CA1301617C

CA1301617C - Apparatus and method for forming an integral object from laminations

Info

Publication number: CA1301617C
Application number: CA000539030A
Authority: CA
Inventors: Michael Feygin
Original assignee: Individual
Current assignee: Individual
Priority date: 1986-06-06
Filing date: 1987-06-05
Publication date: 1992-05-26
Anticipated expiration: 2009-05-26
Also published as: EP0272305A1; EP0272305B1; DE3789213D1; JPH01500575A; JP2517338B2; HK173795A; WO1987007538A1; US4752352A; AU7589987A; DE3789213T2; EP0272305A4

Abstract

ABSTRACT
An apparatus and method for forming an integral three-dimensional object from laminations of the same or gradually varying shape. The apparatus includes a supply station, a work station for forming a material into a plur-ality of laminations for the three-dimensional object, a control station for directing the operation of the work station, an assembling station for stacking the laminations in sequence into the three-dimensional object, and bonding the laminations to complete the formation of the three-dimensional object. The method includes the steps of pro-viding a work station for forming the laminations for the three-dimensional object, providing the material which can be a bimaterial composite, providing a control station for directing the operation of the work station, entering data concerning the three-dimensional object at the control sta-tion, instructing the control station to direct the opera-tion of the work station, assembling the laminations in sequence into the form of the three-dimensional object, and integrally bonding the laminations to complete the formation of the integral three-dimensional object. By following the method, a unique three-dimensional object formed of indivi-dually contoured laminations of the same or gradually vary-ing shaped is obtained.

Description

13016~7 .~ , :, - . ., APPAR~I'US AND METHOD FOR FORMING
AN INTEGRAL OBJECT FROM LAMINATIONS :
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. ,,' Field of the Invention The present invention generally relate6 to manu- -facturing apparatus, method6 of manufacture, and products -~ -manufactured thereby and, more particularly, to an lntegral three-dimensional ob~ect formed from individually contoured laminations of the same or gradually varying shape. ; -Background of the ~nvention Recently, there ha6 been much discussion concern- -ing the feasibility of building a flexible sy6tem for auto-matic manufacturing of three-dimensional dies, molds, proto-types and product6. Although it i8 presently possible to develop information about a flat figure or a three-dimen-15 sional ob~ect in a computer memory and then have that figure -or object reproduced in two-dimensional fashion on a piece - -of paper by incremental movements of a plotter pen, it is ;
not yet possible to actually produce the ob~ect in three-dimensions in the same manner. Neverthele6s, it would be 20 highly de6irable to produce three-dimen6ional ob~ect~ from ~ -existing computer ~ssi6ted design 6y6tem6 (CAD sy~tems), ~ -6ince among the benefit6 to be derived would be reduction in expense and increa6e in efficiency.
Based upon a consideration of the feature6 of CAD
~y6tems, it does not at first appear that there i6 any logi-cal manner for producing three-dimensional ob~ect6 of gradu-ally varying shape. Upon further investigation, however, a three-dimensional object might be producible utili2ing thin ~ '' '~ .
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~30~617 .

plane cr~ss-section~ of ~ 601id body ~8 it~ building blocks with each ~f the cross-section6 belng cut or formed ~epar-ately. Each cross-section could be cut or formed by a laser located on a positioning "plotter-like" table, or by ~ome other technique such a6 chemical etching, ~nd then attached to another cross-section using a suitable bonding technique. ~ ~
In this manner, ~ny complex three-dimensional ob~ect could ~-be built once its design had been completed with the use of .... . ..
a CAD system.
With this method, only one machine and one tool would be needed for production of the three-dimensional ob~ect. The only software required for cros6-sect~on gener-ation would be the one that already exists in modern CAD --systems, and it would presumably work for any three-dimen-lS sional ob~ect. Being information intensive, this theoreti- ;~ -cal technique could easily be incorporated into knowledge-based engineering, design, or model-shop sy3tems.
on a s~all scale, the three-dimensional production system for creation of prototypes can be established as a computer peripheral. It might al80 evolve into a device for manufacturing lightweight laminated composite pArts which are finding widespread use in our energy-sensitlve indus-trial environment. On a large 6cale, the three-dimensional production system can perform as a full flexible manufac-turing system for maXing dies, molds, prototypes and prod-ucts.
Certain discrete components of the suggested three-dimensional production 6yBtem have been u6ed in appli- ~ -cations of various types. Unfortunately, until the present inventlon, there ha6 been no practical means for combining -~- thrée components~and~developing still additional needed components lnto a complete, workable ~ystQm. For lnstance, `~ ~hll- laser b~-ed manufacturing~ C~D systems~ and lamination :
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processes are all known, lt has remained to combine them into an integrated three-dimensional production system.
The power of l~sers utilized in laser cutting machinery allows accurate cuts in metals up to 0.25 inches ~-thick. Moreover, CNC-controlled contouring enables cutting of virtually any shape. The cutting speeds of such machin-ery can range from three thousand feet per minute for plas~
tic films to as low ~B a few inches per minute for thick or ~ -high temperature metals. Similarly, the u6e of photo etch-ing techniques to create numerou~ complex flat plate6 has been known for ye~r6, but has never been utilized as a por-tion of a technique for creating laminated three-dimensional `
objects. Also, CAD system6 have gained enough sophistica- ~:
tion to allow solid body representation. Moreover, some CAD ;~ -systems can accumulate accurate three-dimen6ional informa~
tion along with accommodating ~ectioning of solid ob~ects. ;
Additionally, ~ome types of laminated dies held together mechanically by bolting or the like have been produced by conventional machlning for many year6. ~However, despite advances in laminatlon processes, it has remained to imple-ment the advantages of automat~on in three-dimensional pro- ~ :
duction. -The present invention is directed to overcoming the above stated problems and accomplishing the stated ob-~ects by providing a unique apparatus and method for forminga composite from laminations.

Summary of the Invention Accordingly, the present invention is directed to an apparatus and method for forming an integral three-dimen-sional ob~ect *rom laminations of the same or graduallyvarying shape, The apparatus includeQ ~ station for storing and supplying a material together with means for *or~ing the : -material into a plurality of individually contoured lamina-. . .

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tions ln ~hapes required for assembly in a preselected 6e- ~-quence into the three-dimen610nal ob~ect. It also includes means for controlling the operation of the laminatlon form- ~
ing means to provide the individually contoured lamlnations - ~ -for the three-dimensional ob~ect in re6ponse to data entered concerning the three-dimensional ob~ect and further includes - - -means for a6sembling the plurality of lndividually contoured laminations formed from the material in the pre-selected sequence into the form of the three-dimen6ional ob~ect. The apparatus also includes means for integrally bonding each of the individually contoured laminations to the next ad~acent of the individually contoured laminations. With the unique ~ ~
apparatu6 of the invention, the formation of an integral three-dimen6ional ob~ect from lamination6 of the same or gradually varying shape can be succe6sfully completed.
In a preferred embodiment, a supply station houses ~ -~
rolls or container6 of thin sheet-like material and the 6heet-like material is a sheet metal ribbon. With this arrangement, the apparatus alQo preferably includes a feed-ing mechanism for advancing the ribbon from the rolls. In addition, the lamination forming ~eans preferably includes a work station having a position for cutting the ,sheet-like material together with means for cutting the sheet-like material into the required shapes at the cutting position.
Preferably, the cutting means includes a la6er beam generating device operatively associated with the work station, and also advantageously includes means for focusing --a laser beam from the generating devioe onto the ~heet-like material at the cutting position. Moreover, the apparatus 30 preferably includeE means for directing the laser be,am from the generating devi,e about the sheet-like material to form ~ :
the required ~hapes at the cutting position.
In the preferred embodiment, the operation con- ` -'' trolling means includes a computer a6sisted drafting station :: .
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for entering d~ta concexning the three-dimensional object.
There is a1BO provided mean~ associated with the computer assisted drafting station for transferring operation con-trolling signal6 to the lamination forming means. Addition-ally, the operation controlling means includes means fordetermining the thickness, individual contour6, ~equence of forming, and sequence of as6embling the individually con- ~ -toured laminations into a single, permanently bonded three- - -dimens~onal object in a predetermined operating sequence. - -In the preferred embodiment, the lamination assem-bling means include6 an a6sembly 6tation having a location for stacking the individually contoured lamination6. It also preferably includes mean6 for moving the individually contoured laminations from the cutting position of the work station to the stacking location of the a6sembly station.
Specifically, the moving mean6 i~ preferably an electromag-netically operated pick-up plate movable between the cutting position of the work station and the 6tacking location of the assembly station.
In an alternative embodiment, the moving means is a conveyor belt for tran6porting the individually contoured ~ -lamination~ from the cutting position of the work station to the stacking location of the assembly ~tation. The sheet-like material in th~ embodiment i~ a ~heet-like plastic ~ -ribbon having ~ pressure sensitive adhesive on the top - -thereof covered with a ~urface protecting tape. With this arrangement, the apparatus includes means for removing the tape before the pla~tic ribbon enters the cutting position o~ the work station.
In addit~on, the as6embly station then compri6es a stacking device including a movable plate at a stacking location. The plate is disposed on a stacking platform for ~ -axial movement to pres6 lndividually contoured laminations assembled on the plate to the next ad~acent individually ., . ~, .' '' ,-'' '~ ~
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contoured lamination carried from the cutting po6ition of the work ~tation to the stacking location of the assembly 6tation. Preferably, ~ load cell 16 a660ciated wlth the ~ -plate to en6ure A force sufficient to cau6e an adhesive bond s between the ind~vidually contoured lamination6.
A further aspect of the Apparatus of the present invention includes the av~ilability of providinq a plurality ;~
of work stations. In this respect, each work station has a position for cutting the sheet-like material and a single . -laser beam generating device i6 operatively a660ciated with each of the work stations through a beam splitter and through mean~ for directing and focusing laser beams from ~ ~ -the beam 6plitters onto the sheet-like material at the re-spective cutting positions of the work stations. Moreover, a 6ingle assembly ~tation;having a location for stackinq the indiv~dually contoured laminations from all of the work stations iB provided.
In still a further embodiment, the lamination forming means inoludes a plotter for producing the required 6hapes as a negative image on a transparent sheet-like ma-terial~for use as artwork-in the chemical etching of the sheet-llke ~aterial for the three-dimensional ob~ect. The sheet-like material of the three-dimensional ob~ect compris- -~-es a metal sheet coated with a photoresistant material for exposure to ultraviolet light. With thi6 arrangement, the lamination forming mean6 still further includes an etching station to receive the coated metal sheet selectively ex-posed to the ultraviolet light through the plotter generated ~ ;
artwork.
0 In yet another embodlment, the mat-rial stored and supplied at the station is~a powder. The lamin~tion forming ~---means then lncludes a powder receiving plàtform, means for bompressing the powder on the platform to a predetermined :-thickness, and means for integrally bonding at lea6t ~ome of ~ -.''..
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~30i617 the powder to complete formation of o~e of the individually contoured laminations. T~e lamination a6sembling means ~-include6 means for moving the powder receiving platform in ~ -cyclical fashion from the powder storing and supplying 6ta-tion to the powder compressing means and to the integral bonding mean6. Preferably, the powder compressing means includes a heated roller controlled by an actuator regulated to control the force of the roller on the powder to achleve -bonding during compression.
The present invention i~ also directed to a unique method of forming an integral three-dimensional ob~ect from very thin laminations of the 6ame or gradually varying ~hape. The method includes the step of providing means for forming a material into a plurality of individually con-lS toured laminations in shapes required for assembly in a pre-selected eequence into the three-dimensional composite.
It also includes the 6tep of providing means for controlling the operation of the lam~nation forming means to provide the individually contoured laminations for the three dimensional object. The method further lncludes the step of entering ~ -data concerning the three-dimen6ional ob~ect into the opera-tion controlling means nnd thereafter in~tructing the opera- ~-tlon controlling means to operate the lamination forming ~-means in a controlled manner BO as to form the plur~llty of ~ ;-individually contoured lamination6. It al~o includes the step o~ assembling the plurality of individually contoured laminations in the pre-selected sequence into the form of the three-dimensional ob~ect. The method still ~urther ~ -comprises the plurnlity of individually contoured lamlna-~
30 tlon6 being assembled ~uch that each of the individually ~ -contoured laminations is integrally bonded to t~e next ad~a- - --cent of the indivldually oontour~d lamination~. By follow-ing the steps of the m-thod of the invention, the formation ~ ':
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of the three-dimensional object from laminations can be successfully completed.
In yet another form of the invention, a unique method ~ -of forming an integral three-dimensional object from laminations is disclosed. The method includes positioning a platform in proximity to means for storing and supplying a powder based material, forming a layer of the powder based material of a predetermined thickness by bringing a quantity of the powder based material into contact with the platform, compressing the layer of the powder based material to cause the powder based material to be formed into a coherent mass, utilizing means for delivering concentrated energy to change a property of at least a portion of the layer of the powder based material to form an individually contoured lamination and to facilitate separation of the remainder of the layer of the powder based material from the individually contoured lamination and repeating the layer forming, compressing and utilizing steps to form a plurality of the individually contoured laminations. By following the steps of the method each of the individually contoured laminations is integrally i bonded to the next adjacent of the individually contoured laminations by at least one of the compressing and utilizing ~ -steps. ~;
Finally, the present invention is directed to an integral three-dimensional object formed from laminations by ~-the uniq~e method as set forth hereinabove. More particularly, -the invention also comprises an integral three-dimensional ~-object formed from laminations by a method comprising the steps of entering data concerning the three-dimensional object into ~ -~
an operation controlling means, instructing the operation controlling means to operate a~ lamination forming means in a -~
controlled manner so as to form a plurality of individually contoured laminations and assembling the plurality of ~
individually contoured laminations in a pre-selected se~uence ~ ;
into the form of the three-dimensional object, the plurality of individually contoured laminations being assembled such that -each of the individually contoured laminations is integrally bonded to the next adjacent of the individually contoured ~
laminations to complete formation of the three-dimensional ~ -object.
Other aspects, advantages and features of the present .-: ' .-, ~ ' ,.

