Claims:
1. An apparatus for manufacturing a three-dimensional object, the apparatus comprising:
a tool handling means for supporting a detachable tool to facilitate fabrication of the three-dimensional object; and
a printing bed for supporting the three-dimensional object,
wherein the tool handling means and the printing bed in unison provides at least five degrees of freedom to said apparatus, and
wherein said detachable tool is any of an interface material dispensing means and a cutting means.
2. The apparatus of claim 1, wherein the printing bed is configured to move, with respect to the tool handling means, linearly along at least two orthogonal axes and rotationally around at least two axes.
3. The apparatus of claim 1, wherein the tool handling means provides translatory motion to the detachable tool.
4. The apparatus of claim 1, further comprising a controller to analyze one or more pre-determined directional paths for movement of the detachable tool and the printing bed with respect to each other based on a digital model of the three-dimensional object.
5. The apparatus of claim 1, wherein the interface material dispensing means is an extruder mechanism to discharge the interface material along a pre-determined directional path to enable additive manufacturing of the three-dimensional object.
6. The apparatus of claim 1, wherein the cutting means is a cutting tool to cut the three-dimensional object along a pre-determined directional path to enable subtractive manufacturing of the three-dimensional object.
7. The apparatus of claim 6, wherein the cutting means is rotated by a driving means selected from the group consisting of an electric motor, a servo motor, or a stepper motor.
8. The apparatus of claim 1, wherein the apparatus is operatively configured with a Computer Numerical Control (CNC) system.
9. A method for manufacturing a three-dimensional object, the method comprising steps of:
creating, at a computing device, a digital model of the three-dimensional object;
generating, at the computing device, one or more pre-determined directional paths based on the created digital model;
converting, at the computing device, the one or more pre-determined directional paths into a machine-readable code; and
transmitting, at the computing device, the machine-readable code to a controller configured with a three-dimensional object manufacturing apparatus.
10. The method of claim 9, wherein the controller controls movement of a tool handling means and a printing bed of the three-dimensional object manufacturing apparatus with respect to each other along the one or more pre-determined directional paths.

, Description:
TECHNICAL FIELD
[0001] The present invention relates generally to the field of manufacturing of three dimensional objects, and more specifically, to apparatus and method that enable additive as well as subtractive manufacturing of the three-dimensional objects.

BACKGROUND OF THE INVENTION
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Additive Manufacturing refers to a process in which digital design data of a three-dimensional (3D) object is used to construct the object by layer-wise deposition of a semi-solid material. 3D printers use the technique of additive manufacturing, which allows creation of 3D objects of any shape or geometry by depositing layers of material under control of a controller. Such creation of objects is done based on digital model data derived from an Additive Manufacturing File (AMF) file or a Computer-Aided Design (CAD) model.
[0004] Conversely, subtractive manufacturing is a process by which three-dimensional objects are constructed by successively cutting material away from a solid block. Subtractive manufacturing can be done by manually cutting the material, but typically, is performed using a CNC Machine. Advanced CNC machines utilize multiple tools to cut along at least three axes (X, Y, and Z axes of a rectangular coordinate system) such that the manufacturing process involves minimal human intervention.
[0005] Traditional methods adopted by 3D printers use an extruder enabled to move linearly with respect to an object while depositing a material. A typical 3D printer includes a nozzle capable of discharging a material, and a table that can be positioned to receive the material discharged from the nozzle. Additionally, in known techniques, deposition of the material is automated and controlled in order to enable systematic deposition of the material. However, material can be deposited only where there is a base on which deposition of material is required. In an instance where the object requires an overhang, or requires fabrication of a larger dimension, subtractive manufacturing/machining of the object can be performed in order to provide a definite shape and size to the object. During the process of subtractive manufacturing, a suitable tool is used to cut away extra material from a solid block to create a desired three-dimensional object. Such subtractive manufacturing may require human involvement that may be time consuming, may increase production costs and may not provide required accuracy. Further, most printers provide three degrees of freedom for manipulation and/or positioning of the object. However, such 3D printers do not provide operational freedom for accurate manufacturing of the three-dimensional object.
[0006] Therefore, there is a need in the art to provide apparatus and method that can enable additive as well as subtractive manufacturing and at the same time provide varied degrees of freedom to enable accurate fabrication of a three-dimensional object.
[0007] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0008] In some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0009] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0010] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

OBJECTS OF THE INVENTION
[0011] It is a general object of the present disclosure to provide apparatus and method for manufacturing a three-dimensional object.
[0012] It is another object of the present disclosure to provide apparatus and method that provides linear and rotational degrees of freedom while manufacturing of a three-dimensional object.
[0013] It is another object of the present disclosure to provide apparatus and method that enables additive as well as subtractive manufacturing for manufacturing of a three-dimensional object.
