Plates and prototype workpieces produced with a device for performing a fast prototyping process

Abstract

A plate for producing a prototype part using a rapid prototyping process is made of metal, plastic or a metallo-plastic composite material, including thermofusible, thermoplastic and thermosettable materials, and is machined with the machining tool of a prototyping machine which further includes a plate mold integrated in the prototyping machine. The mold is adapted to receive a material matching the shape of the mold, and to subject the plate to a heating/cooling cycle using a heating/cooling device integrated in the mold body, and additionally includes a vat, a base plate, a heating circuit and a fluid circulation circuit.

1 . A plate for a prototype part comprising a plurality of plates produced by a process for machining each plate to form a laminate for a collection of laminates placed as an array for producing the prototype part, using a rapid prototyping process defined by a computer-aided breakdown of the prototype part into the collection of the laminates, the process comprising the steps of:
 machining the plate while in a mold incorporated in a rapid prototyping machine, wherein the mold has a defined shape, and wherein the mold receives material for producing the plate in a shape that hugs the shape of the mold; and   subjecting the machined plate to a heating and cooling cycle while in the mold, including holding the plate in the mold in a cold state during the machining, for release from the mold by heating lower portions of the plate sufficient to detach the plate from the mold after the machining.   
     
     
         2 . The plate of  claim 1  wherein the process further includes the step of forming the plate of a material selected from the group of materials consisting essentially of metals, plastics and metallo-plastic composites which are capable of changing from a liquid phase to a solid phase. 
     
     
         3 . The plate of  claim 1  wherein the process further includes the step of forming the plate of a material selected from the group consisting essentially of thermosettable and thermoplastic materials. 
     
     
         4 . The plate of  claim 1  wherein the shape of the mold which receives the material includes surface portions which are open to exterior portions of the mold, and wherein the process further includes the step of exposing the open surface portions to a machine tool during the machining of the plate. 
     
     
         5 . The plate of  claim 4  wherein the process further includes the step of machining the exposed surface portions with the machine tool during the machining of the plate. 
     
     
         6 . The plate of  claim 5  wherein the machine tool is separate from the mold. 
     
     
         7 . The plate of  claim 1  wherein the process further includes the steps of heating the material for producing the plate, following the machining, and ejecting the machined plate from the mold following the heating.