~30~617 invention will become apparent from a consideration of the following specification when taken in conjunction with the accompanying drawings.
Brief Description of the Drawings In the drawings:
Fig. lA is a perspective view of a product part to be made with a die or mold formed in accordance with the present invention;
Fig. lB is a perspective view of one-half of a die or -mold to be used to manufacture the product part of Fig. lA;
Fig. lC is a perspective view of the other half of a die or mold to be used to manufacture the product part of Fig. lA;
Fig. 2A is a perspective view of a computer assisted drafting system for entering data concerning the product part and die or mold illustrated in Figs. lA - lC;
Fig. 2B is a perspective view illustrating the formation of individually contoured laminations for a three-dimensional object such as the die or mold illustrated in Figs. lB and lC; ~
Fig. 3 is a cross-sectional view taken on the line ~ -3 - 3 of Fig. 2B;
Fig. 4 is a perspective view~illustrating the assembly of individually contoured laminations into an integral three-dimensional object such as the die or mold illustrated in Figs. lB and lC:
Fig. 5 is a cross-sectional view schematically illustrating removing roughness from an integral three-dimensional object formed from individually contoured laminations such as the die or mold illustrated in Figs. lB and lC;
Fig. 6 is a cross-sectional view schematically illustrating plating an integral three-dimensional object formed from individually contoured laminations such as the die or mold illustrated in Figs. lB and lC;
Fig. 7 is a perspective view of an apparatus for forming an integral three-dimensional object from laminations ~
in accordance with the present invention, as shown with- ~- -Fig. 10; ; ~-Fig. 8 is a perspective view of an alternative embodiment of an apparatus for forming an integral three-dimensional object from laminations in accordance with the present invention;

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- 10 - , Fig. 9 i6 a perspective of a sen~or for locating - --edges of an individually contoured lamination during assem-bly of an integral three-dimensional ob~ect from laminations in accordance with the present invention;
Fig. 10 iæ A per6pective view of a plotter for producing artwork required for chemical etching the required 6hapes for individually contoured laminations for an lnte- -gral three-dimensional ob~ect; ~
Fig. 11 i6 a perspective view of chemical etching ~ -after selective exposure of a sheet-like material to ultra- - -violet light through the plotter generated artwork;
Fig. 12 iB a ~chematic illustration of furnace ;~
brazing to complete formation of an integral three-dimen-sional ob;ect formed of individually contoured laminations -, in accordance with the present invention;
~ Fig. 13 is a plan view illustrating a method for attachment of non-contiguou6 cro~s section portions; ~ -Fig. i4 i~ a perspective view of still ~nother embodiment of apparatus for forming an integral three-dimen- ~;-6ional ob~ect from laminations in acoordance with the pres- ;
ent invention; ~ -Fig. 15 i6 a ~chematic illustration of a method of ~-forming an integral three-dimen6ional ob~ect from individu-ally contoured laminations utilizing a powder material; and Fig. 16 i6 a side elevational view of an apparatus for forming an integral three-dimen6ional ob~ect from indiv-idually contoured laminations utilizing a powder material.

petailed De6cription of the Preferred Embodiments ` ~--Referring to Fig. 7, the reference numeral 20 designate~ generally an apparatus for forming an integral three-dimensional ob~ect 22 from lamination~ 24 of the 6ame ,~
or gradually varying ~hape. The apparatu~ 20 includes a ~tation 26 for ~toring and ~upplying a material 28 and means 130i617 :

for forming the material 28 into a plurality of individually - -contoured laminations 24 in shape6 required for assembly in a preselected sequence into the three-dimensional ob~ect 22.
More par~icularly, the lamination for~ing means includes a ~ -~
work ~tation 30 having a position 32 for cutting the mater-ial together with means for cutting the material 28 into the required 6hapes at the cutting position 32 such a6 the laser beam generating device 34 operatively associated with the work 6tation 30. The apparatus 20 al60 includee means for controlling the operation of the work station 30 to provide the individually contoured laminatione 24 for the three-dimen6ional ob~ect 22 in re~pon6e to data entered concerning the three-dimen6ional ob~ect 22. More 6pecifically, the operation controlling mean6 include6 a computer ae~isted 15 drafting 6tation 36 for entering data concerning the three- -dimen6ional ob~ect 22 (~ee Fig. 2a). The apparatu~ 20 ~till further includes an as~embly 6tation 38 for assembling the ;-plurality of individually contoured lamination6 24 formed ~ ~
from the material 2~ in the pre-selected sequence into the ~ -form of the three-dimensional ob~ect 22. With thi~ arrange~
ment, the individually contoured laminations 24 of the ~ame or gradually varying ehape can be integrally bonded to com- -~
plete formation of the three-dimen6ional ob~ect 22.
In thi~ connection, the apparatus 20 includes means for integrally bonding each of the individually con-toured laminations 24 to the next ad~acent of the lndividu- -ally contoured lamination6 24 to complete the formation of the three-dimen6ional ob~ect 22. When the material 28 i6 a sheet-like material such as 6heet metal ribbon, the integral bonding means comprise6 epot brazing the ind$vi~ually con-toured laminations 24 at the assembly etation 38 by utiliz- -ing the laser beam generating device 34 in a manner to be ; ~ -described h~reinafter. Alternatively, if the heet-like -~
~aterial 28 is of another material, ~uch as a sheet-like ~
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Still referring to Fig. 7, the supply station 26 i8 preferably a roll 40 for storlng the sheet-like material 28. It will also be appreciated that, with this arrange-ment, the apparatus 20 will include a feeding mechanism 42 for advancing the sheet-like m~terial 28 (such as a 6heet metal ribbon) from the roll 40 through the work ~tation 30, substantially as shown. By utilizing a pair of frictional drive rollers 44 and 46, together with a motor 48 for driv-ing one of the rollers 46, the sheet-like material 28 can be ~ -fed through the cutting position 32 of the work 6tation 30.
With the arrangement illustrated in Fig. 7, the cutting means also includes means for focusing a laser beam 50 from the generating device 34 onto the sheet-like materi~
al 28 at the cutting position 32. This preferably includes a lens 52 through which the la~er beam 50 passe6 before reaching the sheet-like material 28 at the cutting position ~i ~
32. The cutting mean6 alBo includes means for directing the ~ ~-laser beam 50 from the generating device 34 about the sheet-like material 28 to form the required shapes at the cutting ~ ~-position 32. This preferably includes a pair of mirrors 54 and 56 adapted to direct the laser beam 50 from the generat-ing device 34 through the lens 52. A~ shown, the mirrors 54 and 56 are ~paced from the generatlng device 34, the lens 52, and one another.
In a preferred embodiment, the means for directing the la~er beam 50 includes a po~itioning table 58 for ~up-portinq the mirrors 54 and 56 for axial movement along mutu-30 - ally perpendicular axes 60 and 62. The positioning table 58 --~upport~ one of the mirror6 54 for movement toward and away from the generatinq device 34 along the axis 60, and it also - ~upport~ the other of the mirrors 56 for movement with the one of the mirror~ 54. Additionally, the po~itioning table .': ' : ., ,.',-,,~ '-".

