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

• US 10,245,822 B2
• Filed: 12/11/2015
• Issued: 04/02/2019
• Est. Priority Date: 12/11/2015
• 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
• Primary Examiner(s): Vajda, Peter L
• Application Number:
  US14/966,098
• Publication Number:
  US 20170165916A1
• Time in Patent Office: 1,208 Days
• CPC Class Codes: B29C 33/448 destructible B29C33/52 takes precedence; in particular used in injection moulding B29C45/4457
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/171 specially adapted for manufacturing multiple 3D objects
• CPC Class Codes: B29C 64/176 Sequentially
• CPC Class Codes: B29C 64/182 in parallel batches
• CPC Class Codes: B29C 64/336 of two or more materials
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2995/0005 Conductive
• CPC Class Codes: B29L 2031/753 Medical equipment; Accessories therefor bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

Methods and apparatuses for making multiple three-dimensional objects from multiple solidifiable materials are shown and described. In accordance with the method, the objects are designed with variable removable support heights along the build axis so that each object has an interface between first and second materials that is the same height from the build platform. The technique simplifies the process of producing multiple three-dimensional objects from multiple solidifiable materials which may have different build axis heights of first and second finished object sections so that the sources of solidifiable materials need only be switched once during the building of multiple objects.

Claims

1. A method of concurrently making a plurality of three-dimensional objects on a build platform, each object comprising a support section formed from a first solidifiable object material, a first object section formed from the first solidifiable object material, and a second object section formed from a second solidifiable object material, wherein the first object section and the second object section of each object have respective heights along a build axis and meet at an interface, the method comprising:

determining a height of the first object section of each object along the build axis;

determining a desired interface distance between each object'"'"'s interface and a build platform along the build axis, wherein the desired interface distance is the same for each object;

determining a support section height along the build axis for each object, wherein the support section height of each object equals the difference between the desired interface distance and the object'"'"'s first object section height along the build axis;

solidifying each object'"'"'s support section by solidifying a plurality of support layers of the first solidifiable object material until the object'"'"'s support section height is reached, wherein each plurality of layers is removably adhered to the build platform;

solidifying each object'"'"'s first object section by solidifying a plurality of first object section layers of the first solidifiable material until the object'"'"'s first section height is reached, wherein at least some of the objects in the plurality of three-dimensional objects have different first object section heights;

solidifying each object'"'"'s second object section by solidifying a plurality of second object section layers of the second solidifiable object material until the second section height is reached.

2. The method of claim 1, wherein the step of solidifying each object'"'"'s support section comprises contacting the build platform with the first solidifiable object material and solidifying a plurality of support section first layers on the build platform, wherein each support section first layer corresponds to one of the plurality of three dimensional objects.

3. The method of claim 1, wherein following the step of solidifying each object'"'"'s first section, a plurality of partially formed objects is present on the build platform, each partially formed object corresponds to one of the plurality of three-dimensional objects, has an exposed surface comprised of solidified first solidifiable object material, and has an overall height relative to the build platform equal to the interface distance, the method further comprising contacting each exposed surface of each partially formed object with the second solidifiable object material and solidifying a first layer of the second solidifiable object material concurrently in contact with the exposed surface of each partially formed object.

4. The method of claim 1, wherein the steps of solidifying each object'"'"'s support section and solidifying each object'"'"'s first object section collectively comprise supplying solidification energy to a plurality of layers of the first solidifiable object material in accordance with a first plurality of solidification energy patterns, and each solidification energy pattern in the first plurality of solidification energy patterns corresponds to one of the layers of the first solidifiable object material and corresponds to the support section or the first object section of each of the plurality of three-dimensional objects.

5. The method of claim 4, wherein each solidification energy pattern is defined by a bitmap.

6. The method of claim 4, wherein each solidification energy pattern is defined by a row of a voxel matrix.

7. The method of claim 4, wherein each solidification energy pattern is defined by a set of data strings.

8. The method of claim 4, wherein the step of solidifying each object'"'"'s second section comprises solidifying a second plurality of layers of the second solidifiable object material in accordance with a second plurality of solidification energy patterns, and each solidification energy pattern in the second plurality of solidification energy patterns corresponds one of the layers of the second solidifiable object material and corresponds to the second object section of at least some of the plurality of three-dimensional objects.

9. The method of claim 1, further comprising placing a source of the first solidifiable object material in alignment with a projection area of a source of solidification energy.

10. The method of claim 9, wherein the source of solidification energy is a digital light projector.

11. The method of claim 9, further comprising placing a source of the second solidifiable object material in alignment with a projection area of a source of solidification energy after the step of solidifying each object'"'"'s first section.

12. The method of claim 11, wherein the source of solidification energy is a laser diode, the laser diode is in optical communication with a rotating polygonal mirror, and the laser diode and the rotatable polygonal mirror define a first linear solidification device.

13. The method of claim 1, further comprising placing the build platform in alignment with a source of the first solidifiable object material.

14. The method of claim 13, further comprising placing the build platform in alignment with a source of the second solidifiable object material after the step of solidifying each object'"'"'s first object section.