium oxide, etc. The second layer forms a cap, via which the dental crown can be applied to a tooth stump (28) of a patient (1). The invention also relates to a dental replacement component consisting of the dental crown.
    Type: Grant
    Filed: November 4, 2004
    Date of Patent: April 12, 2011
    Assignee: Nobel Biocare Services AG
    Inventors: Matts Andersson, Per-Olof Karlsson, Urban Nilsson
  • Patent number: 7920937
    Abstract: A mechanical part useful in various fields of application including plastic and metal processing is produced using a computer-aided design process including a preliminary break-down of the body of the part into elementary strata, followed by manufacture of the elementary strata, and reconstruction of the part. During break-down of the part, at least one fluid transport circuit, which is designed and modeled beforehand, is broken down into elementary chambers (20) in accordance with the break-down of the part. The elementary chambers are produced in the elementary strata (7i) forming the part during manufacture of the strata, and the fluid transport circuit is reconstructed during superposition and assembly of the strata.
    Type: Grant
    Filed: July 15, 2003
    Date of Patent: April 5, 2011
    Assignee: Cirtes SRC, SA Cooperative d'Ues
    Inventors: Claude Barlier, Cyril Pelaingre, Denis Cunin, Christophe Levaillant
  • Patent number: 7917243
    Abstract: A method for generating build sequence data for a computer-aided design model of a three-dimensional object, the method comprising identifying a location of an insert data representation in the computer-aided design model, slicing the computer-aided design model into a plurality of sliced layers, generating a plurality of support layers for at least a portion of the plurality of sliced layers, and generating an unfilled region in the computer-aided design model at the identified location of the insert data representation.
    Type: Grant
    Filed: January 8, 2008
    Date of Patent: March 29, 2011
    Assignee: Stratasys, Inc.
    Inventors: David M. Kozlak, Donald J. Holzwarth, J. Samuel Batchelder
  • Patent number: 7912569
    Abstract: A method for generating data for a jetting program, includes the steps of: a) obtaining substrate data for a substrate, which is to be provided with deposits and components; and b) for each component which is to be placed on the substrate: —fetching component data for the component from said substrate data; and—selecting a matching predefined deposit pattern, comprising at least one deposit, which matches a desired deposit pattern for said component data, wherein the deposit pattern comprises, for the/each deposit, deposit data comprising deposit extension and deposit position; or—if no matching predefined deposit pattern exists, defining a deposit pattern, comprising at least one deposit, for the component data, comprising the step of defining, for the/each deposit, deposit data, which step comprises determining deposit extension and deposit position.
    Type: Grant
    Filed: November 15, 2004
    Date of Patent: March 22, 2011
    Assignee: Mydata Automation AB
    Inventors: Jens Byléhn, Håkan Sandell, William Holm
  • Publication number: 20110060445
    Abstract: A process for three-dimensional modeling in which water soluble thermoplastic material is used in an additive deposition process to form a soluble support structure for a three-dimensional model formed via layer-by-layer deposition of the model's geometry. The water-soluble thermoplastic material includes a base of vinyl alcohol. Following the completion of the model, the model is placed in a cold water bath to dissolve the support structure. The water-soluble material can also be used to form soluble model directly.
    Type: Application
    Filed: September 2, 2010
    Publication date: March 10, 2011
    Inventor: Timothy J. Heenan
  • Publication number: 20110060446
    Abstract: A method of producing a flexible vessel model for simulating a surgical operation, which is a three-dimensional model being capable of reproducing an aneurysm or narrowing occurring in the artery or vein based on CT/MRI image data of a patient obtained in practice and thus allowing vascular therapy trainings and preoperative simulations, with the use of a precise lamination modeling machine, wherein a vascular model having an affected part is fabricated by using a lamination technique together with a supporting material for sustaining the shape of the three-dimensional model during the fabrication in the precise lamination modeling machine and, after the completion of the fabrication by the lamination machine technique, the supporting material is removed.
    Type: Application
    Filed: May 7, 2009
    Publication date: March 10, 2011
    Inventors: Hidenori Ono, Akio Morita
  • Publication number: 20110049754
    Abstract: A method of forming hoses is provided. The method includes generating a virtual design for at least one of a solid durable core and a hollow sacrificial core. At least one of the solid durable core and the hollow sacrificial core is formed using rapid prototyping. A mold cavity is formed using the solid durable core. The hose is formed about the hollow sacrificial core with the hollow sacrificial core in the mold cavity.
