Method and system for direct writing, editing and transmitting a three dimensional part and imaging systems therefor

Abstract

A method and apparatus for creating three dimensional solid forms in metals, ceramics, organics or any combination thereof is made possible using a computer controlled system to create local environmental conditions that favor deposition from a material stream, precursor gas, weld process or plasma. In order to increase control and accuracy, the material can also be placed while the target area is monitored by a broadband poly-spectral imaging system, which provides dimensional, geometrical, chemical composition, stress and temperature feedback to the computer controlling the process. The local environmental conditions in the deposition area are controlled for magnetic, electric, and acoustic fields as well as for temperature, pressure, flow dynamics, and atmospheric composition. Complex materials can be “written” to match a computer's file of a three dimensional shape with virtually any material composition, surface finish, and geometrical complexity. Discrete components, such as microspheres, optical, electronic or any other components or materials that do not lend themselves to the deposition process, can be inserted and the shape written around them to make them an integral part of the final form. While the system can “write” a three-dimensional shape it can also be used to “erase” some or all of a shape. The environmental conditions can also be changed so that material can be removed under computer controlled so that any corrections or final features can be created including such operations as final polishing or surface finishing. The digital files containing the three-dimensional image, environmental and compositional data can be sent to remote locations where the data can be used to write a new three dimensional object.

1 - 25 . (cancelled).  
     
     
         26 . A method of manufacturing a three dimensional article through a deposition process, wherein, during the deposition process, the deposited material is monitored by a multi-dimensional imaging system which provides spatial dimensional information relating to the shape of deposited material, and information derived from the monitoring is provided to a computer control system in a feedback loop to permit the control system to continuously supervise and control the deposition process.  
     
     
         27 . A method according to  claim 26 , wherein the information derived from the monitoring includes spectral information, including at least one infrared spectral information, visible spectral information, and ultra-violet spectral information.  
     
     
         28 . A method according to  claim 26 , wherein the imaging system includes an ultra-violet imaging system or a spectral imaging system for providing information on at least one chemical parameter of the material.  
     
     
         29 . A method according to  claim 28 , wherein compositional gradients within the article are controlled.  
     
     
         30 . A method according to  claim 26 , wherein at least one of a dynamically controllable magnetic, electrical, acoustic and electrostatic field controls the deposition of material.  
     
     
         31 . A method according to  claim 26 , wherein the material includes particulates.  
     
     
         32 . A method according to  claim 26 , wherein a previously manufactured article is incorporated into the article.  
     
     
         33 . A method according to  claim 32 , wherein data describing the article is provided to a remote location, and feed materials for forming the article are optionally stored at the remote location.  
     
     
         34 . A method according to  claim 33 , wherein the remote location is a space station beyond earth's atmosphere.  
     
     
         35 . A method according to  claim 34  wherein at least one of the feed materials is provided by a waste recycling system.  
     
     
         36 . The method according to claim  44  wherein the waste recycling system is a carbon scrubbing system.  
     
     
         37 . An apparatus for manufacturing a three dimensional article through a deposition process, comprising a multi-dimensional imaging system for monitoring the deposited material during the deposition process and providing spatial dimensional information relating to the shape of the deposited material, and a computer control system receiving the information in a feedback loop to continuously supervise and control the deposition process.  
     
     
         38 . Apparatus according to  claim 37 , wherein the information derived from the monitoring includes spectral information, including at least one infrared spectral information, visible spectral information, and ultra-violet spectral information.  
     
     
         39 . Apparatus according to  claim 37 , wherein the imaging system includes an ultra-violet imaging system or a spectral imaging system for providing information on at least one chemical parameter of the material.  
     
     
         40 . Apparatus according to  claim 39 , wherein compositional gradients within the article are controlled.  
     
     
         41 . Apparatus according to  claim 37 , wherein at least one of a dynamically controllable magnetic, electrical, acoustic and electrostatic field controls the deposition of material.  
     
     
         42 . Apparatus according to  claim 37 , wherein the material includes particulates.  
     
     
         43 . Apparatus according to  claim 37 , wherein a previously manufactured article is incorporated into the article.