Three dimensional model and mold making method using thick-slice subtractive fabrication

摘要

A method of rapid prototyping which can utilize existing subtractive fabrication devices for the purpose of forming complex three- dimensional objects from a computer model. The method extends the capability of existing milling machines and other subtractive devices thereby allowing them to create objects of greater complexity than would normally be possible. Complex objects are subdivided by a computer control program into optimal machinable layers having a uniform outer geometry which permits simplified alignment and fixturing and wherein portions of the object are temporarily suspended by integrally machined support membranes. A minimum number of layers are required and these layers will have substantial thickness as compared with those of conventional additive fabricators. Surfaces of the models will be smooth and require little or no hand finishing. Methods for creating various types of molds from the models are described and a visualization and verification aid is provided for the operator, together with various diagnostic information.