:, ., -l:~Oi617 58 6upports the other of the mirror~ 56 for movement toward and away from the one of the mirrore 54 along the axi~ 52.
As w~ll be appreciated from Fig. 7, the mirrors 54 and 56 move in a plane generally parallel to the plane of the sheet-like material 28 at the cutting position 32. It will also be seen that the po6itioning table 58 supports the lens 52 for movement with the other of the mirrors 56 such that the lens 52 is adapted to.move with the mirror6 54 and 56 in a plane generally parallel to the plane of the mir- -rors. Moreover, the lens 52 is also ~upported for move-ment along an axis 64 generally perpendicular to the plane : .
of the mirror6 54 and 56. ~ -AB previously mentioned, the lamination as6embling means includes an assembly station 38 having a location 66 :: :
for stacking the individually contoured laminations 24. It will also be appreciated that means are provided for moving . ;~
the individually contoursd lamination6 24 from the cutting ~ :
position 32 of the work station 30 to the stacking location ;~
66 of the assembly station 38. In the embodiment illustrat~
20 ed in Fig. 7, the moving mean6 iB an electromagnetically :
operated pick-up plate 68 movable between the cutting posi-tion 32 of the work station 30 and the ~tacking location 66 ~ : -of the a66embly ~tation 38. .~ :
A6 ~hown, the apparatu~ 20 preferably includes a - ~:
grinding belt 70 intermediate the cutting po6ition 32 of the work station 30 and the ~tacking location 66 of the a~sembly ~:
station 38. The pick-up plate 68 i8 adapted to place the -individually contoured lamination6 24 in contact with the ..
grinding belt 70 during movement from the cutting posltion 32 of the work station 30 to the stacking location 66 of the a6sembly station 38. In this manner, any rough edge6 creat-ed during cutting can be removed between the ¢utting posi~
tion 32 o~ the work tation 30 and the stacking location 66 of the assembly ~tation 38. -~

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Al o as shown, the as6emb1y station 38 includes a ~pring biased stacking plate 72 at the Rtacking location 66 disposed for axial movement in a stAc~ holder 74 adapted to receive and retain the individually contoured laminations 24. The 6tack holder 74 i8 adapted for limited movement in a plane parallel to the plane of the 6tacking plate 72 and includes at lea6t one retaining lip 76, and preferably a pair of retaining lip~, adapted to cooperate with the 6pring biased stack~ng plate 72 to retain the individually con-toured lamination6 24 therebetween. With thi6 construction, the individually contoured lamination6 24 each have an iden-tical generally rectangular outer contour and the 6tacking .-plate 72, ~tack holder 74, and retaining lip6 76 cooperate with the generally rectangular contour to a66emble the indi- -~
vidually contoured lamination6 24 into the form of the three-dimen6ional ob~ect 22.
Preferably, the ~tacking plate 72 include6 a pair - -of locating pin6 78 adapted to precieely position the indi- ~-vidually contoured laminations 24 into the form of the three-dimensional ob~ect 22. For this purpose, the indivi-~ ~
dually contoured lamination6 24 each hAve a pair of pin- ; -receiving locating hole6 80 (6ee Fig. 12) in the generally rectangular outer contour outwardly of any inner contour ~uch as 82. ;
Referring once again to Fig. 7, the electromagne- ~ -tically operated pick-up plate 68 is operatively as~ociated with the len6 ~upporting portion 52 of the po6itioning table 58. The pick-up plate 68 i~ adapted to be placed in contact with the individually contoured laminations 24 at the cut-ting po6ition 32 of the work ~tation 30 to be electromagnet- ;
ically attached thereto, and the po~itioning tabl~ 58 i adapted to move tho individually contoured lamin~tions from the cutting po&ition 32 of the work atation 30, ~irst, to the grinding belt 70 and, next, to the ~tacking location 66 1301617 ;-of the a~se~bly station 38. Thereafter, the individually contoured la~ination6 24 are adapted to be relea~ed from the pick-up plate 68 and are adapted to be 6pot brazed with the laser beam generating device 34 at the 6tacking location 66 5 of the a6sembly 6tation 38.
In an alternative embodiment illustrated $n Fig.
14, the apparatus 20' has a conveyor belt 84 for directly tran6porting the individually contoured laminations 24' from the cutting position 32' of the work station 30' to the 6tacking location 66' of the a~6embly etation 38'. ~he sheet-like material 28' i~ pxeferably a sheet-like plastic ribbon having a pressure ~ensitive adhesive on the top 28a' thereof covered with a surface protecting tape 86, although it i8 also contemplated that the sheet-like plastic ribbon may be provided without a pre-coated adhesive in which oase the apparatus 20' would include a coating 6tation where a thin layer of adhesive would be applied to the ribbon prior to cutting. With the former type of material, the apparatus -~
20' includes mean6 6uch a~ a roller 88 for removing the tape ~- -86 before the plaetic ribbon 28' Qnters the cutting position 32' of the workstation 30'. `~
Still referring to Fig. 14, the as6embly station 38' comprises a ~tacking device 90 including a movable plate 92 at the stacking location 66'. ~he plate 92 is dispo6ed on a stacking platform 94 for axial movement to pre~6 indi-vidually contoured lamination~ 24' as6embled on the plate 92 to the next ad~acent individually contoured lamination 24' carried from the cutting position 32' of the work6tation 30' to the ~tacking location 66' of the assembly station 38'.
Moreover, as shown, a load cell 96 i~ a6eoc$ated with the plate 92 to en~ure a force sufficient to cause an adhesive bond between the $ndividually contoured lamination6 24'.
In still one other alternative embodiment illus- ~-trated in Fig. 8, the lamination forming mean6 includes a ~;; ;

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130~617 -:

plurality of workstations 30a", 30~", 30c", 30d", etc., each having a position 32a", 32b", 32c", 32d" etc., for cutting the 6heet-like material 28~ into the required shape6 at their re~pective cutting positions. The cutt~ng means may 5 include a ~ingle laser beam generating device 34" operative- -ly associated with each of the work6tat$0ns 30a", 30b", - -.. . . .
30c", 30d", etc. through beam splitters 98, 100, 102, 104, etc. together with means for directing and focusing la6er beams 106, 108, 110, 112, etc. from the beam splitters 98, 100, 102, 104, etc. onto the 6heet-like material 28" at the cutting positions 32a", 32b", 32c", 32d" etc. With thi6 arrangement, the apparatus 20" offers high 6peed formation of an integral three-dimensional object 22" from a plurality -~
of individually contoured lamination6 24". ~-~
Still referring to Fig. 8, the means for directing and focusing the laser beams 106, 108, 110, 112 etc. in-cludes a pair of mirrors and a lens 6upported for movement ~ ~ -at each of the po6itioning table6 58a", 58b", 58c~, 58d"
etc. The positioning tables 58a", 58b", 58cn, 58d", etc.
preferably include respective pair6 of mirrors 54a" and 56a", 54b" and 56b~, 54c" and 56c", 54d" and 56d", etc. and ~ -respective lenses 52a", 52b", 52c", 52d" etc., all of which operate in the manner described in detail in connection w~th corresponding components of the 6ingle positioning table 58 illu6trated in Fig. 7, with the exception that the mirrors 54a", 54b", 54cn, 54d" etc. are movable toward and away from the per~pective beam splitters 98, 100, 102, 104, etc. rath-er than with respect to the laser beam generating device 34". With thi6 arrangement, a plurality of individually contoured l~mination~ 24' can be cut ~imultaneously at the - re~pective workstations 3oan~ 30bn, 30c", 30d" etc. to expe-dite the formation of the three-dimensional ob~ect 22n.
As shown in Fig. 8, the lamination as6embling mean~ includes a ~ingle assembly station 38" having a loca-.

- ' ~ , ' . :' - .,, ~.

; ~ .

130~6~7 .
tion 66" for stacking the i~dividually contoured laminations 24" from all of the work6tations 30a", 30b", 30cn, 30d" etc.
In addition, the apparatu6 20" includes means such as the ~ ~
electromagnetically operated pick-up plate 68" for movinq ~ .
the individually contoured laminations 24" from the cutting ~ -positions 32a", 32b", 32c", 32d" etc. of the workstations 30a", 30b", 30c", 30d" etc. to the stacking location 66" of the single assembly ~tation 38".
Still referring to Fig. 8, the apparatus 20" in-cludes a co~puter a6~isted drafting station 36" for entering data cGncerning the three-dimen6ional ob~ect 22" together ~- -with means associated with the computer as~isted drafting -~
station 36" for transferring operation controlling 6ignals to the work ~tations 30a", 30b", 30c", 3odn. ~n particular, the signal transferring mean6 preferably comprises a multi-plexer 114 that is operatively associated both with the computer assisted drafting station 36" and with the work stations 30a", 30b", 30c", 30d" etc. in convent~onal fashion and the computer a~sisted drafting station 36H is provided with 60ftware for determining the thicknes~ of the indivi-dually contoured lamination 24", for determining the indivi-dual contours of the individually contoured laminations 24"
for determining the ~eq~ence of forming the lndividually contoured laminations 24" and for determining the sequence of assembling the individually contoured laminations 24"
into the three-dimensional ob~ect 22". With this arrange-ment, the computer assisted drafting station 36" is opera-tive to insure for each of the individually contoured lamin-ations 24" that, after the thickne3s and individual contours 30 have been determined, the sequence of forming the individu- -~
ally contoured laminations 24" iB such that each o~ the ~;
lndividual contours does not contain any other lncluded contour. -" ;~
. .:., :;: .
'. "~': ". :.'' '' "' ' .

'.. "--130~617 ", Wh~e ~t ~pecifically ~hown, it will be under-6tood and appreciated that a similar computer a~i6ted ~ -drafting ~tation will be utilized with either of th¢ embodi- ~ -ments illustrated in Figs. 7 and 14, as well.
s In still another embodiment, the lamination form-ing means include6 a plotter 116 (Fig. 10) for producing the ;
reguired shapes as negative image6 on a separate transparent sheet-like material 118 for u~e a6 artwork in the chemical etching process. The sheet-like material 118 i6 supplied to -~ ~
10 the plotter 116 from a ~upply otation housing rolls or con- ~ -tainers of the material. Referring now to Fig. 11, the use of the plotter generated artwork in a chemical etching pro-cess can be under~tood. The sheet-like material 120 for the three-dimensional ob~ect 22 comprises a bi-metallic ~trip of thin metal coated with a photore6istent material for expo-sure to ultraviolet light. As will be appreciated, the sheet-like material 120 must be thin in relation to the overall ~ize of the three-dimensional ob~ect 22 BO that gradual changes in the three-dimen6ional geometry c~n be reproduced in the laminating process.
Still referring to Fig. 11, the apparatus 122 supplies the sheet-like material 120 from the roll 124 to the sthtion 126 where 6elective exposure to ultraviolet light occurs. At thi6 station 126, the shQet-like material 25 118 with the plotter generated artwork i6 gradually unwound ,~
from the roll 128 ~nd rewound onto the roll 130 as the sheet- -like material 120 moves under the artwork at the same ~peed for exposure to the ultraviolet light through the ~rtwork from the source 132. Preferably, the ~peed of the artwork on the sheet-like material 118 and the speed of the 6heet-like material 120 i5 equalized through use of a series of conventional sprockets (not ~hown) cooperating with re6pec-tive mating perforations 134. ~;

:''.'' ~, :', : : :

