Multi-material stereolithography

• US 20060022379A1
• Filed: 07/30/2004
• Published: 02/02/2006
• Est. Priority Date: 07/30/2004
• Status: Active Grant

• Current Assignee: Board of Regents of the University of Texas System (University of Texas System)
• Original Assignee: Board of Regents of the University of Texas System (University of Texas System)
• Inventors: Medina, Francisco, Elkins, Christopher, Wicker, Ryan
• Granted Patent: US 7,556,490 B2
• Time in Patent Office: Days
• US Class Current: 264/255
• 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: 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
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing

Abstract

Methods and systems of stereolithography for building cost-efficient and time-saving multi-material, multi-functional and multi-colored prototypes, models and devices configured for intermediate washing and curing/drying is disclosed including: laser(s), liquid and/or platform level sensing system(s), controllable optical system(s), moveable platform(s), elevator platform(s), recoating system(s) and at least one polymer retaining receptacle. Multiple polymer retaining receptacles may be arranged in a moveable apparatus, wherein each receptacle is adapted to actively/passively maintain a uniform, desired level of polymer by including a recoating device and a material fill/remove system. The platform is movably accessible to the polymer retaining receptacle(s), elevator mechanism(s) and washing and curing/drying area(s) which may be housed in a shielded enclosure(s). The elevator mechanism is configured to vertically traverse and rotate the platform, thus providing angled building, washing and curing/drying capabilities. A horizontal traversing mechanism may be included to facilitate manufacturing between components of SL cabinet(s) and/or alternative manufacturing technologies.

Claims

1. A stereolithography apparatus comprising:

one or more lasers adapted to perform stereolithography;

one or more polymer retaining receptacles adapted to retain polymers;

one or more movable platforms accessible to the polymer retaining receptacles; and

one or more washing areas accessible to the movable platform.

2. The stereolithography apparatus of claim 1, wherein the one or more polymer retaining receptacles are arranged on a vat apparatus.

3. The stereolithography apparatus of claim 2, wherein the vat apparatus is selected from the group consisting of a fixed stacked apparatus, a movable stacked apparatus, a fixed receptacle apparatus, a movable receptacle apparatus, a rotatable receptacle apparatus and any combination thereof.

4. The stereolithography apparatus of claim 1, wherein the movable platform comprises an elevator mechanism adapted to traverse the movable platform along a vertical axis.

5. The stereolithography apparatus of claim 4, wherein the elevator mechanism further comprises a rotation mechanism adapted to rotate the movable platform about a horizontal axis.

6. The stereolithography apparatus of claim 4, wherein the elevator mechanism is further adapted to rotate about a vertical axis.

7. The stereolithography apparatus of claim 1, wherein the washing area comprises:

one or more rinse jets; and

one or more waste receptacles.

8. The stereolithography apparatus of claim 1, wherein the apparatus further comprises one or more shielded cabinets to house the washing unit.

9. The stereolithography apparatus of claim 1, wherein the laser is an ultraviolet laser.

10. The stereolithography apparatus of claim 1, wherein the receptacle further comprises one or more pumps connected to the polymer retaining receptacle.

11. The stereolithography apparatus of claim 10, wherein the pump is adapted to maintain the level of the polymer to fill or remove the polymer from the polymer retaining receptacle.

12. The stereolithography apparatus of claim 10, wherein the pump is adapted to isolate the polymer from the pump'"'"'s parts.

13. The stereolithography apparatus of claim 1, wherein the polymer is a photocurable polymer.

14. The stereolithography apparatus of claim 1, wherein the polymer is a hydrogel selected from the group consisting of natural polymers, synthetic polymers and any combinations thereof.

15. The stereolithography apparatus of claim 1, wherein the polymer is a resin composition selected from the group consisting of:

a radically polymerizable organic compound, a cationically polymerizable organic compound;

a polyether, polyol compound, elastomer particle and any combination thereof.

16. The stereolithography apparatus of claim 1, wherein the polymer is selected from the group consisting of stereolithography resins, curable inks, photopolymer resins, photopolymer powdered materials and any combination thereof.

17. The stereolithography apparatus of claim 1, wherein the polymer further comprises one or more additives.

18. The stereolithography apparatus of claim 17, wherein the additive is selected from the group consisting of color altering, thermal property altering, electrical property altering, optical property altering, mechanical property altering, strength altering, function altering, biofunction altering additives and any combination thereof.

