METHOD AND APPARATUS FOR MAKING THREE-DIMENSIONAL OBJECTS FROM MULTIPLE SOLIDIFIABLE MATERIALS

• US 20120195994A1
• Filed: 01/30/2012
• Published: 08/02/2012
• Est. Priority Date: 01/31/2011
• Status: Active Grant

• Current Assignee: Gulf Filtration Systems Inc. (Desktop Metal, Inc.)
• Original Assignee: Gulf Filtration Systems Inc. (Desktop Metal, Inc.)
• Inventors: El-Siblani, Ali, Shkolnik, Alexandr
• Granted Patent: US 8,801,418 B2
• Time in Patent Office: Days
• US Class Current: 425/174.4
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/236 for motion in a direction within the plane of a layer
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29C 64/357 Recycling
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• 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 40/20 Post-treatment, e.g. curing, coating or polishing

Abstract

Methods and apparatuses for making three-dimensional objects from multiple solidifiable materials is shown and described. Multiple solidifiable material container assemblies are provided for holding different solidifiable materials. Relative movement between the solidifiable material container assemblies and a build platform allows the solidifiable materials to be switched as an object is built. Several exemplary cleaning stations are provided for removing residual solidifiable materials from the surface of the three-dimensional object as it is built to better ensure smooth transitions between materials on the finished object.

Claims

1. An apparatus for manufacturing a three-dimensional object by solidifying multiple solidifiable materials, comprising:

a first solidifiable material source;

at least one pattern generator;

a second solidifiable material source spaced apart from the first solidifiable material source in first direction defining a first axis; and

a build platform movable along a second direction defining a second axis, wherein at least one of the build platform and the first solidifiable material source is movable along the first direction relative to the other of the build platform and the first solidifiable material source.

2. The apparatus of claim 1, wherein the build platform is movable along the first direction relative to each of the first solidifiable material source and the second solidifiable material source.

3. The apparatus of claim 1, wherein each of the first solidifiable material source and the second solidifiable material source is movable along the first direction relative to the build platform.

4. The apparatus of claim 1, further comprising a cleaning station between the first solidifiable material source and the second solidifiable material source.

5. The apparatus of claim 4, wherein the cleaning station comprises at least one enclosure with an interior that is selectively maintainable at a sub-atmospheric pressure.

6. The apparatus of claim 1, wherein the first solidifiable material source comprises a rigid or semi-rigid transparent solidification substrate, the at least one pattern generator is movable in a third direction defining a third axis, and as the at least one pattern generator moves in the third direction, the rigid or semi-rigid transparent solidification substrate tilts.

7. The apparatus of claim 1, wherein the at least one pattern generator is two pattern generators spaced apart from one another in the first direction, and each pattern generator is movable in a third direction defining a third axis.

8. The apparatus of claim 1, wherein the at least one pattern generator is a linear solidification device.

9. The apparatus of claim 8, wherein the linear solidification device comprises a laser source in optical communication with a rotating light reflector.

10. The apparatus of claim 1, wherein the at least one pattern generator is a digital light projector.

11. The apparatus of claim 1, wherein the first solidifiable material source comprises a rigid or semi-rigid transparent solidification substrate, and the rigid or semi-rigid transparent solidification substrate is curved in a third direction along a third axis.

12. The apparatus of claim 1, wherein the first solidifiable material source includes a rigid or semi-rigid transparent solidification substrate having a resilient coating.

13. The apparatus of claim 12, wherein the at least one pattern generator comprises a laser source in optical communication with a rotating light deflector.

14. An apparatus for manufacturing a three-dimensional object by solidifying multiple solidifiable materials, comprising:

a first solidifiable material source;

a second solidifiable material source;

a first pattern generator movable along a first direction defining a first axis;

a second pattern generator movable along the first direction;

a build platform movable along a second direction defining a second axis and rotatable in a rotation direction around the second axis.

15. The apparatus of claim 14, wherein the build platform is rotatable around the second axis between a first position and a second position, and the first and second positions are spaced apart from one another along the first direction.

16. The apparatus of claim 14, wherein the build platform is rotatable around the second axis between a first position and a second position, wherein the first position and second position are spaced apart from one another along a third direction defining a third axis.

17. The apparatus of claim 14, further comprising at least one cleaning station located at a position lying between the positions of the first and second solidifiable material sources along the first direction.

18. The apparatus of claim 17, wherein the at least one cleaning station comprises an enclosure with an interior and an air-permeable upper surface, wherein the interior is selectively maintainable at a subatmospheric pressure.

19. The apparatus of claim 14, wherein at least one of the first and second pattern generators is a linear solidification device.

20. The apparatus of claim 19, wherein the linear solidification device comprises a laser source in optical communication with a rotating light deflector.

21. The apparatus of claim 14, wherein as the first pattern generator moves along the first direction, the pattern generator selectively projects solidification energy in a third direction defining a third axis.

22. The apparatus of claim 14, wherein the first solidifiable material source includes a rigid or semi-rigid transparent solidification substrate, and as the first pattern generator moves along the first direction, the rigid or semi-rigid transparent solidification substrate tilts.

23. The apparatus of claim 14, wherein the first solidifiable material source includes a rigid or semi-rigid transparent solidification substrate having a resilient coating.

24. The apparatus of claim 23, wherein the at least one pattern generator comprises a laser source in optical communication with a rotating light deflector.

25. The apparatus of claim 14, wherein the first solidifiable material source includes a rigid or semi-rigid transparent substrate that is curved in the first direction.