1:~01617 - 19 ~

It should be understood that the artwork could be ~-created by the plotter on a transparent film attached to the metal ribbon prior to the plotting and ultravlolet light ~-exposure. In another ver6ion of thi6 method the artwork could be created by the plotter directly on the surface of the metal precovered by photoresistant material. ~ -After the exposure to ultraviolet light, a chemi-cal etching solution iB oprayed onto the sheet-like material 120 from a nozzle 136. Individually contoured laminations then drop onto a conveyor 138. At thi6 point, the conveyor 138 moves the individually contoured laminat$ons 6uch as 140a, 140b, 140c, and 140d to a washing station where wash- ~ -ing solution is sprayed from a nozzle 142.
In order to fully utilize the bi-metallic materi-al, more than one cro6s section 6uch a~ 140a, 140b, 140c, 140d can be produced in any given row with each row of etched and wa6hed individually contoured laminations euch as 140a and 140b being tran6ported by the conveyor 138 to an-other conveyor 144 preferably moving generally transver6ely ~ -20 of the direction of the conveyor 138. After accepting a new ~-row of individually contoured lamination6 such a6 140a and 140b, the conveyor 148 advance6 to allow space for another row of individually contoured laminations such a~ 140c and ~-~
140d and to advance the fir~t row of individually contoured - 25 lamination6 onto the stack a6 at 150 with the unused bi~
metallic material being rewound onto a roll 152.
Referring to Fig. 13, a method of attachment for~ ~
non-contiguous portion6 of the ~ame cro6s ~ection can be ~- ;
understood. Portions 154 and 156 are connected by ~ean6 of: ~
30 the thin strip~ 158. After stacking individually contoured ~ -lamination6 and brazing them together, the thin ~trlp~ 158 can be removed by using conventional machining techniques.~ -~
~ eferring to Fig. 12, the pin-receiving locating hole6 80 an either be chemically etched or la6er cut ~n the .. :. ' -, -','' '- -,''": ;

~301617 ~

individually contoured laminat$ons 24. ThiB 1~, of cour6e, done to properly align the inner contour6 ~uch as 82 during the furnace brazing proce6s in a brazing furnace such as 160. As with the embodiment descr$bed in Fig. 7, the align-ment is aided by the cooperation of two locating pin6 6uchas 78 adapted to protrude through the locating hole6 80.
Referring to Figs. lA-lC, one application of the present invention can be understood. It will be seen that a product part 162 i6 illustrated in Fig. lA wlth two die or mold halve6 164 and 166 for making the product part 162 being illu6trated in Figs. 1~ and lC. With thi6 informa-tion, the die or mold halves 164 and 166 can be created from laminations in accordance with the present invention.
In particular, the die or mold design is fir6t created on the computer as6i6ted drafting station 36 (see Fig. 2A). Next, the laser beam 50 is manipulated to cut the individually contoured lamination6 24 and the laminations are ~oined to form the three-dimensional ob~ect 22 (see Fig.
2B and 3). Then, the individually contoured laminations 24 are spot brazed by means of the laser beam 50 and thereafter furnace brazed to complete formation of the three-dimension- -al ob~ect 22 (see Flg. 4). Finally, any roughne6s of the die or mold halve6 164 and 166 i6 removed by mean6 such as grinding (see Fig. 5), and the die or mold halve6 164 and 166 are plated, if de~ired (see Fig. 6).
A6 will be appreciated from this description and ~, the 6chematlc $t de6cribes, the pre6ent invention provides a unique method of forming an integral three-dlmonsional ob-~ect from laminations. The method includes the tep of 4'.,~'' :'' 30 providing mean~ for *orming a material into a plurality of -individually contoured laminat$ons in hapos required for assembly in a pre-~elected ~eguence into the three-dlmen- ~ -sional ob~ect. It al~o includes the step of providing means *or controlling the operation of the lamination forming :, 13016~7 . ~

means to provide the individually contoured laminations for the three-dimen6ional ~b~e~t. The method further includes the ~tep of entering data conc¢rning the three-dimensional object into the operation controlling mean6 and thereafter in6tructing the operation controlling mean6 to operate the lamination forming mean6 in a controlled manner BO aB to form the plurality of individually contoured lamination6.
It al60 include6 the step of as6embling the plurality of individually contoured lamination6 in the pre-selected se-quence into the form of the three-dimen6ional object. The method still further comprises the plurality of individually contoured laminations being a66emb1ed such that each of the ~-individually contoured laminations iB integrally bonded to ; - -the next adjacent of the individually contoured laminations to complete format$on of the three-dimensional ob~ect. With the6e 6teps, a unique three-dimensional ob;ect formed from individually contoured laminations results.
A6 will be ~ppreciated, the lamination forming means preferably is configured in accordance with the de-tails of the embodiments described hereinabove. It i8 also ; -~
advantageous for the Gperation controlling mean6 to be simi-larly configured and to have like feature6 for maximizing -~
the benefits to be gained by following the method of the present invention. By 80 doing, the operation controlling ;
means iB capable of operating the lamination forming mean6 -~
in the nece6sary controlled manner.
With regard to the assembling 6tep, it preferably ~ -includes providing a location for stacking the individually contoured laminations. The individually contoured lamina-tions are then moved from the cutting po6ition o~ the work ~tation to the stacking location. After moving, the indi~
vidually contoured l~mination6 are stacked into the form of ;~ -the three-dimen6ional ob~ect.

.: . . .- -'.-''.

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''''..` ~

13016~7 Preferab~y, if burrs are formed during the cutting operation, the method includes the 6tep of grinding the individually contoured l~minations after cutting the re-quired shape6 at the cutting position of the workstation.
Thi6 i6 done to remove any roughne~ cau6ed by the cutting step although it will be appreciated that thi6 will not be nece66ary in the ca6e of the chemical etching proces6 since no burrs will be formed. AB will be appreciat~d fro~ the embodiment of Fig. 7, the grinding step iB performed when needed at a point in time prior to stacking the individually contoured lamination6 at the stacking locations.
With regard to the step of bonding the lamina-tions, thi6 preferably includes spot brazing each of the laminations to the next ad~acent of the laminations to com-plete formation of the three-dimen6ional ob~ect, although -thi6 i6 not required in the chemical etching proces6. It ~ -al60 preferably includes thereafter furnace brazing the entire three-dimensional ob~ect, a6 shown in Fig. 12, after which the three-dimensional ob~ect become6 a unitary prod-uct, e.g., the two die or mold halve6 164 and 166 are each a unitary portion of the overall die or mold for making the product part 162. After furnace brazing, the method prefer-ably include6 the step of grinding thel three-dimen6ional ob~ect (see Fig. S) and thereafter plating the three-dimen-sional ob~ect (see Fig. 6), although the grindinq again may not be needed in the chemical etching process.
When the material iB a sheet-like material such as, e.g., a ~heet-like plaotic ribbon having a pressure ~ensitive adhesive on the top, the method will lnclude the ~tep of removing the ~urface protecting tape over the pres-~ure ~ensitive adhesive before th~ sheet-like plastic ribbon enters the cutting position of the workstation. The method will also include the step of pressing individually con-toured laminations located at the stacking location to the ~-~

. .
.

next ad~acent indivi~ua~ly ~ontoured lamination moved from the cutting position of the work 6tation to th~ stacking location to cause an adhe6ive bond between the individually contoured laminations. While not limited to the apparatus ~ -that i8 illustrated in the Qmbodiment of Fig. 14, it will be appreciated that thi6 apparatu6 can be utilized to perform ~ - -the unique method de6cribed.
Finally, the method can include the step of pro~
viding a plural~ty of work station6 each having a po6ition for cutting a sheet-like material along with the step of providing means for cutting the sheet-like material into the required shape6 at the cutting position6. The cutting means will then include a single laser beam generating devlce operatively a6sociated with each of the workstations through ~-a beam 6plitter. Moreover, the cutting means will al~o include mean~ for directing and focusing laser beams from the beam splitters onto the sheet-like material at the cut- ~ ~ -ting position6 of each of the workstations.
By utilizing the method of the invention, a unique 20 three-dimensional ob~ect for~ed from individually contoured ~,~
laminations can be provided. Thi6 is accomplished with a ~-technique which can be ut~lized for production of complex three-dimensional parts, die6, molds, prototypes, product6 conventionally produc~d by machining, and even forming parts ~ -for reconstructive bone surgery, and involves creation and then lamination of the thin individually contoured lamina- ~ ~
tions of the solid body using eguipment such as computer -- -a~6isted dra~ting stations, plotters, laser beam generating devices and the like. As ~ r sult, it is possible to signi-ficantly ~horten the ti~e between the design and the manu-facturing stages, reduce labor cost~, increase productivity -- - -and provide a flQxible manufacturing cystem.
The principle of the fl-x~ble manufacturing sy6tem can now be understood. A sheet metal ribbon 28 is fed into ~-'''.'.'' ' "','' ' . :''. .".

;: .
'~
....--....

1~0i6i'7 the work6tation 30 (Bee Fig. 7) from a roll 40 at a ~upply 6tation 26 where the ribbon i8 made from .001-.030 inch thick bimetall~c material, e.g., stael clad with copper on the bottom or any other such materials having different melting temperatures, with the metal having the higher melt-ing temperature con6tituting the thickest layer of the rib- ~-bon on the order of 70 to 98% and with the remainder, i.e., 2 to 30%, con6tituting the low melting temperature portion : -~
used for brazinq the individually contoured laminations 24 together, and a laser beam 50 is generated and directed to a cutting position 32 by means of the mirrors 54 and 56 and the lens 52 attached to the po6itioning table 58. AB noted before, the mirrors 54 and 56 are movable in the plane de-fined by the axes 60 and 62 and the lens 52 is movable along the axis 64 perpendicular thereto.
Similarly, the principle of the flexible ~anu-facturing sy6tem can be understood by referring to Fig. 11.
A 6heet metal ribbon 120 i~ fed under the ultr~violet light ~ -source 132, the etching nozzle 136, and the wa~hing nozzle 142 where the ribbon i~ again made from .001-.030 $nch thick bimetallic material, e.g., ~teel clad with copper on the bottom or any other ~uGh m~terial having different melting temperatures, with the metal having the higher melting temp-erature again constituting the thickest layer of the ribbon on the order of 70 to 98% and with the remainder, i.e., 2 to 30%, constituting the low melting temperature portion u~ed for brazing the individually contoured laminations 24 to-gether, and the overall method is a6 previously described hereinabove. A6 noted before, the individually contoured laminatlons ~uch as 140a, 140b, 140c, and 140d are depo~ited onto the stack 150 after completion of the chemical etching proce~s. ' ~
Referrlng once again to Flg. 7, by utilizing the ;~ ;
positioning table 58 to manipulate the laser baam 50, it is - ''' :' ~''.' 13016~7 - 25 - -~

possible to cut an individually contoured lamination 24 for ~ -the three-dimen~ional ob~ect 22. The 6equence of cutting is determined by the computer assi6ted drafting station soft-ware or the progra~mer in 6uch a manner that portions of the cross-section cut first do not contain any other included contour6 to ensure that there iB alwaysi a small gap between the portion of the 6heet metal ribbon 28 cut and the table ~-168 upon which it drops after cutting. For example, when ~ ~;
the individually contoured lamination 24 is being cut, the ~ -contour 170 must be cut fir6t and the contour 172 must be ;-~
cut after it.
When the individually contoured lamination 24 has -~ -been cut, the positioning table 58 moves the pick-up plate 68 above and in contact with the 6urface of the lamination 24. An electromagnet 174 i6 energized to attract the lamin-ation 24 to the pick-up plate 68 and the lamination 24 is moved into contact with the moving grinding belt 70. By 5iO `` -. .
doing, the dro6s created by the melting and resolidif~cation of the metal at the bottom of the cut line is removed in -:
this operation from the lamination 24. -As will be appreciated, the grinding belt 70 can also tran6port portions of the lamination 24 to~be disicarded into a scrap container 176. This will be helpful, for in~
sitance, when, instead of a mold or die, the By6tem i8i UBed .~
25 to create a pnrt prototype where it may be desirable to ~; -- discard the portion between the contour6 170 and 172. For such applications, the apparatus 20 i6 well suitQd for as- -~embling a plurality of individually contoured laminations 24 into an integral three-dimen6ional ob~ect 22. ~ -More 6pecifically, the contour 170 would be cut ~ -fir6t, if necesary the dro~s would be removed with the . - -grinding belt 70, and the contour 170 would be loaded onto ;
the stacking platform 72. Next, the portion between the contour~ 170 and 172 would be di6carded by first cutting the . .
: ~ ' . ,' .