19. The stereolithography apparatus of claim 17, wherein the additive is selected from the group consisting of an imbedded device, an imbedded material, such as bioactive ingredients and cells, and any combination thereof.

20. The stereolithography apparatus of claim 1, wherein the apparatus further comprises one or more horizontal translation mechanisms adapted to access the polymer retaining receptacle and the washing unit.

21. The stereolithography apparatus of claim 1, wherein the apparatus further comprises one or more curing/drying units.

22. The stereolithography apparatus of claim 21, wherein the curing/drying unit is selected from the group consisting of an ultraviolet light source, a particle bombarder, a chemical sprayer, a radiation impinger, an ink jet, an oven, a fan, a pump, a curing device and a drying device that incorporates convection, conduction and/or radiation heat transfer and any combinations thereof.

23. The stereolithography apparatus of claim 21, wherein the apparatus further comprises one or more horizontal translation mechanisms adapted to access the polymer retaining receptacle, the washing unit and the curing/drying unit.

24. The stereolithography apparatus of claim 21, wherein the apparatus further comprises one or more shielded cabinets to house the washing unit and the curing/drying unit.

25. The stereolithography apparatus of claim 1, wherein the apparatus further comprises one or more alternative manufacturing apparatuses.

26. The stereolithography apparatus of claim 25, wherein the alternative manufacturing process apparatus is selected from the group consisting of:

Computer Numerical Control (CNC) milling apparatuses and tool carousels, Coordinate Measuring Machine (CMM) probes and other vision measurement systems, Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), Layered Object Manufacturing (LOM) and other RP technologies, micro-machining systems, micro-jet and other cutting systems such as water jet, laser and plasma cutting systems, painting apparatuses, ink jets and other fluid and particle dispensing mechanisms and/or other pick and place technologies including robotic materials placement technologies and any combination thereof.

27. The stereolithography apparatus of claim 25, wherein the apparatus further comprises one or more horizontal translation mechanisms adapted to access the polymer retaining receptacle, the washing unit and the alternative manufacturing apparatus.

28. The stereolithography apparatus of claim 25, wherein the apparatus further comprises one or more shielded cabinets to house one or more stereolithography apparatus components selected from the group consisting of the polymer retaining receptacle, the washing unit and the alternative manufacturing process apparatus.

29. The stereolithography apparatus of claim 1, wherein the apparatus further comprises one or more curing/drying units and one or more alternative manufacturing apparatuses.

30. The stereolithography apparatus of claim 29, wherein the apparatus further comprises one or more horizontal translation mechanisms adapted to access the polymer retaining receptacle, the washing unit, the curing/drying unit and the alternative manufacturing apparatus.

31. The stereolithography apparatus of claim 29, wherein the apparatus further comprises one or more shielded cabinets the polymer retaining receptacle, the washing unit, curing/drying unit and the alternative manufacturing process apparatus.

32. The stereolithography apparatus of claim 1, wherein the apparatus further comprises one or more recoating devices.

33. The stereolithography apparatus of claim 1, wherein the polymer retaining receptacle further comprises one or more main vat chamber and one or more overfill vat chamber.

34. A method of multi-material stereolithography comprising the steps of:

(a) solidifying a first polymer into a desired subject part layer;

(b) washing the subject part; and

(c) solidifying a second polymer on the subject part into a desired subject part layer.

35. The method of claim 34, wherein step (a) further comprises the step of traversing the subject part into the first polymer from an initial position to a second position by a distance equal to the desired build layer thickness.

36. The method of claim 35, further comprising the step of waiting for a predetermined time before proceeding to another step.

37. The method of claim 34, wherein step (a) further comprises the step of traversing the subject part into a polymer from an initial position to a second position by a distance greater than the desired build layer thickness.

38. The method of claim 37, further comprising the step of waiting for a predetermined time before proceeding to another step.

39. The method of claim 37, further comprising the step of traversing the subject part from the second position to a third position, wherein the distance from the initial position to the third position is equal to the desired build layer thickness.

40. The method of claim 39, further comprising the step of waiting for a predetermined time before proceeding to another step.

41. The method of claim 34, wherein step (a) further comprises building multiple subject part layers.

42. The method of claim 34, wherein step (a) further comprises building multiple layers within a subject part layer.

43. The method of claim 34, wherein step (c) further comprises the step of traversing the subject part into the first polymer from an initial position to a second position by a distance equal to the desired build layer thickness.

44. The method of claim 43, further comprising the step of waiting for a predetermined time before proceeding to another step.