    Type: Application
    Filed: August 26, 2009
    Publication date: March 3, 2011
    Applicant: Toyota Motor Engineering & Manufacturing North America, Inc.
    Inventor: Matthew James Mahaffy
  • Publication number: 20110054663
    Abstract: A three-dimensional modeling apparatus includes a stage, a head, a movement mechanism, and a control unit. The head supplies a process liquid that is one of a solution and a dispersion liquid onto the stage to cause a material that constitutes a three-dimensional object to be precipitated out of the process liquid by evaporating one of a solvent and a dispersion medium therefrom. The movement mechanism relatively moves the head and the stage. The control unit controls a drive of the movement mechanism to form the three-dimensional object.
    Type: Application
    Filed: August 25, 2010
    Publication date: March 3, 2011
    Applicant: SONY CORPORATION
    Inventors: Takeshi Matsui, Yasuhiro Tanaka, Junichi Kuzusako, Ikuko Tsurui
  • Patent number: 7899569
    Abstract: A method of forming a three-dimensional object using an extrusion-based layered deposition system, the method comprising generating a build path for building a layer of the three-dimensional object, where the build path defines a void region. The method further comprising generating at least one intermediate path in the void region, and generating a remnant path based at least in part on the at least one intermediate path.
    Type: Grant
    Filed: June 19, 2009
    Date of Patent: March 1, 2011
    Assignee: Stratasys, Inc.
    Inventor: Donald J. Holzwarth
  • Patent number: 7896639
    Abstract: Apparatus for producing an object by sequentially forming thin layers of a construction material one on top of the other responsive to data defining the object, the apparatus comprising: a plurality of printing heads each having a surface formed with a plurality of output orifices and controllable to dispense the construction material through each orifice independently of the other orifices; a shuttle to which the printing heads are mounted; a support surface; and a controller adapted to control the shuttle to move back and forth over the support surface and as the shuttle moves to control the printing heads to dispense the construction material through each of their respective orifices responsive to the data to form a first layer on the support surface and thereafter, sequentially the other layers; wherein each printing head is dismountable from the shuttle and replaceable independently of the other printing heads.
    Type: Grant
    Filed: February 18, 2009
    Date of Patent: March 1, 2011
    Assignee: Objet Geometries Ltd.
    Inventors: Eliahu M. Kritchman, Igal Zeytoun
  • Publication number: 20110004335
    Abstract: A fairing can be attached to a prosthetic limb or over a brace to alter the appearance of the prosthetic limb or brace. The outer surface of the prosthetic limb can be a mirror image of an intact limb and the outer surface of the brace can have an outer surface that corresponds to an injured limb. Because the fairing fits closely around the prosthetic limb or brace, the interior surface of the fairing has a surface that corresponds to a mirror image of an intact limb or an outer surface of an injured limb.
    Type: Application
    Filed: September 14, 2010
    Publication date: January 6, 2011
    Applicant: Bespoke Innovations, Inc.
    Inventors: Scott Summit, Kenneth Trauner
  • Patent number: 7862320
    Abstract: A three-dimensional object forming apparatus forms a three-dimensional object by binding powder particles with a curable liquid. The apparatus includes a powder layer forming unit that spreads a powder to a uniform thickness to form a powder layer. A curable liquid ejection head ejects the curable liquid to the powder layer through an ejection nozzle. A sectional data producing device produces sectional data at each of a plurality of cross sections of a desired three-dimensional object according to shape data of the desired three-dimensional object. A cross-sectional member forming section is also included by which cross-sectional members are formed by ejecting the curable liquid to the powder layer from the curable liquid ejection head according to the sectional data and thus binding the powder layer. The cross-sectional member forming section includes a permeation rate controller controlling the permeation rate of the curable liquid to the powder layer.
