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Wall Smoothness, Feature Accuracy and Resolution In Projected Images Via Exposure Levels In Solid Imaging

  • US 20080054531A1
  • Filed: 08/29/2006
  • Published: 03/06/2008
  • Est. Priority Date: 08/29/2006
  • Status: Active Grant
First Claim
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1. A method for forming a three-dimensional object layer-by-layer comprising the steps of:

  • a. forming bit-map data of cross-sectional layers of a three-dimensional object to be built;

    b. delivering a solidifiable photopolymer build material to an imaging area;

    c. projecting an image representative of the bit-map data of a single cross-sectional layer from a radiation source onto the solidifiable photopolymer build material in the imaging area to illuminate pixels in the image area to selectively solidify the photopolymer build material;

    d. controlling boundary polymerization of the build material by controlling the exposure in the image area either by varying the gray scales of the boundary pixels of the radiation source, by controlling the illumination time of different pixels differently, by varying the degree of focus of the pixels to control the width of light distribution of each pixel illumination or by varying the light intensity versus the age of the radiation source, or by combination thereof, thereby defining the object'"'"'s borders; and

    e. repeating steps b, c and d multiple times until a plurality of object cross-sections are formed to obtain an object with smooth walls and fine feature retention.

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