26. An apparatus for making a three-dimensional object, comprising:

a first solidifiable material supply unit comprising a first cartridge having the first solidifiable material disposed therein, a first retractable film having a retracted position and an extended position with respect to the first cartridge, and a first rigid or semi-rigid transparent solidification substrate, wherein the first retractable film has a first surface, the first rigid or semi-rigid transparent solidification substrate has a first surface, and the first surface of the first retractable film faces the first surface of the first rigid or semi-rigid transparent solidification solidification substrate;

a second solidifiable material supply unit spaced apart from the first solidifiable material supply unit in a first direction along a first axis and comprising a second cartridge having the second solidifiable material disposed therein, a second retractable film having a retracted position and an extended position with respect to the second cartridge, and a second rigid or semi-rigid transparent solidification substrate, wherein the second retractable film has a first surface, the second rigid or semi-rigid transparent solidification substrate has a first surface, and the first surface of the second retractable film faces the first surface of the second rigid or semi-rigid transparent solidification substrate;

a pattern generator; and

a build platform movable in a first direction away from the pattern generator along a second axis defining a second direction;

wherein at least one of the first solidifiable material supply unit and the build platform is moveable along the first direction with respect to the other of the first solidifiable material supply unit and the build platform.

27. The apparatus of claim 26, wherein the build platform is movable along the first direction with respect to each of the first solidifiable material supply unit and the second solidifiable material supply unit.

28. The apparatus of claim 26, wherein each of the first solidifiable material supply unit and the second solidifiable material supply unit is movable along the first direction with respect to the build platform.

29. The apparatus of claim 26, further comprising a cleaning station, wherein at least one of the cleaning station and the build platform is movable along the first direction with respect to the other of the cleaning station and the build platform.

31. The apparatus of claim 26, wherein the apparatus comprises a first solidifiable material source comprising the first solidifiable material supply unit, and the first solidifiable material source has a direction of travel and a housing having first and second rollers spaced apart from one another along the direction of travel.

30. The apparatus of 26, wherein the pattern generator has a fixed position along the first direction, and the build platform has a fixed position along the first direction.

32. A cleaning station for removing residual solidifiable material from a solidified surface of a three-dimensional object, the cleaning station comprising a pattern generator and a vacuum device.

33. The cleaning station of claim 32, wherein the pattern generator projects solidification energy having wavelengths ranging from about 350 nm to about 450 nm.

34. The cleaning station of claim 32, wherein the pattern generator is a linear solidification device.

35. The cleaning station of claim 34, wherein the linear solidification device comprises a laser in optical communication with a rotating solidification energy reflector, and when the laser projects solidification energy toward the rotating solidification energy reflector as the rotating solidification energy reflector rotates and the linear solidification device moves in a first direction, the projected solidification energy scans the surface of the three-dimensional object in a second direction.

36. The cleaning station of claim 32, wherein the pattern generator comprises a linear array of imaging elements.

37. The cleaning station of claim 32, wherein the cleaning station further comprises a container.

38. The cleaning station of claim 32, wherein the pattern generator is spaced apart from the vacuum device by a first fixed distance in a first direction, and the pattern generator and the vacuum device are movable with respect to the container in the first direction.

39. The cleaning station of claim 38, wherein the cleaning station further comprises a sponge that is spaced apart from the vacuum device by a second fixed distance in the first direction, and the sponge is movable with respect to the container in the first direction.

40. The cleaning station of claim 39, wherein the sponge is rotatable.

41. An apparatus for producing a three-dimensional object comprising supports connected to a finished object, the apparatus comprising:

a solidifiable finished object material container assembly;

a source of finished object solidification energy;

a build platform movable in a first direction; and

a support former movable in a second direction.

42. The apparatus of claim 41, wherein the support former comprises a plurality of nozzles in fluid communication with a source of the support material and a source of support solidification energy, wherein the support former is spaced apart from the source of finished object solidification energy by a fixed distance in the first direction.

43. The apparatus of claim 41, wherein the source of support solidification energy projects support solidification energy having a first peak wavelength, and the source of finished object solidification energy projects finished object solidification energy having a second peak wavelength, and the first peak wavelength is greater than the second peak wavelength.

44. The apparatus of claim 43, wherein the difference between the first peak wavelength and the second peak wavelength is no less than about 200 nm.

45. The apparatus of claim 43, wherein the first peak wavelength is about 780 nm and the second peak wavelength is about 390 nm.

46. The apparatus of claim 41, wherein the source of support solidification energy is a linear solidification device.

47. The apparatus of claim 46, wherein the linear solidification device is a linear array of imaging elements.

48. The apparatus of claim 46, wherein the linear solidification device comprises a laser in optical communication with a rotating light deflector, and when the laser projects light to the rotating light deflector as the rotating light deflector rotates, the projected solidification energy is scanned in a third direction.

49. The apparatus of claim 42, wherein the nozzles in the plurality of nozzles are spaced apart from one another in a third direction.

50. The apparatus of claim 42, wherein when the solidifiable support material is solidified, the solidified support material is soluble in a polar liquid, and when the solidifiable finished object material is solidified, the solidifiable finished object material is insoluble in the polar liquid.

51. The apparatus of claim 41, wherein the plurality of nozzles is spaced apart from the source of support solidification energy by a fixed distance in the first direction.

52. The apparatus of claim 41, wherein the source of finished object solidification energy is a digital light projector.