SYSTEM, APPARATUS, AND METHOD FOR RESIN LEVEL MAINTENANCE IN A STEREO-LITHOGRAPHY DEVICE

• US 20110049767A1
• Filed: 08/09/2010
• Published: 03/03/2011
• Est. Priority Date: 08/09/2009
• Status: Active Grant

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Inventors: Withey, Paul Anthony, Schlienger, Max Eric
• Granted Patent: US 8,298,472 B2
• Time in Patent Office: Days
• US Class Current: 264/401
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/321 Feeding
• 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

Abstract

A system includes a stereo-lithography device having a primary fluid vessel having an amount of a photo-curable fluid therein. The system includes a leveling reservoir fluidly coupled to the primary fluid vessel, where a fluid level in the leveling reservoir is vertically positionable. The system further includes a controller that maintains a pre-determined level of the photo-curable fluid in the primary fluid vessel by vertically positioning the fluid level in the leveling reservoir.

Claims

1. A system, comprising:

a stereo-lithography device having a primary fluid vessel having an amount of a photo-curable fluid therein;

a leveling reservoir fluidly coupled to the primary fluid vessel, wherein a fluid level in the leveling reservoir is vertically positionable; and

a controller structured to maintain a pre-determined level of the photo-curable fluid in the primary fluid vessel by vertically positioning the fluid level in the leveling reservoir.

2. The system of claim 1, wherein the pre-determined level of the photo-curable fluid in the primary fluid vessel corresponds to a focal plane of an optical device of the stereo-lithography device.

3. The system of claim 1, further comprising a replenishment reservoir selectively fluidly coupled with the primary fluid vessel, wherein the controller is further structured to transfer fluid between the replenishment reservoir and the primary fluid vessel.

4. The system of claim 3, wherein the controller is further structured to transfer fluid between the replenishment reservoir and the primary fluid vessel in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

5. The system of claim 3, wherein the leveling reservoir is vertically moveable, and wherein the leveling reservoir is moved to a default position prior to an operation of the stereo-lithography device to manufacture a layer of a component, and wherein the replenishment reservoir is moved such that a level of the photo-curable fluid in the primary fluid vessel is at the pre-determined level prior to the operation of the stereo-lithography device to manufacture the layer of the component.

6. The system of claim 1, wherein the pre-determined level is changed in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

7. The system of claim 3, wherein the pre-determined level is changed in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

8. The system of claim 7, wherein the leveling reservoir is vertically moveable, and wherein the leveling reservoir is moved to a default position prior to an operation of the stereo-lithography device to manufacture the layer of the component, and a level of replenishment fluid in the replenishment reservoir is vertically positioned such that the level of the photo-curable fluid in the primary fluid vessel is at the pre-determined level prior to the operation of the stereo-lithography device to manufacture the layer of the component.

9. The system of claim 8, wherein the default position comprises a position determined in response to the pre-determined level.

10. The system of claim 1, further comprising a controllable piston that positions the fluid level in the leveling reservoir.

11. The system of claim 1, further comprising a pressurizing pump that controls an overpressure on the leveling reservoir, wherein the amount of the overpressure positions the fluid level in the leveling reservoir.

12. The system of claim 1, wherein the leveling reservoir is vertically moveable.

13. A method, comprising:

providing a stereo-lithography device having a primary fluid vessel having an amount of a photo-curable fluid therein;

providing a leveling reservoir fluidly coupled to the primary fluid vessel, wherein a fluid level in the leveling reservoir is vertically positionable;

providing a replenishment reservoir fluidly coupled to the primary fluid vessel, wherein a replenishment fluid level in the replenishment reservoir is vertically positionable;

positioning the replenishment fluid level in the replenishment reservoir such that a photo-curable fluid level in the primary fluid vessel is at a pre-determined level;

manufacturing a layer of a component in the primary fluid vessel; and

maintaining the pre-determined level of the photo-curable fluid in the primary fluid vessel during the manufacturing by vertically positioning the fluid level in the leveling reservoir.

14. The method of claim 13, further comprising adding photo-curable fluid to the primary fluid vessel, and moving at least one of the fluid level in the replenishment reservoir and the fluid level in the leveling reservoir to return a level of the photo-curable fluid level to the pre-determined level.

15. The method of claim 13, wherein the vertically positioning the fluid level in the leveling reservoir comprises vertically positioning the leveling reservoir.

16. The method of claim 15, further comprising positioning the leveling reservoir at a default position before the positioning the replenishment fluid level.

17. The method of claim 16, further comprising repeating the positioning the leveling reservoir at the default position and positioning the replenishment reservoir such that a photo-curable fluid level in the primary fluid vessel is at the pre-determined level in response to completing the manufacturing the layer of the component in the primary fluid vessel.

18. The method of claim 13, further comprising changing the pre-determined level in response to completing the manufacturing the layer of the component in the primary fluid vessel.

19. The method of claim 13, wherein the pre-determined level comprises a focal plane of an optical device of the stereo-lithography device.

20. The method of claim 13, wherein the vertically positioning the fluid level in the leveling reservoir comprises moving a piston structured to move the fluid level in the leveling reservoir.

21. The method of claim 13, wherein the vertically positioning the fluid level in the leveling reservoir comprises controlling an overpressure on the leveling reservoir, wherein the amount of the overpressure positions the fluid level in the leveling reservoir.

22. A system, comprising:

a stereo-lithography device comprising an optical device and a primary fluid vessel having an amount of a photo-curable fluid therein;

a leveling reservoir fluidly coupled to the primary fluid vessel; and

means for providing a fluid level in the leveling reservoir that corresponds to a focal plane of the optical device.

23. The system of claim 22, further comprising means for maintaining the fluid level in the leveling reservoir during a manufacturing operation of the stereo-lithography device.

24. The system of claim 22, further comprising means for restoring the fluid level in the leveling reservoir after a filling operation of the photo-curable fluid.