Methods and Apparatus for Three-Dimensional Printed Composites Based on Folded Substrate Sheets

Abstract

A three-dimensional object comprises substantially planar or flat substrate layers that are folded and stacked in a predetermined order and infiltrated by a hardened material. The object is fabricated by positioning powder on all or part of multiple substrate layers. On each layer, the powder is selectively deposited in a pattern that corresponds to tiles that each have a slice of the object. For each slice, powder is deposited in positions that correspond to positions in the slice where the object exists, and not deposited where the object does not exist. The tiles of each substrate layer are folded and aligned in a predetermined order. Multiple folded substrate layers mat be combined into a single stack. The powder is transformed into a substance that flows and subsequently hardens into the hardened material in a spatial pattern that infiltrates positive regions, and does not infiltrate negative regions, in the substrate layers.

What is claimed is: 
     
         1 . A method of fabricating a three-dimensional object, comprising the steps of:
 (a) positioning powder on all or part of at least one of a plurality of substrate layers, wherein each substrate layer is a sheet-like structure that is substantially planar or flat;   (b) repeating step (a) for remaining layers in the plurality of substrate layers;   (c) folding each of the substrate layers in a predetermined order for creating the three-dimensional object; and   (d) transforming at least some of the powder into a substance that flows and subsequently hardens into hardened material, thereby binding the plurality of folded substrate layers together, wherein the hardened material is disposed in a spatial pattern that infiltrates or coats at least one positive region in the plurality of folded substrate layers and does not substantially infiltrate or coat at least one negative region in the plurality of folded substrate layers, the three-dimensional object comprising the positive regions of the stacked plurality of substrate layers that are infiltrated or coated by, and bound together by, the hardened material.   
     
     
         2 . The method of  claim 1 , further comprising the step of:
 (e) removing at least some of the negative regions from the stacked folded substrate layers.   
     
     
         3 . The method of  claim 2 , wherein step (e) is performed at least in part by mechanical abrasion. 
     
     
         4 . The method of  claim 1 , further comprising the step of:
 (f) aligning the folded substrate layers in a predetermined manner for creating the three-dimensional object, wherein the folded substrate layers are accurately aligned within the stack by an alignment mechanism.   
     
     
         5 . The method of  claim 1 , wherein the substrate layers are composed of materials selected from the group consisting of carbon fibers, ceramic fibers, polymer fibers, glass fibers, and metal fibers. 
     
     
         6 . The method of  claim 1 , step (a) further comprising the step of applying a liquid on at least part of at least one of the plurality of substrate layers before applying the powder such that the liquid will adhere the powder to the at least one substrate layer. 
     
     
         7 . The method of  claim 1 , wherein the powder is applied to substantially the entire at least one substrate layer in step (a) and further comprising the step of selectively removing at least some of the powder from at least a portion of the at least one substrate layer. 
     
     
         8 . A method of fabricating a three-dimensional object, comprising the steps of:
 (a) applying liquid on all or part of at least one of a plurality of substrate layers, wherein each substrate layer is a sheet-like structure that is substantially planar or flat;   (b) repeating step (a) for remaining layers in the plurality of substrate layers;   (c) positioning powder on at least part of at least one of the plurality of substrate layers, wherein at least some of the powder adheres to the previously applied liquid;   (d) folding the substrate layers in a predetermined order for creating the three-dimensional object; and   (e) transforming at least some of the powder into a substance that flows and subsequently hardens into a hardened material, thereby binding the plurality of substrate layers together, wherein the hardened material is disposed in a spatial pattern that infiltrates or coats at least one positive region in the plurality of substrate layers and does not substantially infiltrate or coat at least one negative region in the plurality of substrate layers, the three-dimensional object comprising the positive regions of the stacked plurality of substrate layers that are infiltrated or coated by, and bound together by, the hardened material.   
     
     
         9 . The method of  claim 8 , further comprising the step of:
 (f) removing at least some of the negative regions from the stacked substrate layers to form the three-dimensional object.   
     
     
         10 . The method of  claim 9 , wherein step (f) is performed at least in part by mechanical abrasion. 
     
     
         11 . The method of  claim 8 , further comprising the step of:
 (g) aligning the folded substrate layers in a predetermined manner for creating the three-dimensional object, wherein the folded substrate layers are accurately aligned within the stack by an alignment mechanism.   
     
     
         12 . The method of  claim 8 , wherein the substrate layers are composed of materials selected from the group consisting of carbon fibers, ceramic fibers, polymer fibers, glass fibers, and metal fibers. 
     
     
         13 . The method of  claim 8 , wherein the powder is applied to substantially the entire at least one substrate layer in step (a) and further comprising the step of selectively removing the powder from that portion of the at least one substrate layer to which the liquid was not applied. 
     
     
         14 . An apparatus for fabricating a three-dimensional object, comprising:
 at least one applicator configured for positioning powder on all or part of a plurality of plurality of substrate layers, wherein each substrate layer is a sheet-like structure that is substantially planar or flat;   folding apparatus configured to fold each substrate layer in a predetermined order for creating the three-dimensional object; and   at least one transformation element configured for transforming at least some of the powder into a substance that flows and subsequently hardens into hardened material, thereby binding at least some of the plurality of folded substrate layers together, wherein the hardened material is disposed in a spatial pattern that infiltrates or coats at least one positive region in the plurality of folded substrate layers and does not substantially infiltrate or coat at least one negative region in the plurality of folded substrate layers, the three-dimensional object comprising the positive regions of the stacked plurality of substrate layers that are infiltrated or coated by, and bound together by, the hardened material.   
     
     
         15 . The apparatus of  claim 14 , further comprising subtractive apparatus configured for removing at least some of the negative regions from the stacked substrate layers. 
     
     
         16 . The apparatus of  claim 14 , further comprising at least one alignment mechanism configured for aligning the folded substrate layers within the stack in a predetermined manner. 
     
     
         17 . The apparatus of  claim 14 , further comprising a liquid applicator configured to selectively deposit liquid on the positive regions before deposition of the powder on the positive regions. 
     
     
         18 . A three-dimensional article of manufacture comprising a plurality of substrate layers that are folded in a predetermined order for creating the article and are infiltrated or coated by, and bound together by, a hardened material, wherein each substrate layer is a sheet-like structure that is substantially planar or flat and is made from materials that can be abraded, abrasively blasted, or chemically removed. 
     
     
         19 . The article of manufacture of  claim 18 , wherein the substrate layers are made from materials selected from the group consisting of carbon fibers, ceramic fibers, polymer fibers, glass fibers, and metal fibers. 
     
     
         20 . The article of manufacture of  claim 18 , wherein the hardened material exhibits a set of one or more characteristics, which set is sufficient for distinguishing the hardened material as having formed as a result of powder having been positioned on the substrate layers and then being at least partially softened followed by hardening. 
     
     
         21 . The article of manufacture of  claim 18 , wherein the substrate layers have at least one material property that is different than any material property of the hardened substance