Process and device for producing a three-dimensional object

• US 10,220,565 B2
• Filed: 05/14/2015
• Issued: 03/05/2019
• Est. Priority Date: 07/04/2007
• Status: Active Grant

• Current Assignee: Envisiontec GmbH
• Original Assignee: Envisiontec GmbH
• Inventors: El-Siblani, Ali
• Primary Examiner(s): Gupta, Yogendra N
• Assistant Examiner(s): Le, Ninh
• Application Number:
  US14/712,268
• Publication Number:
  US 20150246487A1
• Time in Patent Office: 1,391 Days
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 70/88 characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
• CPC Class Codes: B29K 2105/24 crosslinked or vulcanised
• 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 process for producing at least one three-dimensional object by solidifying a solidifyable material, comprising the steps of:

• • providing an object carrier capable of carrying the object to be produced;
  • providing a material capable of solidifying when subjected to energy supply;
  • bringing a solidifyable material carrier/provider in a position to carry/provide solidifyable material at least in a building region where solidifyable material is to be solidified;
  • supplying, to the building region, energy capable of solidifying the solidifyable material; and
  • sensing, measuring and/or controlling a condition selected from the group consisting of pressure and/or strain. Alternatively or in combination, contact pressure, fluid pressure and/or material flowability can be sensed and/or adjusted.

Claims

1. A method of making a three-dimensional object on an object carrier by solidifying a solidifiable material in a solidifiable material container, the method comprising:

solidifying the solidifiable material in a pattern corresponding to the three-dimensional object such that an exposed solidified surface of the three-dimensional object adheres to the solidifiable material container; and

separating the exposed surface of the three-dimensional object from the solidifiable material container, wherein the separating step comprises generating a sensed value by sensing or measuring one selected from a group consisting of a stress, strain, pressure, and force in or at a building region, and providing the sensed value to a feedback controller, and wherein the feedback controller adjusts a relative tilt angle between the solidifiable material container and the object carrier based on the sensed value to separate the exposed surface of the three-dimensional object from the solidifiable material container.

2. The method of claim 1, wherein the separating step further comprises moving the object carrier away from the solidifiable material container along a first axis.

3. The method of claim 1, wherein the step of solidifying the solidifiable material in a pattern corresponding to the three-dimensional object comprises supplying solidification energy from a radiation source selected from a laser system, a UV lamp, and a light emitting diode system.

4. The method of claim 1, wherein the step of solidifying the solidifiable material in a pattern corresponding to the three-dimensional object comprises supplying solidification energy from one selected from a digital light projector and a spatial light modulator.

5. The method of claim 1, wherein the solidifiable material container has a closed bottom and the step of solidifying the solidifiable material in a pattern corresponding to the three-dimensional object comprises supplying solidification energy through the closed bottom of the solidifiable material container.

6. The method of claim 5, wherein the step of solidifying the solidifiable material in a pattern corresponding to the three-dimensional object comprises supplying solidification energy through a transparent plate.

7. The method of claim 6, wherein the solidifiable material container and the transparent plate are integrally formed as one part.

8. The method of claim 1, wherein the step of solidifying the solidifiable material in a pattern corresponding to the three-dimensional object comprises supplying solidification energy to a building plane, and the step of adjusting the relative tilt angle between the solidifiable material container and the object carrier further comprises adjusting a relative tilt angle between the solidifiable material container and the building plane.

9. The method of claim 1, wherein the solidifiable material container is carried on a table with at least one agitator, and the step of adjusting the relative tilt angle between the solidifiable material container and the object carrier comprises activating the at least one agitator.

10. The method of claim 2, wherein the feedback controller further adjusts an upward movement of the object carrier along the first axis based on the sensed value to separate the exposed surface of the three-dimensional object from the solidifiable material container.

11. The method of claim 10 wherein the sensed value is a strain, and the feedback controller does not adjust the relative tilt angle between the solidifiable material container and the object carrier until the sensed value reaches a prescribed threshold.