Method and system for making 3d glass, glass-ceramic and ceramic objects

Abstract

A apparatus for making a three-dimensional object that includes: a gripping fixture having a grip surface or a pedestal having a build surface, the grip or build surface configured to hold an end of a contiguous, preformed material; a feed system having a feed outlet positioned above the grip or build surface, the feed system configured to feed the contiguous, preformed material into a build zone between the feed outlet and the grip or build surface; and a laser delivery system arranged to direct at least one laser beam through the furnace and into the build zone to form a hot spot in the build zone; and a positioning system arranged to effect relative motion between the grip or build surface and the feed outlet. In some implementations, the apparatus for making a 3D object can also include a furnace enclosing the build zone and the feed outlet.

What is claimed is: 
     
         1 . A method of making a three-dimensional object, comprising:
 developing a hot spot in a build zone located between a feed outlet and a build surface;   feeding a contiguous, preformed material through the feed outlet into the build zone and using the hot spot to selectively heat an attachment end of the contiguous, preformed material to a viscous state;   attaching the attachment end in a viscous state to the build surface;   feeding the contiguous, preformed material through the feed outlet into the build zone and using the hot spot to selectively heat a build portion of the contiguous, preformed material above the attachment end to a viscous state; and   forming the object in the build zone by effecting relative motion of the build portion and the feed outlet according to an object creation pattern,   wherein the object creation pattern is based at least in part on a description of a three-dimensional object.   
     
     
         2 . The method of  claim 1 , wherein the step of developing a hot spot comprises directing at least one laser beam into the build zone. 
     
     
         3 . The method of  claim 1 , wherein the step of developing a hot spot comprises directing at least two laser beams into the build zone, the at least two laser beams being arranged to approach the build zone from different directions. 
     
     
         4 . The method of  claim 1 , wherein the forming is conducted by effecting relative motion of the build portion and the feed outlet in three orthogonal directions according to the object creation pattern. 
     
     
         5 . The method of  claim 1 , wherein the forming is conducted by effecting relative motion of the build portion and the feed outlet in three orthogonal directions and in at least one of a rotational direction and a tilt direction according to the object creation pattern. 
     
     
         6 . The method of  claim 1 , wherein the contiguous, preformed material comprises at least one of a glass, a glass-ceramic and a ceramic. 
     
     
         7 . The method of  claim 6 , wherein the contiguous, preformed material is in the form of a rod, a fiber, a tube, a sheet, a plate or a ribbon. 
     
     
         8 . A method of making a three-dimensional object, comprising:
 developing a hot spot in a build zone located between a feed outlet and a grip surface;   attaching an attachment end of a contiguous, preformed material to the grip surface;   feeding the contiguous, preformed material through the feed outlet into the build zone and using the hot spot to selectively heat a build portion of the contiguous, preformed material above the attachment end to a viscous state; and   forming the object in the build zone by effecting relative motion of the build portion and the feed outlet according to an object creation pattern,   wherein the object creation pattern is based at least in part on a description of a three-dimensional object.   
     
     
         9 . The method of  claim 8 , wherein the step of developing a hot spot comprises directing at least one laser beam into the build zone. 
     
     
         10 . The method of  claim 8 , wherein the step of developing a hot spot comprises directing at least two laser beams into the build zone, the at least two laser beams being arranged to approach the build zone from different directions. 
     
     
         11 . The method of  claim 8 , wherein the forming is conducted by effecting relative motion of the build portion and the feed outlet in three orthogonal directions according to the object creation pattern. 
     
     
         12 . The method of  claim 8 , wherein the forming is conducted by effecting relative motion of the build portion and the feed outlet in three orthogonal directions and in at least one of a rotational direction and a tilt direction according to the object creation pattern. 
     
     
         13 . The method of  claim 8 , wherein the forming is conducted such that the effecting relative motion comprises positioning the grip surface above the build zone according to the object creation pattern. 
     
     
         14 . The method of  claim 8 , wherein the contiguous, preformed material comprises at least one of a glass, a glass-ceramic and a ceramic. 
     
     
         15 . The method of  claim 14 , wherein the contiguous, preformed material is in the form of a rod, a fiber or a tube.