SOLID IMAGING APPARATUS AND METHOD
First Claim
1. A solid imaging apparatus for creating a build layer-by-layer, said apparatus comprising:
- a) an image plane assembly comprising a rigid surface transparent to solid imaging radiation;
b) a build platform located adjacent to said rigid transparent surface on one side thereof for receiving a build pad and supporting a build thereon, said build platform elevatingly disposed with respect to said rigid transparent surface;
c) at least one source of solid imaging radiation for illuminating said rigid transparent surface opposite said build platform;
d) an elevator for moving said build platform with respect to said rigid transparent surface;
e) a cartridge comprising;
(i) a cartridge housing;
(ii) a source of solid imaging build material contained in said cartridge housing; and
(iii) an extendable and retractable reciprocating transport surface contained in said cartridge housing and transparent to solid imaging radiation for transporting build material layer-by-layer from said source of build material to said image plane between said build platform and said rigid transparent surface, whereby said elevator moves said build platform for supporting a build and build pad into and out of solid imaging contact with the build material on said transport surface for illumination from said at least source of solid imaging radiation through said rigid surface and said transport surface; and
f) a controller in controlling communication with said apparatus, whereby a build is alternately coated and imaged with layers of solid imaging build material.
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Accused Products
Abstract
A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build. The invention also provides for tilting the build elevator to reduce air entrainment and for releasing the build from the image plane.
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Citations
25 Claims
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1. A solid imaging apparatus for creating a build layer-by-layer, said apparatus comprising:
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a) an image plane assembly comprising a rigid surface transparent to solid imaging radiation; b) a build platform located adjacent to said rigid transparent surface on one side thereof for receiving a build pad and supporting a build thereon, said build platform elevatingly disposed with respect to said rigid transparent surface; c) at least one source of solid imaging radiation for illuminating said rigid transparent surface opposite said build platform; d) an elevator for moving said build platform with respect to said rigid transparent surface; e) a cartridge comprising; (i) a cartridge housing; (ii) a source of solid imaging build material contained in said cartridge housing; and (iii) an extendable and retractable reciprocating transport surface contained in said cartridge housing and transparent to solid imaging radiation for transporting build material layer-by-layer from said source of build material to said image plane between said build platform and said rigid transparent surface, whereby said elevator moves said build platform for supporting a build and build pad into and out of solid imaging contact with the build material on said transport surface for illumination from said at least source of solid imaging radiation through said rigid surface and said transport surface; and f) a controller in controlling communication with said apparatus, whereby a build is alternately coated and imaged with layers of solid imaging build material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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23. A method for solid imaging to produce three-dimensional objects, said method comprising the steps of:
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a) transporting a layer of solid imaging build material from a source thereof to an image plane; b) contacting a build surface with the layer of build material; c) imaging the layer in the image plane to solidify imaged portions of the layer onto the build surface; d) returning uncured build material remaining on the transport surface to source thereof; and e) repeating steps (a) through (d) to produce three-dimensional object. - View Dependent Claims (24, 25)
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Specification