    Type: Grant
    Filed: July 16, 2008
    Date of Patent: January 4, 2011
    Assignee: Seiko Epson Corporation
    Inventors: Toshio Kumagai, Kazutoshi Fujisawa, Akio Ito
  • Publication number: 20100330532
    Abstract: The present invention is a dental implant utilizing a polymeric dental post. The actual prosthetic portion of the implant may also be manufactured from a polymer. Various post designs are disclosed for setting and securing the post in a patient's jaw. Numerous polymers are disclosed and may be blended to achieve desired characteristics for both the post and prosthetic.
    Type: Application
    Filed: June 25, 2010
    Publication date: December 30, 2010
    Applicant: CAO GROUP, INC.
    Inventor: Steven D. Jensen
  • Patent number: 7860594
    Abstract: The present invention provides a method for making an ophthalmic device. In particular, the present invention provides a method for production of a contact lens by means of stereolithography. A preferred stereolithography technique is based on polymerization and solidification of a contact lens forming liquid material by actinic irradiation one layer at a time. In addition, the present invention provides systems and methods for making a contact lens for a specific patient based on the prescription.
    Type: Grant
    Filed: April 17, 2007
    Date of Patent: December 28, 2010
    Assignee: Novartis AG
    Inventors: Rafael Victor Andino, Robert Scott Meece, David Rosen, Benay Sager
  • Publication number: 20100319204
    Abstract: A method of forming a functional razor cartridge for repeated shaving comprises rapid prototyping a housing of a razor cartridge. The housing has a front wall, a rear wall and opposing side walls disposed transverse to and between said front and rear walls. The method further comprises loading a metal insert with one or more elongate blade assemblies and disposing the metal insert in the housing such that the one or more blade assemblies extend between the opposing side walls of the housing.
    Type: Application
    Filed: June 9, 2010
    Publication date: December 23, 2010
    Inventors: Mark Peterson, Dominic Michael Piff
  • Publication number: 20100312375
    Abstract: An artificial bone forming method, comprising a) a powder layer forming step (32) for forming, into a flat powder layer (6), a powder bone material (5) having biocompatibility and hardening by hydration, b) a partial hardening step (34) for jetting an aqueous solution (7) with biocompatibility to a part of the powder layer to harden a jetted portion (6a) by hydration, and c) an artificial bone forming step (36) for repeating the steps a) and b) for lamination to form a specified artificial bone (9) of a predetermined three-dimensional structure in which the hardened portions (6a) are connected to each other.
    Type: Application
    Filed: June 9, 2010
    Publication date: December 9, 2010
    Applicants: RIKEN, NEW X-NATIONAL TECHNOLOGY K.K.
    Inventors: Kenji Yamazawa, Masahiro Anzai, Hideo Yokota, Shigeki Suzuki
  • Publication number: 20100305742
    Abstract: An integrated additive manufacturing cell (IAMC) that combines conventional manufacturing technologies with additive manufacturing processes is disclosed. Individual IAMCs may be configured and optimized for specific part families of complex components, or other industrial applications. The IAMCs incorporate features that reduce hardware cost and time and allow for local alloy tailoring for material properties optimization in complex components.
    Type: Application
    Filed: August 16, 2010
    Publication date: December 2, 2010
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Wendell V. Twelves, JR., James W. Norris, Bernard J. Raver
  • Publication number: 20100290319
    Abstract: In illustrative implementations of this invention, a mechanical clock is produced in a manner such that, once its separate parts are made, the clock requires no further assembly. In one implementation of this invention, a mechanical clock is designed using standard CAD (computer-aided design) modeling tools and made with a rapid prototyping machine. The support material used in rapid prototyping is then removed. Once the support material is removed, the clock runs without any additional assembly. In this implementation, the clock contains all the components that are required and they are all constructed in the rapid prototyping process.
    Type: Application
    Filed: May 13, 2010
    Publication date: November 18, 2010
    Inventors: Robert Swartz, Peter Schmitt
  • Publication number: 20100291508
    Abstract: There are provided systems, methods and apparatuses related to bone augmentation shells. In particular, in accordance with an aspect, there is disclosed an apparatus for bone augmentation. The apparatus includes a biocompatible body being shaped to fit over basal supporting bone structure. The body has an interior surface defining a cavity into which bone growth material may be inserted. Additionally, the body includes a rib portion located at an apex of the body, a first surface extending downward on a first side from the rib portion and a second surface extending downward on a second side from the rib portion. At least a portion of the first and second surfaces is roughened to have a micro-topography conducive to soft tissue attachment.
