Systems and methods for fabricating 3-D objects

• US 20050275129A1
• Filed: 06/14/2004
• Published: 12/15/2005
• Est. Priority Date: 06/14/2004
• Status: Active Grant

• Current Assignee: Align Technology Incorporated
• Original Assignee: Align Technology Incorporated
• Inventors: Kaza, Srinivas, Sambu, Shiva P., Doung, Michael J., Phan, Long
• Granted Patent: US 7,481,647 B2
• Time in Patent Office: Days
• US Class Current: 264/113
• CPC Class Codes: A61C 13/0013 using stereolithographic techniques
• CPC Class Codes: A61C 13/12 Tools for fastening artificial teeth; Holders, clamps, or stands for artificial teeth A61C8/0089 takes precedence
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29L 2031/7536 Artificial teeth
• 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 80/00 Products made by additive manufacturing

Abstract

Systems and methods are disclosed for a platform to form a three-dimensional article from successively selectively solidified layers of a liquid medium which is solidifiable by application thereto of a prescribed energy. The platform can be coated or uncoated. The platform can have an array of openings therethrough. Upon completion, the article can be removed from the platform using a punch having a plurality of projections adapted to engage openings in the platform. Alternatively, a tool can be used to push articles from the platform.

Claims

1. An apparatus, comprising:

a platform having a plurality of openings therethrough; and

a punch having a plurality of projections adapted to engage openings in the platform.

2. The apparatus of claim 1, wherein the openings comprise a regular array.

3. The apparatus of claim 1, wherein the openings are formed in an irregular pattern.

4. The apparatus of claim 1, wherein each opening is circular shaped or oval shaped.

5. The apparatus of claim 1, wherein each opening is rectangular shaped.

6. The apparatus of claim 1, wherein each opening is tear-drop shaped.

7. The apparatus of claim 1, wherein each opening is elongated.

8. The apparatus of claim 1, wherein the openings are positioned on one or more columns.

9. The apparatus of claim 1, wherein the platform comprises Teflon-coated material.

10. The apparatus of claim 1, further comprising a rapid prototyping machine adapted to receive the platform.

11. A method of forming a three-dimensional article from successively selectively solidified layers of a liquid medium which is solidifiable by application thereto of a prescribed energy, comprising:

placing a platform having a plurality of openings therethrough in said liquid medium;

forming the article above the platform; and

applying a punch having a plurality of projections to engage openings in the punch to remove said article.

12. The method of claim 11, wherein the openings comprise a regular array.

13. The method of claim 11, wherein the openings are formed in an irregular pattern.

14. The method of claim 11, wherein each opening is circular shaped or oval shaped.

15. The method of claim 11, wherein each opening is rectangular shaped.

16. The method of claim 11, wherein each opening is tear-drop shaped.

17. The method of claim 11, wherein each opening is elongated.

18. The method of claim 11, wherein the openings are positioned on one or more columns.

19. The method of claim 11, wherein the punch comprises a rigid plastic material and the platform comprises a Teflon-coated material.

20. A rapid prototyping machine, comprising:

a container filled with a material capable of solidification upon exposure to irradiation,

a platform disposed within said container for supporting said object, the platform having a plurality of openings therethrough;

an irradiation device producing a beam of electromagnetic radiation for solidifying said object; and

a punch having a plurality of projections adapted to engage openings in the platform, the punch adapted to eject said object from said container.

21. A platform forming a three-dimensional article from successively selectively solidified layers of a liquid medium which is solidifiable by application thereto of a prescribed energy, comprising:

a base having a plurality of openings therethrough; and

means for removing said article.

22. The platform of claim 21, wherein the platform comprises a material including one of:

High Density Poly-Ethylene (HDPE), High Molecular Weight Poly-Ethylene (HMWPE), Ultra High Density Poly-Ethylene (UHDPE), and Ultra High Molecular Weight Poly-Ethylene (UHMWPE).

23. The platform of claim 21, wherein the platform further comprises Heat Stabilizer(s) and UV Stabilizer(s).

24. The platform of claim 21, further comprising a coat covering the base.

25. The platform of claim 24, wherein the base comprises a material including Aluminum Alloys, Stainless Steels, or High Strength Alloys.

26. The platform of claim 24, wherein the coat comprises a material including one of:

Fluorinated Ethylene-Propylene (FEP), Polytetrafluoroethylene (PTFE), and silicone.

27. The platform of claim 24, wherein the coat comprises one of:

Teflon, Xylon, and Wearlon.

29. The machine of claim 21, further comprising a tool adapted to push said object from said platform.

28. A rapid prototyping machine, comprising:

a container filled with a material capable of solidification upon exposure to irradiation,

a coated platform disposed within said container for supporting a formation of an object; and

an irradiation device producing a beam of electromagnetic radiation for solidifying said object.