Rapid prototyping and manufacturing system and method

• US 20070075460A1
• Filed: 09/30/2005
• Published: 04/05/2007
• Est. Priority Date: 09/30/2005
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Wahlstrom, Ben, Stonesmith, Matthew, Hunter, Don
• Granted Patent: US 7,520,740 B2
• Time in Patent Office: Days
• US Class Current: 264/401
• 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: B29C 64/182 in parallel batches
• 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 50/02 for controlling or regulating additive manufacturing processes

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.

Claims

1. Apparatus for producing three-dimensional objects from building media in response to energy applied to the media to build the object layer-by-layer, said apparatus comprising:

a) a housing having at least one interior frame defining a chamber within said housing for producing three-dimensional objects from a building medium;

b) a container for the building medium adapted to be received within said chamber and releasably fixed in position with respect to said frame;

c) a source of energy within said chamber for supplying energy to selected portions of a surface layer thickness of the building medium in said container to solidify the layer portions;

d) a build platform for supporting solidified layer portions of building medium, said build platform adapted to fit within said container beneath the surface of the building medium;

e) an elevator translatably fixed to said frame for vertically upward and downward movement and extending horizontally into said chamber to releasably secure said platform on said horizontal extension, thereby to raise and lower said building platform;

f) a cart releasably fixed in position with respect to said container of building media and having telescoping arms for receiving said build platform and three-dimensional object and removing these from said elevator; and

g) a controller operatively connected to said energy source, said elevator, and said cart for controlling supplying energy to the building medium, for vertical translation of said build platform, and for removing said build platform and the three-dimensional object from said elevator.

2. Apparatus according to claim 1, wherein said build platform is a first build platform and said apparatus further comprises a second build platform supported by telescoping arms on said cart for deposit on said elevator in response to said controller after said first build platform has been removed from said elevator.

3. Apparatus according to claim 2, wherein said controller comprises a programmable processor for receiving one or more object representations, controlling said energy source and elevator in response to said one or more object representations, and controlling said elevator and said cart to accomplish removing said first build platform from said elevator and placing said second build platform on said elevator.

4. Apparatus according to claim 2, wherein said telescoping arms comprise a single set of said arms having first and second portions, said first portion for supporting said first build platform and said second portion for supporting said second platform.

5. Apparatus according to claim 1 wherein said apparatus is a stereolithography apparatus, said container is a vat for liquid resin, and said energy source is a laser.

6. Apparatus according to claim 5 further comprising a drip tray supported by said telescoping arms for receiving a build platform.

7. Apparatus according to claim 1 further comprising a recoater operatively connected to said controller and translatably secured to said frame for movement vertically and horizontally in response to said controller.

8. Apparatus according to claim 1 further comprising a sensor operatively connected to said controller and fixed to said frame for determining the level of the surface of the building medium within said container.

9. Apparatus according to claim 1 comprising two interior frames each defining a chamber for separately producing three-dimensional objects.

10. Stereolithography apparatus for producing three-dimensional objects from a liquid resin by application of a laser to the resin layer-by-layer, said apparatus comprising a cart having telescoping arms for unattended exchange of build platforms.

11. A cart operatively connected to a controller for operator unattended removal from a stereolithography apparatus of a build platform, said cart comprising a base, a vertically extending support member, and telescoping arms extending from said support member responsive to a controller for extending into a stereolithography chamber for receiving a build platform thereon.

12. The cart according to claim 11 wherein said telescoping arms support a second build platform for an unattended exchange of build platforms.

13. The cart according to claim 11 wherein said telescoping arms comprise a drip tray for receiving a build platform.

14. A cart operatively connected to a controller for accomplishing one unattended exchange of build platforms in a stereolithography chamber, said cart comprising a base, a vertically extending support member, and telescoping arms supporting a drip tray and extending from said support member responsive to a controller for extending into a stereolithography chamber for receiving a build platform on said drip tray, and telescoping arms supporting another build platform thereon for extending into the stereolithography chamber for introducing another build platform in the stereolithography chamber to accomplish the exchange.

15. A method for producing three-dimensional objects from building media in response to energy applied to the media to build the objects layer-by-layer in accordance with a preprogrammed controller, said method comprising performing in response to a preprogrammed controller the steps of completing at least one first build and automatedly removing the at least one first build so that at least one second build can be initiated.

16. A method according to claim 15 further comprising the step of initiating at least one second build in response to a preprogrammed controller.

17. A method according to claim 15 wherein the step of removing the at least one first build comprises parking the recoater.

18. A method according to claim 15 comprising completing at least two first builds and automatedly removing the first builds so that one or more second builds can be initiated.

19. A method according to claim 18 wherein the step of completing at least two first builds comprises alternately for one build and then the other of the two first builds applying energy from a single source thereof to a layer of fresh media to solidify the media, sweeping a recoater over the solidified layer of first one build and then the other between the applications of energy to deposit thereon a layer of fresh media, and repeating alternately applying energy to a layer and sweeping a recoater across the solidified area, wherein the two first builds are completed by performing an alternating sequence of steps of layer-wise applying energy and recoating.

20. A stereolithography method for building three-dimensional objects layer-by-layer on an object support platform in a vat of liquid resin comprising completing a first build on a first object support platform in a vat of liquid resin and unattendedly exchanging the first build and platform with a second platform for a second build.