Rapid prototyping and manufacturing system and method
First Claim
1. A stereolithography apparatus comprising a longitudinally extending recoater and a carrier for said recoater, and wherein said recoater has a blade body with front and back surfaces and top and bottom surfaces, a foot for sensing blade gap at each end of said blade body extending laterally outward from said front surface thereof and having a flat bottom surface level with the bottom surface of said blade body and a top surface tapering distally from said blade to a thinned-down blade gap sensing portion of said top surface of said foot, whereby a sensor in sensing communication with said sensing portion of said foot can sense the distance of the top of said foot from a liquid resin surface.
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Accused Products
Abstract
A stereolithography apparatus having a resin vat with resupply containers in one-way flow communication and a leveling container in two-way flow communication, an automatic offload cart to remove and replace build support platforms, an elevator assembly for supporting and releasably retaining a build platform removably attached to the stereolithography apparatus frame such that elevator forks supporting the build platform can be released into the vat and removed from the stereolithography apparatus with the vat, and a recoater assembly and recoater blade for mapping the resin surface in the vat and applying a fresh coating of resin to a cross-section being built in the vat.
98 Citations
11 Claims
- 1. A stereolithography apparatus comprising a longitudinally extending recoater and a carrier for said recoater, and wherein said recoater has a blade body with front and back surfaces and top and bottom surfaces, a foot for sensing blade gap at each end of said blade body extending laterally outward from said front surface thereof and having a flat bottom surface level with the bottom surface of said blade body and a top surface tapering distally from said blade to a thinned-down blade gap sensing portion of said top surface of said foot, whereby a sensor in sensing communication with said sensing portion of said foot can sense the distance of the top of said foot from a liquid resin surface.
- 7. A method for stereolithography by which three-dimensional objects are produced from liquid resin by alternately applying laser energy to the uncured resin surface to at least partially cure the resin surface, recoating the at least partially cured resin surface with uncured resin, and repeating alternately applying energy and recoating to build the objects layer-by-layer in accordance with a predetermined object representation, said method comprising, prior to applying laser energy to the uncured resin surface, establishing a predetermined blade gap for a recoater and storing the predetermined blade gap in a controller, determining the distance between the bottom of the recoater and the resin surface at each end of the recoater at a plurality of points throughout the length of travel of the recoater and storing the determined distances in a controller, and during recoating, controlling the blade gap in response to the stored predetermined blade gap throughout the length of travel of the recoater and maintaining the recoater parallel to the resin surface throughout its length of travel at the predetermined blade gap.
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10. A method for recoating a layer of at least partially cured resin in a stereolithography apparatus having a recoater, said method comprising the step of adjusting the height of each end of the recoater above the resin surface throughout the length of travel of the recoater at the predetermined blade gap, thereby to maintain the recoater parallel throughout its length of travel across the resin surface.
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11. A method for keeping a recoater parallel with a resin surface in a stereolithography apparatus, said method comprising the step of rotating the recoater about a central axis thereof along the direction of travel of the recoater across the resin surface.
Specification