[0014] It is another object of the present disclosure to provide apparatus and method for manufacturing of a three-dimensional object possessing higher tensile strength.
[0015] It is another object of the present disclosure to provide apparatus and method for manufacturing of a three-dimensional object that is cost effective.

SUMMARY
[0016] The present invention relates generally to the field of manufacturing of three dimensional (3D) objects, and more specifically, to apparatus and method to enable additive as well as subtractive manufacturing.
[0017] An embodiment of the present disclosure pertains to an apparatus for manufacturing a three-dimensional object, the apparatus comprising: a tool handling means for supporting a detachable tool to facilitate fabrication of the three-dimensional object; and a printing bed for supporting the three-dimensional object, wherein the tool handling means and the printing bed in unison provides at least five degrees of freedom to said apparatus, and wherein said detachable tool is any of an interface material dispensing means and a cutting means.
[0018] In an embodiment of the proposed system, the printing bed is configured to move, with respect to the tool handling means, linearly along at least two orthogonal axes and rotationally around at least two axes.
[0019] In an embodiment of the proposed system, the tool handling means provides translatory motion to the detachable tool.
[0020] In an embodiment, the proposed system further comprises a controller to analyze one or more pre-determined directional paths for movement of the detachable tool and the printing bed with respect to each other based on a digital model of the three-dimensional object.
[0021] In an embodiment of the proposed system, the interface material dispensing means is an extruder mechanism to discharge the interface material along a pre-determined directional path to enable additive manufacturing of the three-dimensional object.
[0022] In an embodiment of the proposed system, the cutting means is a cutting tool to cut the three-dimensional object along a pre-determined directional path to enable subtractive manufacturing of the three-dimensional object.
[0023] In an embodiment of the proposed system, the cutting means is rotated by a driving means selected from the group consisting of an electric motor, a servo motor, or a stepper motor.
[0024] In an embodiment of the proposed system, the apparatus is operatively configured with a Computer Numerical Control (CNC) system.
[0025] Another embodiment of the present disclosure pertains to a method for manufacturing a three-dimensional object, the method comprising steps of: creating, at a computing device, a digital model of the three-dimensional object; generating, at the computing device, one or more pre-determined directional paths based on the created digital model; converting, at the computing device, the one or more pre-determined directional paths into a machine-readable code; and transmitting, at the computing device, the machine-readable code to a controller configured with a three-dimensional object manufacturing apparatus.
[0026] In an embodiment of the proposed method, the controller controls movement of a tool handling means and a printing bed of the three-dimensional object manufacturing apparatus with respect to each other along the one or more pre-determined directional paths.
[0027] It would be appreciated that although aspects of the present disclosure have been explained with respect to an apparatus to enable manufacturing of three-dimensional objects, the present disclosure is not limited to the same in any manner whatsoever and any other form of apparatus that allow additive as well as subtractive manufacturing is completely covered within the scope of the present disclosure.
[0028] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0030] In the figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
[0031] FIG. 1 illustrates an exemplary representation of the proposed apparatus enabling additive manufacturing of a three dimensional object in accordance with an embodiment of the present disclosure.
[0032] FIG. 2 illustrates an exemplary representation of the proposed apparatus enabling subtractive manufacturing of a three dimensional object in accordance with an embodiment of the present disclosure.
[0033] FIG. 3 illustrates an exemplary representation of proposed method for manufacturing a three-dimensional object in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0034] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0035] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This disclosure may however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the disclosure to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the disclosure, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).
[0036] Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, illustrations, and the like represent conceptual views or processes illustrating systems and methods embodying this disclosure. The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing associated software. Similarly, any electronic code generator shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program control and dedicated logic, or even manually, the particular technique being selectable by the entity implementing this disclosure. Those of ordinary skill in the art further understand that the exemplary hardware, software, processes, methods, and/or operating systems described herein are for illustrative purposes and, thus, are not intended to be limited to any particular named.
[0037] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0038] The present invention relates generally to the field of manufacturing of three dimensional (3D) objects, and more specifically, to apparatus and method that enable additive as well as subtractive manufacturing.
[0039] An embodiment of the present disclosure pertains to an apparatus for manufacturing a three-dimensional object, the apparatus comprising: a tool handling means for supporting a detachable tool to facilitate fabrication of the three-dimensional object; and a printing bed for supporting the three-dimensional object, wherein the tool handling means and the printing bed in unison provides at least five degrees of freedom to said apparatus, and wherein said detachable tool is any of an interface material dispensing means and a cutting means.
[0040] In an embodiment of the proposed system, the printing bed is configured to move, with respect to the tool handling means, linearly along at least two orthogonal axes and rotationally around at least two axes.
[0041] In an embodiment of the proposed system, the tool handling means provides translatory motion to the detachable tool.
[0042] In an embodiment, the proposed system further comprises a controller to analyze one or more pre-determined directional paths for movement of the detachable tool and the printing bed with respect to each other based on a digital model of the three-dimensional object.
