Apparatus for production of three-dimensional objects by stereolithography

• US 10,086,566 B2
• Filed: 01/02/2015
• Issued: 10/02/2018
• Est. Priority Date: 01/02/2014
• Status: Active Grant

• Current Assignee: Old World Labs
• Original Assignee: Old World Labs
• Inventors: Liverman, Nicholas Lee
• Primary Examiner(s): Kennedy, Timothy
• Application Number:
  US14/588,553
• Publication Number:
  US 20150183168A1
• Time in Patent Office: 1,369 Days
• Field of Search: 264401
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29K 2071/02 Polyalkylene oxides, e.g. PEO, i.e. polyethylene oxide, or derivatives thereof
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

A system for making three dimensional objects. The system may have a frame, a build platform movably coupled to the frame, a vat removably secured so that the build platform may be lowered within the vat, and a movable radiation source capable of movement along an x and y-axis. The vat may have a radiation permeable flat bottom. The build platform may have a work surface disposed thereon. There may be at least one stepper motor capable of moving the radiation source, the build platform, or both the radiation source and the build platform. There may also be a power source, a data reader device and or computer communication device, and a microcontroller in communication with the at least one stepper motor and at least one of the data reader device or computer communication device.

Claims

1. A system for making a three-dimensional physical object comprising:

a frame;

a build platform coupled to the frame, wherein the build platform is movable along a z-axis and has a work surface disposed thereon;

a vat mounted within the frame and situated so that the work surface of the build platform may be lowered within the vat, wherein the vat has sidewalls and a radiation permeable flat bottom, the vat configured to hold a photo-curable polymer;

a radiation source, wherein the radiation source is capable of movement along an x-axis and a y-axis, wherein the radiation source is a laser and the radiation permeable flat bottom of the vat is laser transparent, the laser having a laser housing lined with roughened cardboard soaked with high heat flat black low vapor paint for reducing light reflections surrounding a collimated beam;

at least one stepper motor for moving the radiation source, the vat, and/or the build platform;

a power source;

at least one data reader device or computer communication device; and

a microcontroller in communication with the at least one stepper motor and at least one of a data reader device or computer communication device.

2. The system of claim 1, wherein the work surface of the build platform has a downwardly facing work surface and the radiation source is upwardly facing.

3. The system of claim 1, wherein the laser serving as the radiation source further comprises a laser diode configured to project at least two different wavelength beams, a dynamically adjustable focusing lens, a stepper motor for adjusting the focusing lens during operation, a photodiode configured to measure and communicate beam characteristics, a suspended collimating lens configured to adjust beam characteristics based on data communicated by the photodiode, a filter configured to affect beam intensity, and a camera for monitoring a curing process.

4. The system of claim 1, further comprising at least one window disposed within at least one exterior panel, wherein the at least one window will not allow UV or low visible light between 200 to 550 nm to leak through and activate the photo-curable polymer.

5. The system of claim 1, wherein the vat or a vat mounting assembly is horizontally hinged to the frame at a first end of the vat or vat mounting assembly and is connected to or in contact with a vat stepper motor or a connector thereof at a second end, so as to allow the vat or vat mounting assembly with a vat therein to rotate about the hinged first end.

6. The system of claim 1 further comprising 4 stepper motors, wherein one moves an x rail along a y-axis, a second moves a radiation source along an x-axis on a x rail, a third moves the build platform along a z-axis, and a fourth moves a vat mounting assembly.

7. The system of claim 1 wherein the photo-curable polymer is polyethylene diacrylate 200.

8. The system of claim 1 wherein the distance between the radiation source and a target voxel is 40 mm or less.

9. The system of claim 1 wherein a radiation intensity of radiation emitted from a focusing lens of the laser serving as the radiation source is less than 500 microwatts and a wavelength of the radiation is greater than 200 nanometers and less than 550 nanometers.

10. The system of claim 1 wherein the radiation permeable flat bottom of the vat is quartz.

11. The system of claim 1 further comprising a GPU hardware accelerator in communication with the computer and microcontroller.

12. A method for making three-dimensional physical objects comprising:

providing a system for making three-dimensional physical objects having;

a frame,

a build platform coupled to the frame, wherein the build platform is movable along a Z axis and has a work surface disposed thereon,

a vat mounted within the frame and situated so that the work surface of the build platform may be lowered within the vat, wherein the vat has sidewalls and a radiation permeable flat bottom, the vat configured to hold a photo-curable polymer,

a radiation source, wherein the radiation source is capable of movement along an x-axis and a y-axis, wherein the radiation source is a laser and the radiation permeable flat bottom of the vat is laser transparent, the laser having a laser housing lined with roughened cardboard soaked with high heat flat black low vapor paint for reducing light reflections surrounding a collimated beam,

at least one stepper motor for moving the radiation source, the vat, and/or the build platform,

a power source,

at least one data reader device or computer communication device, and

a microcontroller in communication with the at least one stepper motor and at least one of a data reader device or computer communication device;

filling the vat with a photo-curable polymer;

providing a three dimensional drawing file to the data reader or computer; and

with the system, communicating the file data to the microcontroller and subsequently controlling the stepper motors and radiation source to cure the photocurable polymer and form an object in accordance with the data file.

13. The method of claim 12, further comprising using a GPU hardware accelerator to process the data file.

14. The method of claim 12, wherein the photocurable polymer is polyethylene diacrylate 200.

15. The method of claim 12 wherein the distance between the radiation source and a target voxel is 40 mm or less.

16. The method of claim 12 wherein a radiation intensity of radiation emitted from a focusing lens of the laser serving as the radiation source is less than 500 microwatts and a wavelength of the radiation is greater than 200 nanometers and less than 550 nanometers.

17. The method of claim 12, further comprising providing a vat stepper motor for tilting the vat away from a work surface to peel a completed work layer from the vat bottom and subsequently returning the vat to a horizontal orientation after the work surface has been raised a distance of one work layer along a Z-axis.

18. The method of claim 12, further comprising optically trapping the photo-curable polymer using a beam having a different wavelength from a curing beam, prior to curing the photo-curable polymer with the curing beam.