contour 172, then lifting it by mean~ of the pick-up plate 68 and releasing it above the moving grinding belt 70 which will transport that portion to the scrap container 176.
Finally, the outer rectangular contour 178 and the pin re-s ceiving locating holes 80 will be cut by means of the laser beam So. ~` -In the embodiment illustrated in Fig. 7, the outer rectangular contour 178 i8 important for stacking individu-ally contoured laminations 24 in a manner accommodating accurate spot brazing. A6 wa6 previously done with the inner contour 170, the outer rectangular contour 178 i8 ` ' picked up and positioned above the stack holder 74 after which it i8 pushed against the 6tack of individually con-toured laminations 24 60 that the spring 180 compresses.
When the pick-up plate 68 returns to its upper position, the spring 180 pushes the stacking plate 72 until the individu- -ally contoured lamination 24 ~ust loaded pu6hes aga~nst the retaining lipB 76.
8ecause of the triangular shape of the lips 76, the ~tack of individually contoured laminations 24 can be pushed down but are prevented from being pushed up beyond the retaining lips 76. Thu~, each lamination 24 ends up at ~ -the 6ame level after its initial loading, i.e., the level of the retain$ng lips 76. After initial loading, the position~
lng table 58 positions the mirrors 54 and 56 where needed and positions the lens 52 within the focal ~istance from the - -~u~t loaded lamination 24, and the system ~pot brazes the ~ust loaded lamination 24 to the stack with ~hort laser ;~
pul~es.
As will be appreciated, opot brazing iB needed only to hold the individually contoured laminations 24 together temporarily until furnace brazing at a later ~tage of assembly, although if each individually contoured lamin-: - ,, . ~ .
, ,, , . . , , , ., ,, " , ., , ~,,, ., , .,, ., ., .. :~

:

~3016~7 ~ ~

- 27 - ~;

tion 24 consi~t6 of a single p$ece of metal, the spot braz~
ing 6tep ~ay be omitted. ~ ~-While the positioning table 58 i~ pr~ci~e enough to accurately locate the individually contoured laminations 24, the stacking proce~6 it~elf iB aided by the two locating -~
pins 78. These pins 78, which are located perpendicularly to the 6tacking plate 72, have conical end6 and, when each ~-individually contoured lamination 24 i6 pu6hed onto the -6tack, the pin6 78 protrude through the locating holes 80.
If the hole6 80 are not perfectly concentric with the pins 78, their inner diameter6 press again6t the conical surfaces of the pin6 78 to produce enough force to move the stack ~ -holder 74 with re6pect to the 6tack holder hou6ing 182. - - ~-In thi6 connection, the ~tack holder hou6ing 182 has a pair of grooves 184 di6po6ed in a generally horizontal plane. These groove6 loosely receive a pair of tongue~ 186 .
projecting outwardly from the sides of the ~tack holder 74.
With thi~ con~truction, the tongue6 186 ~upport the stack --holder 74 for limited movement with minimal friction in a -generally horizontal plane. -~-After each of the individually contoured lamina-tion6 24 i6 spot brazed to the stack, the feeding mechanism 42 advance6 the ~heet metal ribbon 28 and the cycle-re6umes.
After all of the individually contoured lamina- ~
25 tion6 24 have been attached to form the three-dlmensional ~-~. ..... ....
object 22, the three-dimensional ob~ect 22 can be placed in -: :
the brazing furnace 160 (see Fig. 12). Unacceptable rough-ne66 after brazing can be eliminated by grinding (see Fig.
5) before the mold urface i6 coated (by us~ng an electro-les6 nickel proce6s or other fini6hing technigue) to achieve the de6ired tolerance and surface finish ¢haracteristics.
In the case of a mold or die, both halve6 are laminated ;~
~imultaneously in a ~ingle proces~, and cutting, dro66 re- ~ -moval, loading, and spot brazing are done by the ame posi- ~ ~
~ : .
- -. ,. ~ .'' ... .. .

..: ., 1301617 ~:

.
,, .

tioning table driven by a computer assisted drafting sta-tion. -, Referring once again to the embodiment lllustrated ~- -in Fig. 14, the apparatus 20' is well suited for making pla6tic threfe-dimensional prototypes under the principles described in detail hereinabove. The primary reason for using plastics ls to reduce the needed laser power ~uffi-ciently to accommodate the UBe of a compact, inexpens$ve laser which can be easily installed in an engineering, de- ~
sign, re6earch laboratory or model 6hop environment. In .'!`' ' . ' effect, the apparatu6 20' would be another computer output peripheral analogous to a printer or plotter.
With the apparatus 20', the plastic ribbon 28' coated on the top with ~ pressure sensitive adhesive is fed from a roll 190. A mechanism which consists of several rollers 88 will remove the surface protecting tape 86 which ~ --is provided to protect the surface of the plastic ribbon 28' -~ -covered with adhesive. When the tape 86 has been removed, the laser beam 50' will cut the individually contoured lam~
inations 24' in accordance with the ~eguence described here- P`~
inabove.
With the apparatus 20' in Fig. 14, the portions cut from the plastic ribbon 28' will drop on the conveyor belt 84. Those portions comprising the individually con~
25 toured lamination6 24' that are to be attached to the stack at the stacking platform 90 will be advanced by the conveyor belt 84 over a certain distance and po~itioned under the ~tacking platform 94. Additionally, those portions to be dlscarded will be advanGed by the conveyor belt 84 until 30 they drop into a wrap conta~ner.
- After an individually contoured lamination 24~ is po~itioned under the 6taoking platform 94, the ~tacking - ~-~
platform 94 moveB down until the stacking plate 92 presses the stack to the individually contoured lamination 24~ to be ~ -.
.,. ~
.,, '',..' .'. .
: ~ '.,:' f : ~
, . :., .-" .
f ~

: :

130i617 :: -attache~. The load cell 96 transmits feedback about the load, and t~e amount of the load neces6ary to attach a par~
ticul~r individually contoured lamination 24' is calculated by a computer. In thi6 manner, an adhesive bond develops ~ -between the indivldually contoured lamination 24' and the ~-remainder of the stack, and the lamination 24' stay6 at- - -tached to the 6tack when the stack move6 up with the stack-ing platform 94. ~ -With regard to the embodiment illu6trated in Fig.
10 8, the apparatus 20" compri6es an automated production line utilizing the principles of the pre6ent invention. All of the wor~ 6tation6 30a", 30b", 30c", 30d" etc. c~n cut croes-6ection6 from metal or plastic ~imultaneou~ly and can either -share the same ribbon a~ shown in Fig. 8, or can have an 15 arrangement ~imilar to the one shown in Figs. 7 and 14 where individual ribbon feedere are provided for each substation positioned perpendicularly to a common carrying conveyor.
After all of the individually contoured laminations 24" have been cut, the conveyor 192 moves them one-by-one to the -unloading substation 194 where they are removed to the 6tacking station 38" in the previously described manner.
With this embodiment, there iB no phy~ical limit to the number of wor~ ~tations 30a", 30b", 30c", 30d" etc.
which can be installed in the automated production line. In addition, a number of such work stations can be powered by the eame laser beam generating device 34H by providing the laser beam 50" by means of beam splitter6 98, 100, 102, 104 etc. In addition, all of ~uch work 6tations can 6hare the same computer assisted drafting ~tation 36n~ conveyor belt 3~ 192, and stacking ~tation 38" to produce both plastic and metal part~.
With regard to the system repreeented in Figs. 10 and 11, a chemical etching process 1B utilized to automatic-ally produce composites. Ihe three-dimensional compoeites .,. ,.,."~ .,, ~., can comprise spec~alized part~, die~, molds, product proto-types and other ob~ects which can be described a8 geometri- :
cally bounded shape~. ~asically, Figs. lO and ll are repre-~entative of a process and apparatu~ that utilize6 a number of advance6.
In particular, advance6 in the field of polymer ~cience have lead to the creation of molded part~ with such good mechanical propertie6 that they are directly replacing -metal parts. By contra6t, die6 and mold6 are now produced -primarily by machining block6 of steel with milling machines and other conventional and numerically controlled machine tool6. With the present invention, an entirely new method for manufacturing dies and mold6 iB provided which takes advantages of the advances in the field of polymer science.
In this connection, chemical etching or machining i~ a process in which material ig removed by chemical and electrochemical dis60lution of preferentially exposed sur-faces of a work piece. Thi6 process, which i6 alBo known a6 chemical milling, photo fabricating and photo etching, pos-6e66e~ many technical and economical advantages in the manu-facture of flat metal components. Part6 of intricate de- ~ -6ign, such as oomputer ch1p6 and printed circuit board6, are produced by thi~ method.
Because the metal i6 removed not only very pre-ci6ely but also without the u6e of mechanical force andheat, pro~lem6 of dro66, burned edges, ~tress, ~train, warp-ing and burrs are avoided. The tooling costs are 6mall compared with conventional or numerical control tooling and time costs are reduced because of the comparatively rapid~;~
turnarounds which can be achieved. Many material6 can be chemically milled, including aluminum, nickel, brass, cop-per, ~tainle~s ~teel, spring steel and molybdenum. --~
The making of a laminated aold or di- wlth the use of chemical milling or etching 1B illustrated in Figs. lO
-,- - .. ~
'. ~ .

