Apparatus and method for hybrid manufacturing
An apparatus for hybrid manufacturing comprising a frame, a build plate that is adapted to move relative to the frame, a material pump that is adapted to pump one or more materials, a mixing head that is adapted to mix the one or more materials, a mixing hose that is in fluid communication with the material pump and the mixing head, a vacuum pump that is adapted to remove air from a mold, a vacuum hose that is in fluid communication with the vacuum pump and the mold, a vat that is adapted to retain a liquid, and a radiation source that is disposed adjacent to the vat. The apparatus prints the mold and fills the mold. A method comprising printing the mold with one or more mold materials, removing air from the mold, filling the mold with one or more primary materials, and dissolving the mold.
1. A method for hybrid manufacturing, said method comprising:
a. providing an apparatus for hybrid manufacturing, said apparatus comprising:
(i) a frame;
(ii) a build plate, said build plate being adapted to move relative to the frame;
(iii) a material pump, said material pump being adapted to pump one or more materials;
(iv) a first mixing hose, said first mixing hose being in fluid communication with the material pump;
(v) a vacuum pump, said vacuum pump being adapted to remove air from a mold;
(vi) a first vacuum hose, said first vacuum hose being in fluid communication with the vacuum pump;
(vii) a vat; said vat being adapted to retain a liquid;
(viii) a radiation source, said radiation source being disposed adjacent to the vat;
b. providing a mixing head, a second mixing hose, and a second vacuum hose that are in fluid communication, wherein the mixing head and the second vacuum hose are connected with openings of the build plate;
c. printing the mold with one or more mold materials such that the second mixing hose and the second vacuum hose are connected with the mold;
d. removing air from the mold;
e. filling the mold with the one or more primary materials;
f. dissolving the mold;
wherein the apparatus for hybrid manufacturing prints the mold and fills the mold.
2. The method of claim 1 wherein the mold is continuously printed.
3. The method of claim 1 wherein the mold is printed via continuous energy.
4. The method of claim 1 wherein the mold is printed via continuous build plate movement.
5. The method of claim 1 wherein the mold is water-soluble.
6. The method of claim 1 wherein the mold comprises at least one of a high impact polystyrene, a polyvinyl alcohol, an acrylic monomer, a sugar, and a wax.
7. The method of claim 1 wherein the primary material comprises at least one of a resin, a ceramic, a metal powder, a silicon, a urethane, a clay material, a plastic, a fiber, a biological material, and a bio-active material.
8. The method of claim 1 further comprising the placement of a solid sacrificial material within the mold.
9. The method of claim 8 wherein the solid sacrificial material is connected to the mold via a sprue.
10. The method of claim 9 wherein the solid sacrificial material is dissolved after the mold is filled with the primary material.
11. The method of claim 10 wherein a secondary material is conveyed into an open space left by the dissolved solid sacrificial material.
12. The method of claim 1 wherein the apparatus for hybrid manufacturing prints the mixing head.
13. The method of claim 1 wherein the apparatus for hybrid manufacturing prints the second mixing hose.
14. The method of claim 1 wherein the apparatus for hybrid manufacturing prints the second vacuum hose.
15. The method of claim 1 wherein the vat comprises at least one of a PVDC layer and a FEP layer.
16. The method of claim 1 further comprising controlling water permeation.
17. The method of claim 1 further comprising detecting manufacturing defects.
18. The method of claim 1 wherein the frame defines a chamber.
19. The method of claim 18 further comprising controlling the environment in the chamber.
20. A method for hybrid manufacturing, said method comprising:
a. providing an apparatus for hybrid manufacturing, said apparatus comprising:
(i) a frame;
(ii) a build plate, said build plate being adapted to move relative to the frame;
(iii) a material pump, said material pump being adapted to pump one or more materials;
(iv) a first mixing hose, said first mixing hose being in fluid communication with the material pump;
(v) a vacuum pump, said vacuum pump being adapted to remove air from a mold;
(vi) a first vacuum hose, said first vacuum hose being in fluid communication with the vacuum pump;
(vii) a vat; said vat being adapted to retain a liquid;
(viii) a radiation source, said radiation source being disposed adjacent to the vat;
b. printing the mold, a mixing head, a second mixing hose, and a second vacuum hose that are in fluid communication with one or more mold materials;
wherein the mixing head and the second vacuum hose are connected with openings of the build plate; and
wherein the second mixing hose and the second vacuum hose are connected with the mold;
c. removing air from the mold;
d. filling the mold with the one or more primary materials;
e. dissolving the mold;
wherein the apparatus for hybrid manufacturing prints the mold and fills the mold.