    Type: Application
    Filed: March 10, 2010
    Publication date: November 18, 2010
    Inventor: Ole T. Jensen
  • Publication number: 20100291505
    Abstract: The invention provides a method and system for substantially coterminous modification of a patient situation and a manufactured prosthetic to achieve the desired fit. Rather than utilizing a serial approach, a parallel approach is taken where both patient situation and prosthetic device can be modified at the same time (or substantially the same time).
    Type: Application
    Filed: January 22, 2010
    Publication date: November 18, 2010
    Inventors: Curt Rawley, David Tzu-Wei Chen
  • Patent number: 7833001
    Abstract: A printing system for creating a three-dimensional object. The printing system includes a plurality of printheads including a first printhead configured to print a first material and a second printhead configured to print a second material. The system includes one or more curing mechanisms for curing the printed materials. The system includes at least one object incorporation device configured to incorporate a non-printed object into the three-dimensional object when partially complete. At least one printhead is configured to print one or more electrical connections to the incorporated object.
    Type: Grant
    Filed: April 17, 2007
    Date of Patent: November 16, 2010
    Assignee: Silverbrook Research Pty Ltd
    Inventor: Kia Silverbrook
  • Patent number: 7833000
    Abstract: There is provided an optical modeling apparatus that forms a model of a desired shape by sequentially forming hardened layers by irradiating a light-curable resin with light. The apparatus includes a first light source that emits a light beam for plotting on the resin, a scanning device that scans the light beam from the first light source over the resin, a second light source that emits light that irradiates one fixed region of the resin at a time, and a spatial light modulator that spatially modulates the light from the second light source to blanket-expose a specified region of the resin. The light beam from the scanning device and the light from the spatial light modulator form each hardened layer.
    Type: Grant
    Filed: December 21, 2007
    Date of Patent: November 16, 2010
    Assignee: Sony Corporation
    Inventors: Nobuhiro Kihara, Masanobu Yamamoto, Kimihiro Saito, Yuichi Aki, Takeshi Yamasaki
  • Patent number: 7831328
    Abstract: The invention relates to a method for producing a three-dimensional object by solidification of a material solidifiable under the action of electromagnetic radiation by means of energy input via an imaging unit comprising a predetermined number of discrete imaging elements (pixels), The method comprises performing solidification with exposure using bitmap mask. The bitmap mask may be formed from a stack of bitmap data provided by an overlap analysis of a three-dimensional volume completely or partially enclosing a three-dimensional model of at least a part of the three-dimensional object to be produced. Alternatively, bitmap mask may be formed from a two-dimensional data set comprising overlap information. Solidification may be performing with exposure using bitmap mask generated “on the fly”. The invention is also directed to devices, and a computer and a data carrier useful for performing or executing the method.
    Type: Grant
    Filed: September 22, 2008
    Date of Patent: November 9, 2010
    Assignee: Envisiontec GmbH
    Inventors: Volker Schillen, Hendrik John, Ali Siblani
  • Publication number: 20100280648
    Abstract: Fuselage sections of an aircraft are joined using splice elements that compensate for gaps caused by mismatches between mating surfaces on the fuselage sections. The fuselage sections are virtually assembled using computer models that are based on non-contact measurements of as-built fuselage sections. The virtually assembled fuselage sections are used to map the gaps between the mating surfaces. The mapped gaps are used to produce tool inserts having profiles that reflect the dimensions of the gaps. The tool inserts are used to manufacture splice elements having profiles that fill the gaps when the fuselage sections are assembled and joined, thereby eliminating the need for shims and spaces to fill the gaps.
    Type: Application
    Filed: July 14, 2010
    Publication date: November 4, 2010
    Inventors: Bobby J. Marsh, Kinson D. VanScotter, Karen Malen-Hogle
  • Publication number: 20100268138
    Abstract: A custom device and method for fabricating the custom device includes marking a body with reference points and/or other indicators. Multiple images of the body from multiple angles are then obtained. The images are used to determine the contours of the body and the other markings are located and used to design the custom device. The custom device can be fabricated as a single piece structure or in multiple pieces that are assembled to complete the custom device.