45. The method of claim 34, wherein step (c) further comprises the step of traversing the subject part into a polymer from an initial position to a second position by a distance greater than the desired build layer thickness.

46. The method of claim 45, further comprising the step of waiting for a predetermined time before proceeding to another step.

47. The method of claim 45, further comprising the step of traversing the subject part from the second position to a third position, wherein the distance from the initial position to the third position is equal to the desired build layer thickness.

48. The method of claim 47, further comprising the step of waiting for a predetermined time before proceeding to another step.

49. The method of claim 34, wherein step (c) further comprises building multiple subject part layers.

50. The method of claim 34, wherein step (c) further comprises building multiple layers within a subject part layer.

51. The method of claim 34, wherein the method is repeated for additional polymers.

52. The method of claim 34, wherein the polymers are arranged on a vat apparatus.

53. The method of claim 52, wherein the vat apparatus is selected from the group consisting of a fixed stacked apparatus, a movable stacked apparatus, a fixed receptacle apparatus, a movable receptacle apparatus, a rotatable receptacle apparatus and any combination thereof.

54. The method of claim 34, further comprises the step of maintaining a desired level of the polymer by either filling or removing the polymer via a pump.

55. The method of claim 34, further comprises the step of maintaining a desired level of the polymer in the receptacle, wherein if the level is polymer is more than desired, then the receptacle passively removes excess polymer to the receptacle'"'"'s overfill vat chamber.

56. The method of claim 34, further comprising the step of sweeping the polymer surface with a recoating device.

57. The method of claim 56, further comprising the step of waiting for a predetermined time before proceeding to another step.

58. The method of claim 57, wherein the predetermined time is equal to the time needed for the polymer to reach a state of equilibrium.

59. The method of claim 34, further comprising the step of eliminating trapped volumes on the surface of the subject part.

60. The method of claim 34, further comprising the step of eliminating trapped volumes left on the platform.

61. The method of claim 34, further comprising the step of dipping the subject part into the polymer.

62. The method of claim 34, wherein the method further comprises rotating the subject part about a horizontal axis.

63. The method of claim 34, wherein the method further comprises performing an alternative manufacturing technology on the subject part.

64. The method of claim 63, wherein the alternative manufacturing technology is selected from the group consisting of:

Computer Numerical Control (CNC) milling apparatuses and tool carousels, Coordinate Measuring Machine (CMM) probes and other vision measurement systems, Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), Layered Object Manufacturing (LOM) and other RP technologies, micro-machining systems, micro-jet and other cutting systems such as water jet, laser and plasma cutting systems, painting apparatuses, ink jets and other fluid and particle dispensing mechanisms and/or other pick and place technologies including robotic materials placement technologies and any combination thereof.

65. The method of claim 34, wherein the method further comprises the step of curing/drying the subject part in a curing/drying unit.

66. The method of claim 65, wherein the curing/drying unit is selected from the group consisting of an ultraviolet light source, a particle bombarder, a chemical sprayer, a radiation impinger, an ink jet, an oven, a fan, a pump, a curing device and a drying device that incorporates convection, conduction and/or radiation heat transfer and any combinations thereof.

67. The method of claim 34, wherein the polymer is a photocurable polymer.

68. The method of claim 34, wherein the polymer is a hydrogel selected from the group consisting of natural polymers, synthetic polymers and any combinations thereof.

69. The method of claim 34, wherein the polymer is a resin composition selected from the group consisting of:

a radically polymerizable organic compound, a cationically polymerizable organic compound, a polyether, polyol compound, elastomer particle and any combination thereof.

70. The method of claim 34, wherein the polymer is selected from the group consisting of stereolithography resins, curable inks, photopolymer resins, photopolymer powdered materials and any combination thereof.

71. The method of claim 34, wherein the method further comprises the step of incorporating an additive into one or more of the polymers.

72. The method of claim 71, wherein the additive is selected from the group consisting of color altering, thermal property altering, electrical property altering, optical property altering, mechanical property altering, strength altering, function altering, biofunction altering additives and any combination thereof.

73. The method of claim 71, wherein the additive is selected from the group consisting of imbedded devices and imbedded materials, such as bioactive ingredients and cells, and any combination thereof.

74. The method of claim 34, further comprising the step of using one or more lasers to solidify a polymer.

75. A method of stereolithography comprising the steps of:

(a) solidifying a polymer into a desired subject part layer;

(b) washing the subject part; and

(c) performing an alternative manufacturing technology on the subject part.

