Method and apparatus for making three-dimensional objects from multiple solidifiable materials

• US 10,124,532 B2
• Filed: 11/23/2016
• Issued: 11/13/2018
• Est. Priority Date: 01/31/2011
• Status: Active Grant

• Current Assignee: Gulf Filtration Systems Inc. (Desktop Metal, Inc.)
• Original Assignee: Gulf Filtration Systems Inc. (Desktop Metal, Inc.)
• Inventors: El-Siblani, Ali, Shkolnik, Alexandr
• Primary Examiner(s): SANDERS, JAMES M
• Application Number:
  US15/359,855
• Publication Number:
  US 20170072635A1
• Time in Patent Office: 720 Days
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/236 for motion in a direction within the plane of a layer
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29C 64/357 Recycling
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion 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 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 40/20 Post-treatment, e.g. curing, coating or polishing

Abstract

Methods and apparatuses for making three-dimensional objects from multiple solidifiable materials is shown and described. Multiple solidifiable material container assemblies are provided for holding different solidifiable materials. Relative movement between the solidifiable material container assemblies and a build platform allows the solidifiable materials to be switched as an object is built. Several exemplary cleaning stations are provided for removing residual solidifiable materials from the surface of the three-dimensional object as it is built to better ensure smooth transitions between materials on the finished object.

Claims

1. A method of making a three-dimensional object from multiple solidifiable materials, the method comprising:

aligning a build platform with a first solidifiable material source;

first moving a linear solidification device along a first axis while scanning solidification energy in a first plurality of linear scans having lengths along a second axis to solidify the first solidifiable material in a first pattern corresponding to the first plurality of linear scans;

moving the build platform away from the first solidifiable material source along a third axis;

aligning the build platform with a second solidifiable material source;

second moving a linear solidification device along one of the first axis and the second axis while scanning solidification energy in a second plurality of linear scans having lengths along the other of the first axis and the second axis to solidify the second solidifiable material in a second pattern corresponding to the second plurality of linear scans,

wherein the first solidifiable material source comprises a first container with a transparent bottom, the step of first moving a linear solidification device along a first axis while scanning solidification energy in a first plurality of linear scans having lengths along a second axis further comprises projecting the solidification energy through the transparent bottom of the first container, the second solidifiable material source comprises a second container with a transparent bottom, and the step of second moving a linear solidification device along the one of the first axis and the second axis while scanning solidification energy in a second plurality of linear scans having lengths along the other of the first axis and the second axis further comprises projecting the solidification energy through the transparent bottom of the second container, and wherein during the step of first moving a linear solidification device along the first axis, the transparent bottom of the first container tilts about the second axis.

2. The method of claim 1, wherein the step of first moving a linear solidification device along a first axis while scanning solidification energy in a first plurality of linear scans along a second axis comprises moving the linear solidification device along the first axis while projecting solidification energy to a rotating energy deflector rotating in plane perpendicular to the first axis.

3. The method of claim 1, wherein the step of first moving a linear solidification device along a first axis while scanning solidification energy in a first plurality of linear scans having lengths along a second axis comprises moving a first linear solidification device along the first axis while scanning solidification energy in the first plurality of linear scans having lengths along the second axis, and the step of second moving a linear solidification device along the one of the first axis and the second axis while scanning solidification energy in a second plurality of linear scans along the other of the first axis and the second axis comprises moving a second linear solidification device along the one of the first axis and the second axis while scanning solidification energy in the second plurality of linear scans having lengths along the other of the first axis and the second axis.

4. The method of claim 1, further comprising rotating the build platform about the third axis from a first position in alignment with the first solidifiable material container to a second position in alignment with a cleaning station.

5. The method of claim 4, wherein the cleaning station is a vacuum cleaning station.

6. The method of claim 4, further comprising rotating the build platform about the third axis from the second position in alignment with the cleaning station to a third position in alignment with the second solidifiable material container.

7. The method of claim 1, wherein the step of aligning the build platform with a second solidifiable material source comprises moving at least one of the build platform and the second solidifiable material source relative to the other of the build platform and the second solidifiable material source.

8. The method of claim 1, wherein the step of aligning the build platform with a second solidifiable material source comprises rotating the build platform about the third axis.

9. The method of claim 3, wherein the first linear solidification device and the second linear solidification device are spaced apart from one another along the first axis.

10. The method of claim 3, wherein the first linear solidification device and the second linear solidification device are spaced apart from one another along the second axis.

11. The method of claim 1, wherein the step of second moving a linear solidification device along the one of the first axis and the second axis while scanning solidification energy in a second plurality of linear scans having lengths along the other of the first axis and the second axis comprises second moving a linear solidification device along the first axis while scanning solidification energy in a second plurality of linear scans having lengths along the second axis, and wherein during the step of second moving a linear solidification device moves along the first axis, the transparent bottom of the second container tilts about the second axis.

12. The method of claim 1, wherein when viewed along the second axis, the transparent bottom of the first container is curved along the first axis.