    Type: Application
    Filed: June 25, 2010
    Publication date: October 21, 2010
    Inventors: Scott Summit, Kenneth B. Trauner
  • Patent number: 7814862
    Abstract: A method and apparatus are described for forming a structure on a substrate. The structure may be a circuit element. The method uses a digital specification 910 for forming the structure, including specifications for printing and curing. The structure is printed (step 112) using a drop-on-demand printer 400, wherein the printing dispenses at least one material on the substrate 420 according to the digital specification 910. The structure is cured (step 130) by irradiating the dispensed material from one or more electromagnetic radiation sources 520, 525 in the printer 400, wherein curing parameters are specified by the digital specification 910 to obtain a desired electrical property when the structure is a circuit element. The curing specification may specify the intensity of the irradiation and the location of irradiation points in the print region.
    Type: Grant
    Filed: May 12, 2006
    Date of Patent: October 19, 2010
    Assignee: Canon Kabushiki Kaisha
    Inventors: Alison Joan Lennon, Peter Kirkland Thomson, Nicolas Rowland Bingham
  • Patent number: 7818084
    Abstract: Methods, apparatuses, computer program products, devices and systems are described that include accepting one or more blood vessel sleeve dimensions based on blood vessel data from an individual; and making a rapid-prototyped blood vessel sleeve at least partly based on the one or more blood vessel sleeve dimensions.
    Type: Grant
    Filed: August 20, 2007
    Date of Patent: October 19, 2010
    Assignee: The Invention Science Fund, I, LLC
    Inventors: Edward S. Boyden, Ralph G. Dacey, Jr., Colin P. Derdeyn, Joshua L. Dowling, Roderick A. Hyde, Muriel Y. Ishikawa, Eric C. Leuthardt, Nathan P. Myhrvold, Clarence T. Tegreene, Lowell L. Wood, Jr., Victoria Y. H. Wood, Gregory J. Zipfel
  • Publication number: 20100260410
    Abstract: A closed-loop control method for an electron beam freeform fabrication (EBF3) process includes detecting a feature of interest during the process using a sensor(s), continuously evaluating the feature of interest to determine, in real time, a change occurring therein, and automatically modifying control parameters to control the EBF3 process. An apparatus provides closed-loop control method of the process, and includes an electron gun for generating an electron beam, a wire feeder for feeding a wire toward a substrate, wherein the wire is melted and progressively deposited in layers onto the substrate, a sensor(s), and a host machine. The sensor(s) measure the feature of interest during the process, and the host machine continuously evaluates the feature of interest to determine, in real time, a change occurring therein. The host machine automatically modifies control parameters to the EBF3 apparatus to control the EBF3 process in a closed-loop manner.
    Type: Application
    Filed: March 31, 2010
    Publication date: October 14, 2010
    Applicants: Space Administration
    Inventors: Karen M. Taminger, Robert A. Hafley, Richard E. Martin, William H. Hofmeister
  • Publication number: 20100262054
    Abstract: A custom brace and method for fabricating the custom brace includes marking a body with reference points and/or other indicators. Multiple images of the body from multiple angles are then obtained. The images are used to determine the contours of the body and the other markings are located and used to design the custom brace. Fenestrations can be added to the brace design. The custom brace can be fabricated with the fenestrations as a single piece structure or in multiple pieces that are assembled to complete the custom device.
    Type: Application
    Filed: June 25, 2010
    Publication date: October 14, 2010
    Inventors: Scott Summit, Kenneth B. Trauner
  • Publication number: 20100262272
    Abstract: A method and apparatus for making a three-dimensional object from a solidifiable material such as a photopolymer is shown and described. In accordance with the method, positions relative to a build axis are subdivided into first and second exposure data subsets, and the first and second exposure data subsets are solidified in alternating sequences to reduce the surface area of solidified material in contact with a solidification substrate.
    Type: Application
    Filed: April 14, 2009
    Publication date: October 14, 2010
    Inventors: Alexandr Shkolnik, Ali El-Siblani
  • Patent number: 7810237
    Abstract: A method is for repairing and/or modifying component parts of a gas turbine. First, at least one, particularly damaged section of the component part that is to be repaired is cut out of the component part. In addition, if it does not exist, a data record is generated for a replacement part that is to be produced. The replacement part is subsequently produced with the aid of a rapid manufacturing process. Subsequently, the replacement part produced is integrated into the component part that is to be repaired.