[0043] In an embodiment of the proposed system, the interface material dispensing means is an extruder mechanism to discharge the interface material along a pre-determined directional path to enable additive manufacturing of the three-dimensional object.
[0044] In an embodiment of the proposed system, the cutting means is a cutting tool to cut the three-dimensional object along a pre-determined directional path to enable subtractive manufacturing of the three-dimensional object.
[0045] In an embodiment of the proposed system, the cutting means is rotated by a driving means selected from the group consisting of an electric motor, a servo motor, or a stepper motor.
[0046] In an embodiment of the proposed system, the apparatus is operatively configured with a Computer Numerical Control (CNC) system.
[0047] Another embodiment of the present disclosure pertains to a method for manufacturing a three-dimensional object, the method comprising steps of: creating, at a computing device, a digital model of the three-dimensional object; generating, at the computing device, one or more pre-determined directional paths based on the created digital model; converting, at the computing device, the one or more pre-determined directional paths into a machine-readable code; and transmitting, at the computing device, the machine-readable code to a controller configured with a three-dimensional object manufacturing apparatus.
[0048] In an embodiment of the proposed method, the controller controls movement of a tool handling means and a printing bed of the three-dimensional object manufacturing apparatus with respect to each other along the one or more pre-determined directional paths.
[0049] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
[0050] FIG. 1 illustrates an exemplary representation of the proposed apparatus enabling additive manufacturing of a three dimensional object in accordance with an embodiment of the present disclosure.
[0051] In an embodiment, the proposed apparatus can include a tool handling means (104) for supporting a detachable tool that facilitates fabrication of the three-dimensional object. The proposed apparatus can further include a printing bed (112) for supporting the three-dimensional object.
[0052] In an exemplary embodiment, the tool handling means (104) can include one or more clamping mechanisms such as vices, stops, clamps, and the like to fixedly support a detachable tool (interchangeably referred to as tool hereinafter). In an exemplary embodiment, the tool handling means (104) can move slidably along a vertical axis to enable translatory movement of the tool. In an exemplary embodiment, movement of the tool handling means (104) can be actuated by a sliding mechanism such as a telescopic slide rail mechanism, a rack and pinion mechanism and the like.
[0053] In an exemplary embodiment, the printing bed (112) can be selected from a group consisting of a trunnion table, a rotatable build platform and the like. In an exemplary embodiment, the printing bed (112) can be provided with one or more jigs and fixtures to enable proper alignment and support of the three-dimensional object.
[0054] Further, the tool handling means (104) and the printing bed (112) in unison can provide at least five degrees of freedom to said apparatus. In an embodiment, the printing bed (112) can be configured to move, with respect to the tool handling means (104), linearly along at least two orthogonal axes and rotationally around at least two axes to achieve complete operational freedom through linear and rotational movement. It would be appreciated that said complete operational freedom can ensure time and cost efficient fabrication of the three-dimensional object. In addition, said complete operational freedom of the printing bed (112) can also improve tensile strength of the object.
[0055] In an exemplary implementation, the tool handling means (104) can provide translatory motion to the tool along an axis, say, Z-axis (106) and the printing bed can be moved linearly along orthogonal axes, say, X-axis (116) and Y-axis (114). Further, the printing bed (112) can be rotated around two orthogonal axes, say A-axis (108) and C-axis (110), where A-axis (108) can be aligned in parallel with the X-axis (116) and C-axis (110) can be aligned in parallel with the Z-axis (106).
[0056] In an exemplary aspect, to enable additive manufacturing, the tool can be configured as an interface material dispensing means (102) enabled to discharge an interface material along a pre-determined directional path to provide layer-wise fabrication of the three-dimensional object. The interface material can include any pre-determined material, such as but not limited to metals, polymers, ceramics, concrete, modelling clay, and the like. The interface material can also include thermoplastics such as polylactic acid (PLA) and Acrylonitrile butadiene styrene (ABS). In an embodiment, the interface material dispensing means (102) can be an extruder mechanism. As would be appreciated by those skilled in the art, the extruder mechanism can include a feeding mechanism, a heating block unit, an extruder motor, and a nozzle that can enable discharging of the interface material in a pre-determined directional path for fabrication of a three dimensional object.
[0057] FIG. 2 illustrates an exemplary representation of the proposed apparatus enabling subtractive manufacturing of a three dimensional object in accordance with an embodiment of the present disclosure.