~3016i7 : -- 31 - ~
: - .- :, and 11. The mold or die design i8 created ~nd then cro6s~
6ectioned at a computer a~6i6ted drafting s~ation and the di6tance ~etween cro6~-6ections or lamination~ as specified to be the 6ame a6 the thickne66 of the sheet material which i6 to be u6ed. In addition, the geometry of each of the ; -individually contoured laminat$0n6 i6 tran6mitted to a 6pec- ;
ified plotter 116 which i6 particularly well ~uited to the ;
production of filled area6.
If multiple plotter6 ~uch a6 116 are u6ed, then ~ -multiple individually contoured lamination6 for the three-dimen6ional ob~ect can be manufactured simultaneously.
Thus, the critical production path elapsed time depends upon a number of plotters such a6 116 used for production of individually contoured lamination6. For instance, if each of the individually contoured laminations require 3.5 min-ute6 and if 10 6uch plotter6 ,are employed, the art work required for production of a four inch thick part can be generated within two hour6.
As previou~ly ~uggested, each of the individually -`
20 contoured laminations will be drawn a6 a negative image with -~
white against a dark background. The background areas will be chemically removed in a ~ub~equent etching process (a6 ~hown in Fig. 11), and the negative6 can be produced on paper or mylar. In this connection, mylar Gould be directly attached to or produced directly on the surface of metal heet6 coated with a photo re6istant material for expo6ure to ultraviolet light.
To perform the 6teps for chemical blanking, the application of a photoresistant material can be done on a large quantity ba6i~ a6 long as the sheets are stored and handled with care in preparation of work piece~. Expo6ure and etchinq operation6 are fairly fa6t, e.g., for a ~heet of ~-metal .01 inch thick, it will take from 10 to 30 minutes to do bath etching. Since all cross-6ection6 can be tched ~-: . :. ' :.
; .. . ..
.: ' : . ,:.
' :.

simultaneously, the proces6 i6 principally dependant upon the art work production.
After the etching has been completed and the pho-toresistant material has been removed, the ~heets mu6t be stacked together and laminated in a brazing furnace. Upon completion of the brazing process, a monolithic die, mold, prototype or other ob~ect will exist from the three-dimen-sional object formed from the individually contoured lamina-tions. Depending upon the final application for the object, surface coating or finishing can be performed as previously described.
A6 ~hown in Fig. 5, the brazed part will have a -step-like geometry, but the Étep edges can be eliminated by grinding before the surface i8 coated. As previou61y men- ~ -tioned, the surface can be coated using the elQctroless nickel process or other finishing technique to achieve de- -sired tolerances and 6urface finishes.
With regard to the 6heet-like material utillzed for the individually contoured laminations in the laser cutting process and the chemical etching process, it will be understood that this is pre~erably a "bimaterial" meaning ;
that it is co~pri~ed of more than a single material. For instance, it may compri6e a bimetallic material ~uch as steel clad with copper, or it may comprise a metal covered with adhesive, or it may comprise a plastic covered with adhesive, depending upon the exact process utilized, i.e., whether the individuaIly contoured laminations will be inte~
grally bonded by means of brazing or through applied pres-`~
6ure. In addition, either or both sides of the principal - --~
portion of the ~heet-like material may be ouitably covered with the bonding mat-rial.
A~ mentioned previously in connection with the utilization of a bimetallic material, the principal material will compri~e on the order of 70 to 98% of the sheet-like ~;-.' ~ '' ~3016~7 ~

: . ,-: -. .
material with the bonding material compri6ing on the order ~
of 2 to 30% of the ~heet-like material. It will be ~ppre- ~ :
ciated, of cour6e, that in the ca~e of ~ bimetallic materi-al, the principal material 6hould have a melting point suf-ficiently higher than the bonding material BO that the prin-cipal material will not deform during brazing. Similarly, -in the case of an adhesive bond, there will be suffi~ient adhesive to create a ~trong bond following the application of pressure.
In order to form an integral three-dimensional -object from indlvidually contoured laminations, it is highly desirable for the individually contoured laminations to have the same or gradually varying ~hape. This can be achieved provided that each of the individually contoured laminations compri6es no ~ore than approximately 0.125~ of the entire thickness of the integral three-dimensional ob~ect, e.g., approximately 0.030 inches maximum thickne~ for an integral three-dimen~ional ob~ect up to approximately 2 feet thick.
By following these parameters, the contour will be rolative-ly 6mooth and reguire a minimum of grinding prior to plat- i;
ing.
Referring now to Fig. 16, still another apparatus ~ -200 for forming an integral three-dimen~ional ob~ect from ~
laminations i8 illu~trated and include~ a station 202 fori - ~-2~ ~toring and ~upplying a powder material 204. The lamination forming mean~ include6 a powder receiving platform 206, ;~ --means 208 for compre~sing the powder 204 on the platform 206 ~-to a predetermined thickness, and means 210 for integrally bonding at lea~t ~ome of the powder 204 to complete forma-tion of one of the individually contoured laminations. The operation controlling ~ean6 includes a computer assisted drafting ~tation 212 for entQring data concerning the three- ~ - dimen~ional ob~ect and means 214 for transferring operation controlling ~1gn~1~ to tb- lam1n~tion for lng m an~. The ... ...

. . .. .

130~617 lamination a66emb1ing include~ mean6 216 for moving the powder receiving platform 206 in cyclical fn6hion from the powder 6toring and BUpp~ ying station 202 to the powder com-pres6ing mean6 208 and to the integral bonding meane 210.
Preferably, the powder compres6ing means 208 includes a heated roller 218 controlled by an actuator 220 regulated to control the force of the roller 218 on the powder 204 to achieve bonding during compression.
AB will be appreciated from Fig. 16, the integral bonding means 210 preferably compri6es a computer interfaced la6er scanner. The computer interfaced la6er scanner 210 is adapted to integrally bond at least some of the powder 204 formed into a layer as at 222 on the platform 206 which is compressed by the roller 218. After thiB ha~ been done, the integrally bonded powder compri6es one of the individually contoured laminations.
As will be app~eciated, the platform moving means 216 i8 a conveyor. Also, the 6tation 202 for storing and supplying the powder i8 preferably disposed above an upper eurface of the conveyor 216. In addition, a recirculation container 224 iB preferably disposed below the upper ~urface --of the conveyor 216. ~
As shown, the platform 206 i8 preferably attached - ~-to the conveyor 216 by pivotal oide support mountings 226.
The platform 206 receives the powder 204 ~o as to form the layer 222 while it i6 disposed below the container 202 with ~-any excess falling into the recirculation container 224 for ~
periodic recirculation back into the station 202. After the ~ -powder deposition on the platform 206, the conveyor 216 moves the platform 206 under the roller 218.
As this occurs, the roller 218 is brought into contact with the powder layer 222 by action of the linear actuator 220. The roller 218 iB preferably ~lectrically h-nt-d fsom n power Dupply 22~ with th- forc- of th- nctunt~

.
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.

or 220 being regulated in order to achieve proper bonding -during compre6sion of the powder l~yer 222. A6 will be appreciated, the roller 218 has the advantage of having a small area of contact with the powder layer 222 meaning that a relatively small force from the actuator 220 i8 required to achieve the desired presCure.
Next, the conveyor 216 move6 the platform 206 under the computer interfaced laser scanner 210. The ~can-ner sinter6 or melts the material within the boundaries of .. . . ..
the cross-6ection des~gnated by the computer a66i6ted draft-ing 6tation 212 to form the required one of the individually contoured 'amination6. Then, the platform 206 i6 moved around the drum 230 of the conveyor 216 (with exces6 powder 204 falling into the container 232) after which the platform 206 returns to a position under the station 202 for repeat-ing the proce6s to form the next of the individually con-toured lamination6. - -Clearly, the apparatu6 200 illu6trated in detail ~ -in Fig. 16 demonstrate~ that powder technigue6 can be util-ized for laminated ob~ect manufacturing. ~n this process, smaller la6er beam inten6ity is required in compari~on with cro6s-~ection cutting techniguel~, 6uch as those de6cribed ~ ~-hereinabove. Instead of vaporizing metal or plastic (a6 occurs in cutting), the material only ha6 to be selectively heated to a temperature that create6 intermolecular bonds.
At 6uch temperature6, sintering or melting of particles of material occurs. The apparatus 200 implement-ing thi6 powder proce66 is ~impler, e.g., than laminating objects from foil, since cross section6 are created and 30 attached to the stack at the ~ame time. Moreover, by util- ~
izing thi~ technique, problems as~ociated with non-contigu- ;-oU5 contours are entirely avoid~d.
!' ;' 13016~7 Referring specifically to Fig. 15, another method of forminq an inteqral three-dimen6ional ob~ect from lamina- -tions i6 illu6trated. The method include6 the 6tep~ of positioning a platform 234 under a station 236 for storing and supplyinq a powder material 238, depositing a quantity of the powder material 238 on the platform 234 to form a layer 240 of the powder material 238 of a predetermined thickness, compressing the layer 240 of the powder material 238 to cau6e the powder material to be formed into a coher- ~ -ent mass, heatinq at lea6t a portion of the layer 240 of the ~-powder material 238 to form an individually contoured lamin-ation 242, and repeatinq the depositing, compres6ing and heating ~teps to form a plurality of individually contoured laminations ~such as 242). With this method, the individu- -ally contoured laminations such as 242 are each integrally bonded to the next ad~aoent of the individually contoured laminations by the heating steps.
Preferably, the method includes forming the indiv-idually contoured lamination6 ~uch a6 242 to a thickness substantially the same as the thickness of the layers such as 240. It al80 includes providing means for controlling the depositing, compressing and heating step6 to provide the individually contoured laminations such as 242 for the three dimensional ob~ect to be formed thereby. It further in-cludes entering data concerning the three-dimensional ob~ect I into the controlling means and thereafter in6tructing the ~ --¦ controlling mean6 to cau6e the powder material 238 to be -I formed into the individually contoured lamination6 ~uch as 242 for the three-dimensional ob~ect. ~ore ~pecifically, the controlling mean6 preferably includes a computer assist-ed drafting station 244 for the data entering step ~nd means 246 for transferring controlling signals ther-from.
With reference to the apparatu6 and method illus- ~~
trated in Figs. 15 and 16, the layers ~uch as 240 of the ~.~.'. .
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: .. ,.. . . , .... , .. , . .,, ., ., .; ~ ... , --, 130~6~7 powder material 238 are each of a thickness on the order of 0.002 to 0.020 inches ~fter the co~pre6sing ~tep. It will also be appreciated that the compres~ing fitep i~ performed -- -either by the heated roller 218 (Fig. 16) or by a heated press platform 248 (Fig. 15). In either case, the heated portion of the layer 222 or 240 is heated by a computer interfaced laser scanner 210 or 250 adapted to integrally bond at least some of the powder material 204 or 238.
In addition, it will be appreciated that the pow-der material remaining after formation of the three-dimen-sional object formed by the integrally bonded individually ~ -contoured laminations i6 removed. Thi6 can be done as il- - -lustrated in Fig. 16 by a "dumping" method or, alternative- --ly, by subjecting the respective platforms 206 and 234 to vibrations and/or impact. In thi~ manner, the non-sintered or non-melted powder surrounding the three-dimen6ional ob-~ect and filling its holes and cavities i8 loosened and leaves the part. ~-Finally, and referring to Fig. 15, the method can utilize metal, pla~tic or ceramic powder 238. ~he powder 238 flows out of the container 236 through sieve 252 and this deposition proce~s can be enhanced by vibrating the container 236. Preferably, the platform 234 stay6 in this position until the powder layer 240 of desired thickness is deposited.
AB previou~ly mentioned, the powder layer 222 or 24Q i5 compressed by the action of the heated roller 218 or heated press platform 248. At this stage, some intermolec-ular bond6 are formed and the powder layer 222 or 240 is , attached to the platform 206 or 234 or to the next ad~acent layer where one or more layers has already been formed.
Although the bonds are fairly weak, the compressed powder 204 or 238 stays attached ven if the platform 206 or 234 is - turn-d upside-down.

. ~ - ,,~ -'' ~".
~ .... .