    Type: Grant
    Filed: April 1, 2004
    Date of Patent: October 12, 2010
    Assignee: MTU Aero Engines GmbH
    Inventors: Anja Lange, Jens Lange, Uwe Schulze
  • Patent number: 7797071
    Abstract: A printer system is provided for developing a three dimensional (3D) printed structure. The system includes a plurality of spaced apart sets of printing devices. A conveyor system is arranged to serially convey a print medium in register with each set so that printed voxels from each successive set can form successive layers of the 3D printed structure upon the print medium. A placement mechanism is configured to place an object upon layers of the 3D printed structure.
    Type: Grant
    Filed: May 16, 2007
    Date of Patent: September 14, 2010
    Assignee: Silverbrook Research Pty Ltd
    Inventor: Kia Silverbrook
  • Patent number: 7797072
    Abstract: A prosthetic limb has an outer surface that is a mirror image of an intact limb. The intact limb is scanned and the surface data is manipulated to create a virtual mirror image. The end of the amputated limb is also scanned to obtain socket data. A virtual limb is designed using a computer program based upon the mirror image and end of the amputated limb data. The computer program is also used to design a removable fairing that provides color and texture to the prosthetic limb.
    Type: Grant
    Filed: October 5, 2007
    Date of Patent: September 14, 2010
    Assignee: Bespoke Innovations, Inc.
    Inventor: Scott Summit
  • Publication number: 20100228381
    Abstract: A three-dimensional modeling apparatus includes a stage, a supply mechanism, a head, a movement mechanism, and a lifting and lowering mechanism. On the stage, a powder material is accumulated. The supply mechanism supplies the powder material on the stage for each predetermined layer thickness. The head ejects a liquid for forming a three-dimensional object to the powder material on the stage. The liquid is capable of binding the powder material. The movement mechanism moves the stage so that the liquid is supplied from the head to the powder material by the predetermined layer thickness. The lifting and lowering mechanism lowers the stage for each predetermined layer thickness.
    Type: Application
    Filed: March 1, 2010
    Publication date: September 9, 2010
    Applicant: SONY CORPORATION
    Inventors: Takeshi Matsui, Junichi Kuzusako, Hiroyuki Yasukochi
  • Publication number: 20100226502
    Abstract: A method (10) for fabricating a hearing aid using a self-contained hearing aid production laboratory employing three dimensional printing technology. The method (10) comprises the steps of conducting audiometric testing of an individual with a hearing impairment (12, 14); selecting and customizing a product design for the hearing aid to be produced (16, 18); producing the selected and customized hearing aid (20, 22, 24); and performing final adjustments to the produced hearing aid (26, 28).
    Type: Application
    Filed: March 4, 2010
    Publication date: September 9, 2010
    Applicant: Siemens Hearing Instruments, Inc.
    Inventors: James Edward De Finis, Amit Vaze
  • Patent number: 7787979
    Abstract: Fuselage sections of an aircraft are joined using splice elements that compensate for gaps caused by mismatches between mating surfaces on the fuselage sections. The fuselage sections are virtually assembled using computer models that are based on non-contact measurements of as-built fuselage sections. The virtually assembled fuselage sections are used to map the gaps between the mating surfaces. The mapped gaps are used to produce tool inserts having profiles that reflect the dimensions of the gaps. The tool inserts are used to manufacture splice elements having profiles that fill the gaps when the fuselage sections are assembled and joined, thereby eliminating the need for shims and spaces to fill the gaps.
    Type: Grant
    Filed: March 14, 2007
    Date of Patent: August 31, 2010
    Assignee: The Boeing Company
    Inventors: Bobby J. Marsh, Kinson D. VanScotter, Karen Malen-Hogle
  • Publication number: 20100217429
    Abstract: A method of producing an object by sequentially printing layers of construction material one on top of the other, the method comprising: providing the construction material at a first lower temperature; flowing the construction material through a heated flow path in a flow structure to heat the construction material and delivering the heated construction material to a heated reservoir in a printing head; and dispensing the heated construction material from the reservoir to build the object layer by layer.
    Type: Application
    Filed: March 7, 2007
    Publication date: August 26, 2010
    Applicant: Objet Geometries Ltd.