[0058] In an embodiment of the present disclosure, in order to enable subtractive manufacturing, the tool of the proposed apparatus can include a cutting means (202). The cutting means (202) can be a cutting tool to allow for cutting/machining of at least a portion/part of the three-dimensional object along a pre-determined directional path. Also, a driving means (204) such as electric motor, a servo motor, or a stepper motor and the like can drive the cutting means (202) to enable fabrication of the three dimensional object. In an exemplary aspect, the cutting tool can enable shear deformation of at least a part of the three-dimensional object so as to enable subtractive manufacturing. In an exemplary embodiment, the cutting means (202) can be can be selected from a group consisting of milling tools, shaping tools, planning tools, turning tools and the like. It would be appreciated that the cutting means is capable to cut any material such as wood, wax, metals and also the interface material described above.
[0059] In an embodiment, the proposed apparatus can further comprise a controller (not shown). The controller can be configured to analyze one or more pre-determined directional paths for movement of the detachable tool and the printing bed (112) with respect to each other. The pre-determined directional path can be based on a digital model of the three-dimensional object. It would be appreciated by the person skilled in the art that the digital model can include any of Computer-Aided Design (CAD) model, Computer-Aided Manufacturing (CAM) model, Additive Manufacturing File (AMF), and the like. In an exemplary embodiment, digital model of the three-dimensional object can include design data and/or elements of the three-dimensional object such as dimensions, contours, shape, tolerances and the like, and these design elements can be used to construe movement of the tool handling means (104) and the printing bed (112) with respect to each other along requisite directional paths so as to enable efficient manufacturing of the three-dimensional object.
[0060] It would be appreciated that, in an embodiment, the proposed apparatus can be operatively configured with a Computer Numerical Control (CNC) system that provides automation to the process involved in fabrication of the three-dimensional object. In an exemplary embodiment, the controller can be coupled to the CNC system to enable processing of the digital model and provide commands to the CNC system to process movement of the tool handling means (104) and the printing bed (112) along their respective pre-determined paths based on design elements of the three-dimensional object such as dimensions, contours, shape, tolerances and the like included in the digital model of the three-dimensional object. In another exemplary embodiment, dispensation of the interface material from the interface material dispensing means (102) can be controlled by the CNC system based on commands triggered by the controller. In another exemplary embodiment, rotational speed and direction of the cutting means (202) can be regulated by the CNC system based on commands triggered by the controller.
[0061] FIG. 3 illustrates an exemplary representation of proposed method for manufacturing a three-dimensional object 300 in accordance with an embodiment of the present disclosure. As illustrated, the method for manufacturing a three-dimensional object can include a step of creating, at a computing device, a digital model of the three-dimensional object (302). At step 302, a digital model for the three dimensional object can be created by a suitable designing software, such as but not limited to a CAD software, a CAM software and the like using a computing device. As would be appreciated by those skilled in the art that examples of computing device can include a processor, a portable computer, a personal digital assistant, a handheld device, and the like.
[0062] In an embodiment, the proposed method can include a step of generating, at the computing device, one or more pre-determined directional paths based on the created digital model (304). At step 304, the computing device can be enabled to generate pre-determined directional paths for interface material dispensing means (102) and cutting means (202) to ensure accurate fabrication of the three dimensional object.
[0063] In an embodiment, the proposed method can include steps of converting/extracting, at the computing device, the one or more pre-determined directional paths into a machine-readable code (306) and transmitting, by the computing device, the machine-readable code to a controller configured with a three-dimensional object manufacturing apparatus (308). In an exemplary embodiment, the machine-readable code can be any or a combination of an executable code that can be compiled and/or interpreted by the controller configured with the three-dimensional object manufacturing apparatus. In an exemplary implementation, in case when at step 302, the digital model created is a CAM model, at step 306, requisite G-codes and/or M-codes associated with the CAM model can be converted to a standard ISO 4343 format so as to enable extraction of the G-codes and/or M-codes associated with the CAM model into an optimized machine-readable code. Thereafter, at step 308, the optimized machine-readable code can be transmitted to the controller configured with the three-dimensional object manufacturing apparatus to enable construction of the three-dimensional model by enabling movement of the tool handling means (104) and the printing bed (112) along their respective pre-determined directional paths.
[0064] It would be appreciated that various embodiments of the present disclosure can be utilized for several manufacturing activities involved in various fields such as but not limited to architecture, electronics, aerospace, automobiles, wood works, etc.
[0065] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C ….and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc. The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.
[0066] While embodiments of the present disclosure have been illustrated and described, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the disclosure, as described in the claims.

ADVANTAGES OF THE INVENTION
[0067] The present disclosure provides apparatus and method for manufacturing a three-dimensional object.
[0068] The present disclosure provides apparatus and method that provide linear and rotational degrees of freedom while manufacturing of a three-dimensional object.
[0069] The present disclosure provides apparatus and method that enables additive as well as subtractive manufacturing for manufacturing of a three-dimensional object.
[0070] The present disclosure provides apparatus and method for manufacturing of a three-dimensional object possessing higher tensile strength.
[0071] The present disclosure provides apparatus and method for manufacturing of a three-dimensional object that is cost effective.