76. The method of claim 75, wherein step (a) further comprises the step of traversing the subject part into the first polymer from an initial position to a second position by a distance equal to the desired build layer thickness.

77. The method of claim 75, further comprising the step of waiting for a predetermined time before proceeding to another step.

78. The method of claim 75, wherein step (a) further comprises the step of traversing the subject part into a polymer from an initial position to a second position by a distance greater than the desired build layer thickness.

79. The method of claim 78, further comprising the step of waiting for a predetermined time before proceeding to another step.

80. The method of claim 78, further comprising the step of traversing the subject part from the second position to a third position, wherein the distance from the initial position to the third position is equal to the desired build layer thickness.

81. The method of claim 80, further comprising the step of waiting for a predetermined time before proceeding to another step.

82. The method of claim 75, wherein step (a) further comprises building multiple subject part layers.

83. The method of claim 75, wherein step (a) further comprises building multiple layers within a subject part layer.

84. The method of claim 75, wherein the method is repeated for additional polymers.

85. The method of claim 75, wherein the polymers are arranged on a vat apparatus.

86. The method of claim 85, wherein the vat apparatus is selected from the group consisting of a fixed stacked apparatus, a movable stacked apparatus, a fixed receptacle apparatus, a movable receptacle apparatus, a rotatable receptacle apparatus and any combination thereof.

87. The method of claim 75, further comprises the step of maintaining a desired level of the polymer by either filling or removing the polymer via a pump.

88. The method of claim 75, further comprises the step of maintaining a desired level of the polymer in the receptacle, wherein if the level is polymer is more than desired, then the receptacle passively removes excess polymer to the receptacle'"'"'s overfill vat chamber.

89. The method of claim 75, further comprising the step of sweeping the polymer surface with a recoating device.

90. The method of claim 89, further comprising the step of waiting for a predetermined time before proceeding to another step.

91. The method of claim 90, wherein the predetermined time is equal to the time needed for the polymer to reach a state of equilibrium.

92. The method of claim 75, further comprising the step of eliminating trapped volumes on the surface of the subject part.

93. The method of claim 75, further comprising the step of eliminating trapped volumes left on the platform.

94. The method of claim 75, further comprising the step of dipping the subject part into the polymer.

95. The method of claim 75, wherein the method further comprises rotating the subject part about a horizontal axis.

96. The method of claim 75, wherein the alternative manufacturing technology is selected from the group consisting of:

Computer Numerical Control (CNC) milling apparatuses and tool carousels, Coordinate Measuring Machine (CMM) probes and other vision measurement systems, Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), Layered Object Manufacturing (LOM) and other RP technologies, micro-machining systems, micro-jet and other cutting systems such as water jet, laser and plasma cutting systems, painting apparatuses, ink jets and other fluid and particle dispensing mechanisms and/or other pick and place technologies including robotic materials placement technologies and any combination thereof.

97. The method of claim 75, wherein the method further comprises the step of curing/drying the subject part in a curing/drying unit.

98. The method of claim 97, wherein the curing/drying unit is selected from the group consisting of an ultraviolet light source, a particle bombarder, a chemical sprayer, a radiation impinger, an ink jet, an oven, a fan, a pump, a curing device and a drying device that incorporates convection, conduction and/or radiation heat transfer and any combinations thereof.

99. The method of claim 75, wherein the polymer is a photocurable polymer.

100. The method of claim 75, wherein the polymer is a hydrogel selected from the group consisting of natural polymers, synthetic polymers and any combinations thereof.

101. The method of claim 75, wherein the polymer is a resin composition selected from the group consisting of:

a radically polymerizable organic compound, a cationically polymerizable organic compound, a polyether, polyol compound, elastomer particle and any combination thereof.

102. The method of claim 75, wherein the polymer is selected from the group consisting of stereolithography resins, curable inks, photopolymer resins, photopolymer powdered materials and any combination thereof.

103. The method of claim 75, wherein the method further comprises the step of incorporating an additive into one or more of the polymers.

104. The method of claim 103, wherein the additive is selected from the group consisting of color altering, thermal property altering, electrical property altering, optical property altering, mechanical property altering, strength altering, function altering, biofunction altering additives and any combination thereof.

105. The method of claim 103, wherein the additive is selected from the group consisting of imbedded devices and imbedded materials, such as bioactive ingredients and cells, and any combination thereof.

106. The method of claim 75, further comprising the step of using one or more lasers to solidify a polymer