    Inventors: Eliahu M. Kritchman, Slava Shtilerman
  • Publication number: 20100217270
    Abstract: Disclosed herein are devices, systems and methods for the automated design and manufacture of patient-specific/patient-matched orthopedic implants. While the embodiments described herein specifically pertain to unicompartmental resurfacing implants for the knee, the principles described are applicable to other types of knee implants (including, without limitation, other resurfacing implants and joint replacement implants) as well as implants for other joints and other patient-specific orthopedic applications.
    Type: Application
    Filed: February 25, 2010
    Publication date: August 26, 2010
    Applicant: CONFORMIS, INC.
    Inventors: Martin J. Polinski, Paula M. Berg
  • Publication number: 20100216085
    Abstract: A physical model of at least a portion of a patient's dentition has model dental surfaces corresponding to real dental surfaces of the patient's dentition. The physical model includes one or more targets, each configured for facilitating placement of an orthodontic appliance on the model at a desired location. The targets lack mechanical stops that are outwardly protruding from the original model dental surfaces. Also provided are a method of manufacturing a physical model for use in indirect bonding procedures, a method for indirect bonding for use in an orthodontic procedure, a method for providing an indirect bonding transfer tray for use in an orthodontic procedure, and a system for providing a physical model for use in indirect bonding orthodontic procedures.
    Type: Application
    Filed: February 22, 2010
    Publication date: August 26, 2010
    Applicant: CADENT LTD.
    Inventor: Avi Kopelman
  • Publication number: 20100203478
    Abstract: Dental prosthesis, systems, and methods of forming and using a dental prosthesis, are provided. An example of a dental prosthesis includes a first manufactured portion shaped to substantially conform to the three-dimensional surface of a root of a tooth to be replaced and a second manufactured portion shaped to substantially conform to the three-dimensional surface of a crown of the tooth. Furthermore, customized manufactured splints to position and fixate a tooth-shaped prosthesis, are provided. Furthermore, a CAD/CAM based methods of and a systems for manufacturing a customized dental prosthesis are provided. The tooth can be scanned to determine its three-dimensional shape and substantially copied using an imaging system in-vitro like a 3D scanner or in-vivo like a cone beam CT system and CNC machinery. Biocompatible material that is suitable to be integrated into the extraction socket and adopted by existing tissue forming the socket can be manufactured or engineered.
    Type: Application
    Filed: April 19, 2010
    Publication date: August 12, 2010
    Applicant: NATURAL DENTAL IMPLANTS, AG
    Inventor: Ruedger Rubbert
  • Patent number: 7774084
    Abstract: A system for implanting a temporary anchorage device in a jaw bone of a patient makes use of a digital representation of at least a portion of the patient's dental arch, including teeth and corresponding roots, in order to select a temporary anchorage device (TAD) implant site that does not interfere with a tooth root. A surgical guide relates the information from the digital representation to an actual location in the patient's jaw bone. The surgical guide is formed to fit over at least a portion of the occlusal, buccal, labial, and/or lingual surfaces of the dental arch proximate to the selected TAD implant site and includes a physical and/or visual marker that indicates the selected TAD implant site.
    Type: Grant
    Filed: December 7, 2009
    Date of Patent: August 10, 2010
    Assignee: 3M Innovative Properties Company
    Inventor: David K. Cinader, Jr.
  • Patent number: 7772571
    Abstract: To select a scan distance to be used in scanning a wafer with an implant beam, a dose distribution along a first direction is calculated based on size or intensity of the implant beam and a scan distance. The scan distance is the distance measured in the first direction between a first path and a final path of the implant beam scanning the wafer along a second direction in multiple paths. A relative velocity profile along the second direction is determined based on the dose distribution. Dose uniformity on the wafer is calculated based on the wafer being scanned using the relative velocity profile and the determined dose distribution. The scan distance is adjusted and the preceding steps are repeated until the calculated dose uniformity meets one or more uniformity criteria.
    Type: Grant
    Filed: October 8, 2007
    Date of Patent: August 10, 2010
    Assignee: Advanced Ion Beam Technology, Inc.
    Inventors: Cheng-Hui Shen, Donald Wayne Berrian, Jiong Chen