초록 ▼

A method and apparatus for producing a three-dimensional part from a plurality of planar layers using an ultrasonic welder. A sheet of planar material is placed on the partial part and ultrasonically welded, with the first sheet placed on a base. The sheet is cut to the shape of the partial part. Th

A method and apparatus for producing a three-dimensional part from a plurality of planar layers using an ultrasonic welder. A sheet of planar material is placed on the partial part and ultrasonically welded, with the first sheet placed on a base. The sheet is cut to the shape of the partial part. The process of placing of the sheet materials on the partial, welding, and cutting of the two-dimensional contour layer is continued until part is complete. In a preferred embodiment, the three-dimensional part has layers of different material. The materials can be layers of incompatible materials for ultrasonic welding in which voids are created through interposed non-compatible materials for ultrasonic welding, to allow ultrasonic welding of compatible material layers spaced by a sheet of incompatible material. In a preferred embodiment a component, such as a thermal actuator; a optical component; an internal sensor; a plurality of electronic elements, or a mechanical actuator for creating a actively deformable part, is introduced between layers of material of the part. The method described allows the introduction of components which are sensitive to manufacturing temperatures. A pressure mask applies pressure to the top layer as the layer is ultrasonic welded to the part. In a preferred embodiment, the elongated sheets of material are carried on a supply drum and moved over the partial part using a feed system having the supply drum and a take-up drum.

대표청구항 ▼

1. A method of producing a complete part comprising the steps of:providing a pair of planar sheets of material; introducing a pressure mask for applying pressure to the sheets; ultrasonically welding the sheets of material together; cutting the sheet to define a planar portion of the shape of a part

1. A method of producing a complete part comprising the steps of:providing a pair of planar sheets of material; introducing a pressure mask for applying pressure to the sheets; ultrasonically welding the sheets of material together; cutting the sheet to define a planar portion of the shape of a partial part of the complete part and to form excess sheet material; placing an additional planar sheet of material on the partial part; ultrasonically welding the additional sheet to the partial part; cutting the additional sheet to define a portion of the shape of the partial part of the complete part; and repeating the placing, welding, and cutting until the complete part is complete.