Referring to Fig. 15 in particular, the image of the cross-Eection 254 on the computer a66i6ted dra~tlng 6tation 244 i8 rasterized by a computer. The geometrical ~-information about the cros~-~ection 254 i~ tran~mitted from 5 the computer to the computer interfaced laser ~canner 250 --which 6cane the surface of the compres~ed powder 238 wlthin the boundaries of the cro66-section with a laser beam.
Further, the laser beam i6 automatically focu6ed on the ---surface of the cros~-~ection, it6 energy iB delivered in pulses (one pulse per ra6ter dot), and the pulse energy i6 regulated in order to sinter or melt the material to the depth equal to the thickne6s of the cros6-6ection.
With reference to the description of Figs. 15 and 16, the apparatus can ~uitably become a computer peripheral ;~-~
for tool-le6~ manufacturing of virtually any part that can be created on the computer ~creen. Although ~ome secondary 6urface finish~ng of a three-dimen~ional ob~ect produced by the apparatu~ may be required, the apparatu6 re6ults in an ideal method for near-net-~hape manufacturing.
While in the foregoing 6pecification a detailed de6cription of the preferred embodiment~ has been ~et forth, it will be ~ppreciated by tho~e skllled in the art that the details herein given may be varled without departing from the 6pirit and ~cope of the appended claim6.
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Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. An apparatus for forming an integral three-dimensional object from laminations, comprising:
a station for storing and supplying a material;
means for forming said material into a plurality of individually contoured laminations in shapes required for assembly in a pre-selected sequence into said three-dimen-sional object;
means for controlling the operation of said lamin-ation forming means to provide said individually contoured laminations for said three-dimensional object in response to data entered concerning said three-dimensional object; and means for assembling said plurality of individual-ly contoured laminations formed form said material in said pre-selected sequence into the form of said three-dimension-al object;
said plurality of individually contoured lamina-tions being assembled such that each of said individually contoured laminations is integrally bonded to the next adja-cent of said individually contoured laminations to complete formation of said integral three-dimensional object.

2. The apparatus as defined by claim 1 wherein said material stored and supplied at said station is a sheet material.

3. The apparatus as defined by claim 2 wherein said lamination forming means includes a work station having a position for cutting said sheet material and means for cutting said sheet material into said required shaped at said cutting position.

4. The apparatus as defined by claim 3 wherein said cutting means includes a laser beam generating device operatively associated with said work station, means for focusing a laser beam from said generating device onto said sheet material at said cutting position, and means for directing said laser beam form said generating device about said sheet material to form said required shapes at said cutting position.

5. The apparatus as defined by claim 4 wherein said means for focusing and directing said laser beam in-cludes a lens and a pair of mirrors, said mirrors being spaced from said generating device, said lens and one an-other, said means for directing said laser beam including a positioning table supporting said mirrors for axial movement along mutually perpendicular axes.

6. The apparatus as defined by claim 5 wherein said positioning table supports one of said mirrors for movement toward and away form said generating device, said positioning table supporting the other of said mirrors for movement with said one of said mirrors, said positioning table also supporting the other of said mirrors for movement toward and away from said one of said mirrors.

7. The apparatus as defined by claim 6 wherein said mirrors move in a plane generally parallel to the plane of said sheet material at said cutting position, said positioning table supporting said lens for movement with the other of said mirrors such that said lens is adapted to move with said mirrors in a plane generally parallel to the plane of said mirrors, said lens also being supported to move along an axis generally perpendicular to the plane of said mirrors.

8. The apparatus as defined by claim 2 wherein said operation controlling means includes a computer assist-ed drafting station for entering data concerning said three-dimensional object and means associated with said computer assisted drafting station for transferring operation con-trolling signals to said lamination forming means.

9. The apparatus as defined by claim 8 including means associated with said computer assisted drafting sta-tion for determining the thickness of said individually contoured laminations, for determining the individual con-tours of each of said individually contoured laminations, for determining the sequence of forming said individually contoured laminations, and for determining the sequence of assembling said individually contoured laminations into said three-dimensional object.

10. The apparatus as defined by claim 9 wherein said determining means is operative to ensure for each of said individually contoured lamination that, after the thickness and individual contours have been determined, the sequence of forming said individually contoured laminations is such that each of the individual contours does not con-tain any other included contour.

11. The apparatus as defined by claim 3 wherein said laminations assembling means includes an assembly sta-tion having a location or stacking said individually con-toured laminations and means for moving said individually contoured laminations from said cutting position of said work station to said stacking location of said assembly station.

12. The apparatus as defined by claim 11 wherein said moving means is an electromagnetically operated pick-up plate movable between said cutting position of said work station and said stacking location of said assembly station, said sheet material being a sheet metal ribbon stored on a roll at said station and including a feeding mechanism for advancing said ribbon from said roll to said cutting position of said work station.

13. The apparatus as defined by claim 12 includ-ing a grinding belt intermediate said cutting position of said work station and said stacking location of said assem-bly station, said pick-up plate being adapted to place said individually contoured laminations in contact with said grinding belt during movement from said cutting position of said work station to said stacking location of said assembly station.

14. The apparatus as defined by claim 12 wherein said assembly station includes a spring biased stacking plate at said stacking location, said stacking plate being disposed for axial movement in a stack holder adapted to receive and retain said individually contoured laminations on said stacking plate, said stack holder being adapted for limited movement in a plane parallel to the plane of said stacking plate.

15. The apparatus as defined by claim 14 wherein said stack holder includes a retaining lip adapted to coop-erate with said spring biased stacking plate to retain said individually contoured laminations therebetween, said indiv-idually contoured laminations each having an identical gen-erally rectangular outer contour, said stacking plate stack holder and retaining lip cooperating with said generally rectangular outer contour to assemble said individually contoured laminations into the form of said three-dimension-al object.

16. The apparatus as defined by claim 15 wherein said stacking plate includes a pair of locating pins adapted to precisely position said individually contoured lamina-tions into the form of said three-dimensional object, said individually contoured laminations each having a pair of pin-receiving locating holes in said generally rectangular outer contour outwardly of any inner contour thereof.

17. The apparatus as defined by claim 12 wherein said cutting means includes a laser beam generating device operatively associated with said work station, means for focusing a laser beam from said generating device onto said sheet material at said cutting position, and means for directing said laser beam for said generating device about said sheet material to forms aid required shaped at said cutting position, said means for focusing said laser beam including a lens, said means for directing said laser beam including a pair of mirrors, said mirrors being spaced from said generating device, said lens and one another, said means for directing said laser beam including a positioning table supporting said mirrors for axial movement along mutu-ally perpendicular axes.

18. The apparatus as defined by claim 17 wherein said positioning table supports one of said mirrors for movement toward and away from said generating device, said positioning table supporting the other of said mirrors for movement with said one of said mirrors, said positioning table also supporting the other of said mirrors for movement toward and always from said one of said mirrors, said mirrors moving in a plane generally parallel to the plane of said sheet material at said cutting position, said position-ing table supporting said lens for movement with the other of said mirrors such that said lens is adapted to move with said mirrors in a plane generally parallel to the plane of said mirrors, said lens also being supported to move along an axis generally perpendicular to the plane of said mir-rors.

19. The apparatus as defined by claim 18 wherein said electromagnetically operated pick-up plate is opera-tively associated with the lends supporting portion of said positioning table, said pick-up plate being adapted to be placed in contact with said individually contoured lamina-tions at said cutting position of said work station to be electromagnetically attached thereto, said positioning table being adapted to move said individually contoured lamina-tions form said cutting position of said work station to said stacking location of said assembly station, said indiv-idually contoured laminations thereafter being adapted to be released from said pick-up plate at said stacking locating of said assembly station.

20. The apparatus as defined by claim 19 includ-ing integral bonding means for said plurality of individual-ly contoured laminations, said integral bonding means com-prising spot brazing of said individually contoured lamina-tions with said laser beam generating device.

21. The apparatus as defined by claim 11 wherein said moving means is a conveyor belt for transporting said individually contoured laminations from said cutting posi-tion of said work station to said stacking location of said assembly station, said material being a sheet plastic ribbon having a pressure sensitive adhesive on the top thereof covered with a surface protecting tape, and includ-ing means for removing said tape before said plastic ribbon enters said cutting position of said work station.

22. The apparatus as defined by claim 21 wherein said assembly station comprises a stacking device including a movable plate at a stacking location, said plate being disposed on a stacking platform for axial movement to press individually contoured laminations assembled on said plate to the next adjacent individually contoured lamination car-ried from said cutting position of said work station to said stacking location of said assembly station, and including a load cell associated with said plate to ensure a force suf-ficient to cause an adhesive bond between said individually contoured laminations.

23. The apparatus as defined by claim 2 wherein said lamination forming means includes a plurality of work stations each having a position for cutting said sheet material and means for cutting said sheet material into said required shapes at said cutting positions, said cutting means including a single laser beam generating device opera-tively associated with each of said work stations through a beam splitter, said cutting means also including means for directing and focusing laser beams from said beam splitters onto said sheet material at said cutting positions.

24. The apparatus as defined by claim 23 wherein said lamination assembling means includes a single assembly station having a location for stacking said individually contoured laminations from all of said work stations and means for moving said individually contoured laminations from said cutting positions of said work stations to said stacking location of said single assembly station.

25. The apparatus as defined by claim 2 wherein said lamination forming means includes a plotter for produc-ing said required shapes as a negative image on a separate sheet material for use as artwork for chemical etching said sheet material for said integral three-dimensional object, said sheet material for said integral three-dimensional object comprising a sheet coated with a photore-sistant material for exposure to ultraviolet light, said lamination forming means further including an etching sta-tion to receive said coated sheet after attachment of said separate sheet material bearing said negative image.

26. The apparatus as defined by claim 25 wherein said separate sheet material used as artwork is a rib-bon having areas transparent to passage of ultraviolet light, said ribbon being moved at the same speed as said sheet material for said three-dimensional object, said ribbon preferentially exposing said sheet material for said three-dimensional object to ultraviolet light.

27. The apparatus as defined by claim 25 wherein said separate sheet material used as artwork and said sheet material for said three-dimensional object have perforations adapted to cooperate with sprockets for equal-izing the speeds thereof.

28. The apparatus as defined by claim 25 wherein said separate sheet material used as artwork contains artwork for more than one of said individually contoured laminations in a single row.

29. The apparatus as defined by claim 25 includ-ing a conveyor moving parallel to the direction of movement of said sheet material used as artwork and said sheet material for said three-dimensional object and also including another conveyor moving in a direction perpendicu-lar to the direction of movement of said first conveyor for transporting said individually contoured laminations to a stack.

30. The apparatus as defined by claim 2 wherein said lamination forming means includes a plotter for produc-ing said required shapes for use as artwork for chemical etching directly on said sheet material for said inte-gral three-dimensional object, said sheet material for said integral three-dimensional object comprising a sheet coated with a photoresistant material for exposure to ultra-violet light, said lamination forming means further includ-ing an etching station to receive said coated sheet after said negative image has been produced directly on said sheet material.

31. The apparatus as defined by claim 2 wherein said sheet material is a bimaterial ribbon sized such that any single one of said individually contoured lamina-tions comprises no more than 0.125% of the total thickness of said integral three-dimensional object defined by all of said individually contoured laminations.

