3D technique

 

1980s

Early additive manufacturing equipment and materials were developed in the 1980s.^[13]

In April 1980, Hideo Kodama of Nagoya Municipal Industrial Research Institute invented two additive methods for fabricating three-dimensional plastic models with photo-hardening thermoset polymer, where the UV exposure area is controlled by a mask pattern or a scanning fiber transmitter.^[14] He filed a patent for this XYZ plotter, which was published on 10 November 1981. (JP S56-144478).^[15] His research results as journal papers were published in April and November in 1981.^[16][17] However, there was no reaction to the series of his publications. His device was not highly evaluated in the laboratory and his boss did not show any interest. His research budget was just 60,000 yen or $545 a year. Acquiring the patent rights for the XYZ plotter was abandoned, and the project was terminated.

A US 4323756 patent, method of fabricating articles by sequential deposition, granted on 6 April 1982 to Raytheon Technologies Corp describes using hundreds or thousands of "layers" of powdered metal and a laser energy source and represents an early reference to forming "layers" and the fabrication of articles on a substrate.

On 2 July 1984, American entrepreneur Bill Masters filed a patent for his computer automated manufacturing process and system (US 4665492).^[18] This filing is on record at the USPTO as the first 3D printing patent in history; it was the first of three patents belonging to Masters that laid the foundation for the 3D printing systems used today.^[19][20]

On 16 July 1984, Alain Le Méhauté, Olivier de Witte, and Jean Claude André filed their patent for the stereolithography process.^[21] The application of the French inventors was abandoned by the French General Electric Company (now Alcatel-Alsthom) and CILAS (The Laser Consortium).^[22] The claimed reason was "for lack of business perspective".^[23]

In 1983, Robert Howard started R.H. Research, later named Howtek, Inc. in Feb 1984 to develop a color inkjet 2D printer, Pixelmaster, commercialized in 1986, using Thermoplastic (hot-melt) plastic ink.^[24] A team was put together, 6 members^[24] from Exxon Office Systems, Danbury Systems Division, an inkjet printer startup and some members of Howtek, Inc group who became popular figures in the 3D printing industry. One Howtek member, Richard Helinski (patent US5136515A, Method and Means for constructing three-dimensional articles by particle deposition, application 11/07/1989 granted 8/04/1992) formed a New Hampshire company C.A.D-Cast, Inc, name later changed to Visual Impact Corporation (VIC) on 8/22/1991. A prototype of the VIC 3D printer for this company is available with a video presentation showing a 3D model printed with a single nozzle inkjet. Another employee Herbert Menhennett formed a New Hampshire company HM Research in 1991 and introduced the Howtek, Inc, inkjet technology and thermoplastic materials to Royden Sanders of SDI and Bill Masters of Ballistic Particle Manufacturing (BPM) where he worked for a number of years. Both BPM 3D printers and SPI 3D printers use Howtek, Inc style Inkjets and Howtek, Inc style materials. Royden Sanders licensed the Helinksi patent prior to manufacturing the Modelmaker 6 Pro at Sanders prototype, Inc (SPI) in 1993. James K. McMahon who was hired by Howtek, Inc to help develop the inkjet, later worked at Sanders Prototype and now operates Layer Grown Model Technology, a 3D service provider specializing in Howtek single nozzle inkjet and SDI printer support. James K. McMahon worked with Steven Zoltan, 1972 drop-on-demand inkjet inventor, at Exxon and has a patent in 1978 that expanded the understanding of the single nozzle design inkjets (Alpha jets) and help perfect the Howtek, Inc hot-melt inkjets. This Howtek hot-melt thermoplastic technology is popular with metal investment casting, especially in the 3D printing jewelry industry.^[25] Sanders (SDI) first Modelmaker 6Pro customer was Hitchner Corporations, Metal Casting Technology, Inc in Milford, NH a mile from the SDI facility in late 1993-1995 casting golf clubs and auto engine parts.

On 8 August 1984 a patent, US4575330, assigned to UVP, Inc., later assigned to Chuck Hull of 3D Systems Corporation^[26] was filed, his own patent for a stereolithography fabrication system, in which individual laminae or layers are added by curing photopolymers with impinging radiation, particle bombardment, chemical reaction or just ultraviolet light lasers. Hull defined the process as a "system for generating three-dimensional objects by creating a cross-sectional pattern of the object to be formed".^[27][28] Hull's contribution was the STL (Stereolithography) file format and the digital slicing and infill strategies common to many processes today. In 1986, Charles "Chuck" Hull was granted a patent for this system, and his company, 3D Systems Corporation was formed and it released the first commercial 3D printer, the SLA-1,^[29] later in 1987 or 1988.

The technology used by most 3D printers to date—especially hobbyist and consumer-oriented models—is fused deposition modeling, a special application of plastic extrusion, developed in 1988 by S. Scott Crump and commercialized by his company Stratasys, which marketed its first FDM machine in 1992.^[25]

Owning a 3D printer in the 1980s cost upwards of $300,000 ($650,000 in 2016 dollars).^[30]