Radiation imagery chemistry: process – composition – or product th – Imaging affecting physical property of radiation sensitive... – Making named article
Reexamination Certificate
1995-02-22
2001-06-19
Le, Hoa Van (Department: 1752)
Radiation imagery chemistry: process, composition, or product th
Imaging affecting physical property of radiation sensitive...
Making named article
C430S322000, C264S029300, C264S219000, C264S258000, C156S272800, C156S275500
Reexamination Certificate
active
06248504
ABSTRACT:
TECHNICAL FIELD
The present invention relates to methods for manufacturing three-dimensional parts, and more specifically to a method for manufacturing fiber-reinforced three-dimensional parts utilizing stereolithography tooling.
BACKGROUND OF THE INVENTION
The manufacture of fiber-reinforced three-dimensional parts is typically accomplished by one of two methods: master tooling; or “contact lay-up.” The master tooling method includes the fabrication of a solid pattern typically of wood or metal via a multi-step tooling process. This method of tooling is not employed often due to the craftsmanship skills and experience needed to work with a solid wood or metal pattern.
Generally, the contact lay-up method of tooling includes the steps of: (1) fabricating a tool; (2) applying resin-wetted layers of fiber material to the tool; (3) curing the fiber layers; (4) removing the tool; and (5) trimming and cleaning the part. The primary disadvantage of this method of tooling is the amount of time and expense incurred to fabricate the tool. Manufacture of a single three-dimensional part by this method requires a minimum of three intermediate tools. If the part to be manufactured includes negative draft angles or other complex shaping requirements, more than three intermediate tools may be required. Additionally, design changes are difficult to incorporate. Finally, human error, storage and maintenance requirements, and labor-intensive in-processing severely limit this method.
Thus a need has arisen for a manufacturing method whereby fiber-reinforced three-dimensional parts are created utilizing a single-tool process, thereby minimizing material, time and labor resources while offering greater flexibility and accuracy.
SUMMARY OF THE INVENTION
The present invention overcomes the foregoing and other problems associated with the prior art by providing a manufacturing method utilizing stereolithography for making fiber-reinforced three-dimensional parts.
The present invention is a method for the manufacture of fiber-reinforced parts utilizing the single-tool fabrication step of stereolithography. Stereolithography (“SLA”) is a method for generating three-dimensional articles within a fluid medium (photopolymer) by selectively curing successive layers of the liquid medium through the use of a computer-controlled irradiation source and a translation mechanism. SLA is known in the art and is currently utilized to fabricate engineering concept models and as patterns for sand and investment casting.
The method of the present invention includes the following steps: (1) fabricating a tool using SLA; (2) applying layers of resin-wetted fabric to the tool; (3) curing the fabric layers; (4) removing the tool after curing; and (5) cleaning and trimming the part.
The method of the present invention allows three-dimensional fiber-reinforced parts to be generated simply, quickly and economically, even where such parts are complex in shape or require design variations. Since the part is designed with the aid of a computer, human error during the processing stages is virtually eliminated.
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Elwell Keith D.
Fluegel Kyle G.
Jackson Willie K.
Key Roger D.
Thomas Stan W.
Baker & Botts L.L.P.
Le Hoa Van
Raytheon Company
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