32. The apparatus as defined by claim 1 wherein said material stored and supplied at said station is a powder based material.

33. The apparatus as defined by claim 32 wherein said lamination forming means includes a powder based material receiving platform, means for compressing said powder based material on said platform to a predetermined thickness, and means for delivering concentrated energy to change a property of at least some of said powder based material to complete formation of one of said individually contoured laminations and to facilitate separation of the remainder of said powder based material from said individually contoured lamination.

34. The apparatus as defined by claim 33 wherein said operation controlling means includes a computer assisted drafting station for entering data concerning said three dimensional object and means associated with said computer assisted drafting station for transferring operation controlling signals to said lamination forming means.

35. The apparatus as defined by claim 34 wherein said lamination assembling means includes means for performing cyclical movement between said powder based material receiving platform and said powder based material storing and supplying station, and said powder based material compressing means and said concentrated energy delivering means.

36. The apparatus as defined by claim 32 wherein said powder based material compressing means includes a roller, said roller being controlled by an actuator, said actuator being regulated to control the force of said roller on said powder based material to achieve bonding during compression.

37. The apparatus as defined by claim 33 wherein said concentrated energy delivering means includes a computer interfaced laser scanner, said computer interfaced laser scanner being adapted to change a property of at least some of said powder based material, at least some of said powder based material thereafter comprising one of said individually contoured laminations.

38. The apparatus as defined by claim 35 wherein said cyclical movement means is a conveyor, said station for storing and supplying said powder based material is disposed above an upper surface of said conveyor, and including a recirculation container disposed below said upper surface of said conveyor.

39. A method of forming an integral three-dimen-sional object from laminations, comprising the steps of:
providing means for forming a material into a plurality of individually contoured laminations in shapes required for assembly in a pre-selected sequence into said three-dimensional object;
providing means for controlling the operation of said lamination forming means to provide said individually contoured laminations for said three-dimensional object;
entering data concerning said three-dimensional object into said operation controlling means and thereafter instructing said operation controlling means to operate said lamination forming means in a controlled manner so as to form said plurality of individually contoured laminations;
and assembling said plurality of individually con-toured laminations in said pre-selected sequence into the form of said three-dimensional object;
said plurality of individually contoured lamina-tions being assembled such that each of said individually contoured laminations is integrally bonded to the next ad-jacent of said individually contoured laminations to com-plete formation of said three-dimensional object.

40. The method as defined by claim 39 including the step of providing a station for storing and supplying said material, said material comprising a sheet mater-ial.

41. The method as defined by claim 40 wherein said lamination forming means includes a work station having a position for cutting said sheet material and means for cutting said sheet material into said required shapes at said cutting position.

42. The method as defined by claim 39 wherein any one of said individually contoured laminations is sized so as to comprise no more than 0.125% of the thickness of said integral three-dimensional object defined by all of said individually contoured laminations.

43. The method as defined by claim 41 wherein said cutting means includes a laser beam generating device operatively associated with said work station, means for focusing a laser beam from said generating device onto said sheet material at said cutting position, and means for directing said laser beam from said generating device about said sheet material to form said required shapes at said cutting position.

44. The method as defined by claim 39 wherein said operation controlling means includes a computer assist-ed drafting station for entering data concerning said three-dimensional object and means associated with said computer assisted drafting station for transferring operation con-trolling signals to said lamination forming means.

45. The method as defined by claim 44 including the step of providing means associated with said computer assisted drafting station for determining the thickness of said individually contoured laminations, for determining the individual contours of each of said individually contoured laminations, for determining the sequence of forming said individually contoured laminations, and for determining the sequence of assembling said individually contoured lamina-tions into said three-dimensional object.

46. The method as defined by claim 45 wherein said determining means is operative to ensure for each of said individually contoured laminations that, after the thickness and individual contours have been determined, the sequence of forming said individually contoured laminations is such that each of the individual contours does not con-tain any other included contour.

47. The method as defined by claim 41 wherein said assembling step includes providing a location for stacking said individually contoured laminations, moving said individually contoured laminations from said cutting position of said work station to said stacking location, and stacking said individually contoured laminations into the form of said three-dimensional object.

48. The method as defined by claim 47 wherein said individually contoured laminations are provided with a pair of pin-receiving locating holes for aligning said indi-vidually contoured laminations with respect to one another.

49. The method as defined by claim 47 wherein said individually contoured laminations are formed such that any non-contiguous portions are connected by at least one connecting strip.

50. The method as defined by claim 46 including the step of integrally bonding said plurality of individual-ly contoured laminations, said integral bonding step includ-ing furnace brazing said integral three-dimensional object and said connecting strips being removed after said furnace brazing.

51. The method as defined by claim 47 wherein each of said individually contoured laminations include an outer periphery of constant size and shape, each of said individually contoured laminations also being provided with at least two pin-receiving locating holes adjacent said outer periphery.

52. The method as defined by claim 47 including the step of grinding said individually contoured laminations after cutting said required shapes at said cutting position of said work station prior to stacking said individually contoured laminations at said stacking location.

53. The method as defined by claim 40 including the step of integrally bonding said plurality of individual-ly contoured laminations, said integral bonding step includ-ing spot brazing said individually contoured laminations.

54. The method as defined by claim 53 wherein said integral bonding step includes thereafter furnace braz-ing said three-dimensional object.

55. The method as defined by claim 54 including the step of grinding the three-dimensional object after furnace brazing.

56. The method as defined by claim 54 including the step of plating the three-dimensional object after fur-nace brazing.

57. The method as defined by claim 47 wherein said sheet material is a sheet ribbon having a pressure sensitive adhesive on the top thereof covered with a surface protecting tape, and including the step of remov-ing said tape before said ribbon enters said cutting posi-tion of said work station.

58. The method as defined by claim 41 including pressing individually contoured laminations located at said stacking location to the next adjacent individually con-toured lamination moved from said cutting position of said work station to said stacking location to cause an adhesive bond between said individually contoured laminations.

59. The method as defined by claim 41 including the step of providing a plurality of work stations each having a position for cutting said sheet material and including the step of providing means for cutting said sheet material into said required shapes at each of said cutting positions, said cutting positions including a single laser beam generating device operatively associated with each of said work stations through a beam splitter, said cutting means also including means for directing And focusing laser beams from said beam splitters onto said sheet material at said cutting positions.

60. The method as defined by claim 59 wherein said assembly step includes providing a single location for stacking said individually contoured laminations, moving said individually contoured laminations from said cutting positions of said work stations to said single stacking location, and stacking said individually contoured lami-nations into the form of said three-dimensional object.

61. The method as defined by claim 60 wherein said operation controlling means includes a computer as-sisted drafting station for entering data concerning said three-dimensional object and means associated with said computer assisted drafting station for transferring opera-tion controlling signals to said lamination forming means.

62. The method as defined by claim 61 including the step of providing means associated with said computer assisted drafting station for determining the thickness of said individually contoured laminations, for determining the individual contours of each of said individually contoured laminations, for determining the sequence of forming said individually contoured laminations, and for determining the sequence of assembling said individually contoured lamina-tions into said three-dimensional object.

63. The method as defined by claim 62 wherein said determining means is operative to ensure for each of said individually contoured laminations that, after the thickness and individual contours have been determined, the sequence of forming said laminations is such that each of the individual contours does not contain any other included contour.

64. The method as defined by claim 58 including the step of utilizing a plotter for producing said required shapes as a negative image on a separate sheet material for use as artwork for chemical etching said sheet material for said integral three-dimensional object, said sheet material for said integral three-dimensional object comprising a bimaterial sheet coated with a photo-resistent material for exposure to ultraviolet light, and including the step of providing an etching station to re-ceive said coated bimaterial sheet after covering with said separate sheet material bearing said negative image.

65. The method as defined by claim 64 wherein said separate sheet material used as artwork is a rib-bon transparent to the passage of ultraviolet light, said ribbon being moved at the same speed as said bimaterial sheet, said ribbon preferentially exposing said bimaterial sheet to ultraviolet light.

66. The method as defined by claim 64 wherein said separate sheet material used as artwork and said bimaterial sheet have perforations adapted to cooperate with sprockets for equalizing the speeds thereof.

67. The method as defined by claim 64 wherein said separate sheet material used as artwork contains artwork for more than one of said individually contoured laminations in a single row.

68. The method as defined by claim 64 including a conveyor moving parallel to the direction of movement of said sheet material used as artwork and said bimaterial sheet and also including another conveyor moving in a direc-tion perpendicular to the direction of movement of said first conveyor for transporting said individually contoured laminations to a stack.

69. The method as defined by claim 39 including the step of providing a station for storing and supplying said material, said material comprising a powder.

70. A method of forming an integral three-dimensional object from laminations, comprising the steps of:
positioning a platform in proximity to means for storing and supplying a powder based material;
forming a layer of said powder based material of a predetermined thickness by bringing a quantity of said powder based material into contact with said platform;
compressing said layer of said powder based material to cause said powder based material to be formed into a coherent mass;
utilizing means for delivering concentrated energy to change a property of at least a portion of said layer of said powder based material to form an individually contoured lamination and to facilitate separation of the remainder of said layer of said powder based material from said individually contoured lamination; and repeating said layer forming, compressing and utilizing steps to form a plurality of said individually contoured laminations;
each of said individually contoured laminations being integrally bonded to the next adjacent of said individually contoured laminations by at least one of said compressing and utilizing steps.

71. The method as defined by claim 70 wherein said individually contoured laminations are formed to a thickness substantially the same as the thickness of said layers of said powder based material.

72. The method as defined by claim 70 including the step of providing means for controlling said layer forming, compressing and utilizing steps to provide said individually contoured laminations for said three-dimensional object and to facilitate separation of the remainder of said layer of said powder based material from said three-dimensional object.

73. The method as defined by claim 72 including the step of entering data concerning said three dimensional object into said controlling means and thereafter instruct-ing said controlling means to cause said powder based material to be formed into said individually contoured laminations.

74. The method as defined by claim 73 wherein said controlling means includes a computer assisted drafting station for said data entering step and means associated with said computer assisted drafting station for transfer-ring controlling signals for said layer forming, compressing and utilizing steps.

75. The method as defined by claim 70 wherein said layers of said powder material are each of a thickness on the order of 0.002 to 0.020 inches after the step of compressing.

76. The method as defined by claim 70 wherein said layers of said powder based material are each compressed by a press platform.

77. The method as defined by claim 70 wherein said layers of said powder based material are each compressed by a roller.

78. The method as defined by claim 70 wherein said heated portion of said layer is heated by a computer interfaced laser scanner, said computer interfaced laser scanner being adapted to integrally bond at least some of said powder material.

79. The method as defined by claim 70 including the step of removing the remainder of said powder based material from said three-dimensional object formed by said individually contoured laminations using the difference in properties of said powder based material created by said utilizing step.

80. The method as defined by claim 70 wherein said layer forming, compressing and utilizing steps are performed at different stations and including means for performing cyclical movement between said platform and said powder based material storing and supplying station, and said compressing station and said utilizing station.