SYSTEM AND METHOD FOR THREE-DIMENSIONAL PRINTING

• US 20140265032A1
• Filed: 03/14/2013
• Published: 09/18/2014
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Teicher, Mordechai, MILLER, Gershon
• Granted Patent: US 9,573,321 B2
• Time in Patent Office: Days
• US Class Current: 264/401
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• 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 64/227 Driving means
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• 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 50/02 for controlling or regulating additive manufacturing processes

Abstract

Methods and apparatus for preparing a layer of an object being fabricated by a three-dimensional printing process. Embodiments of the invention combine selective deposition with selective curing to benefit from the respective advantages of both techniques. Multiple printing heads deposit a two-dimensional cross section of the object being fabricated on a substrate which is transparent to curing radiation. The multiple printing heads selectively deposit different object body materials in different regions of the cross section and also selectively deposit regions of support material as necessary. The transparent substrate is then moved into registration with the object being fabricated so that the new layer is in contact with the object body, and an ultraviolet two-dimensional image of the cross section is projected through the substrate to selectively cure the new layer.

Claims

1. A method for preparing a two-dimensional layer of a three-dimensional object during a three-dimensional printing of the object, the three-dimensional object including a body structure and a support structure, the method comprising:

receiving two-dimensional image data of a cross section of the three-dimensional object, the image including a body region and a support region, wherein the support region is distinct from the body region;

selectively depositing, on a transparent substrate, a layer that includes at least a first liquid photopolymer body material which covers and encloses the body region, and a liquid support material that is different from the first liquid photopolymer body material and which covers and encloses the support region; and

selectively solidifying the first liquid photopolymer body material by irradiating the layer with curing radiation through the transparent substrate according to the body region, such that some of the liquid body material remains uncured.

2. The method of claim 1, where at least one of the body region or the support region includes at least two distinct non-contiguous areas.

3. The method of claim 1, wherein the irradiating is performed by an image projector.

4. The method of claim 1, wherein the irradiating is performed by a laser.

5. The method of claim 1, further comprising:

subsequent to the selectively depositing and prior to the selectively solidifying;

bringing the first liquid photopolymer body material into contact with a previously-solidified layer of the body structure.

6. The method of claim 1, wherein the liquid support structure material is a second liquid photopolymer different from the first liquid photopolymer, the method further comprising:

selectively curing the second liquid photopolymer by irradiating the layer with curing radiation through the transparent substrate according to the support region.

7. The method of claim 1, wherein the liquid support material solidifies by cooling.

8. The method of claim 1, wherein the selectively depositing places a portion of the first liquid photopolymer body material outside the body region thus remaining uncured subsequent to the irradiating, the method further comprising:

subsequent to the irradiating;

removing the portion of uncured liquid photopolymer body material from the transparent substrate.

9. The method of claim 1, wherein the selectively depositing includes depositing at least two different liquid body materials.

10. An apparatus for preparing a two-dimensional layer of a three-dimensional object during a three-dimensional printing of the object, wherein the three-dimensional object includes a body structure and a support structure, the apparatus comprising:

a controller;

a transparent substrate for receiving a deposited layer of liquid materials on an upper surface thereof;

a selective deposition unit that deposits at least one liquid body material and a liquid support material different from the at least one liquid body material, on the transparent substrate according to signals received from the controller; and

a selective curing unit that selectively solidifies, by curing irradiation, a portion of the deposited layer of liquid body materials on the transparent substrate according to signals received from the controller, such that some of the liquid body material remains uncured.

11. The apparatus of claim 10, further comprising a wiper that removes uncured liquid body material from the transparent substrate.

12. The apparatus of claim 10, further comprising a non-transitory storage containing an instruction sequence which, when executed by the controller, causes the controller to:

receive two-dimensional image data of a cross section of the three-dimensional object, the image including a body region and a support region, wherein the support region is distinct from the body region;

send to the selective deposition unit signals for selectively depositing, on a transparent substrate, a layer that includes at least a first liquid photopolymer body material which covers and encloses the body region, and a liquid support material that is different from the first liquid photopolymer body material and which covers and encloses the support region; and

send to the selective curing unit signals for selectively solidifying the first liquid photopolymer body material by irradiating the layer with curing radiation through the transparent substrate according to the body region.

13. The apparatus of claim 10, wherein the selective curing unit comprises an ultraviolet image projector.

14. The apparatus of claim 10, wherein the selective curing unit comprises an ultraviolet laser.

15. The apparatus of claim 10, wherein the selective deposition unit deposits a plurality of different liquid body materials on the transparent substrate according to signals received from the controller.

16. An apparatus for preparing a two-dimensional layer of a three-dimensional object during a three-dimensional printing of the object, wherein the three-dimensional object includes a body structure and a support structure, the apparatus comprising:

a controller;

a UV-transparent substrate for receiving a deposited layer of liquid materials on an upper surface thereof;

a selective deposition unit arranged to deposit at least one liquid body material and a liquid support material that is different from the at least one liquid body material, on the UV-transparent substrate according to signals received from the controller; and

a UV light projector for providing UV light to selectively solidify, by curing, a portion of the deposited layer of liquid body materials on the UV-transparent substrate, according to signals received from the controller; and

a non-transitory storage unit containing machine-readable instructions, which instructions, when executed by the controller, cause the controller to;

receive two-dimensional image data of a cross section of the three-dimensional object, the image including a body region and a support region, wherein the support region is distinct from the body region;

send to the selective deposition unit signals for selectively depositing, on a transparent substrate, a layer that includes at least a first liquid photopolymer body material which covers and encloses the body region, and a liquid support material that is different from the first liquid photopolymer body material and which covers and encloses the support region; and

send to the selective curing unit signals for selectively solidifying the first liquid photopolymer body material by irradiating the layer with curing radiation through the transparent substrate according to the body region.

17. The apparatus of claim 16, further comprising a wiper that removes uncured liquid body material from the transparent substrate.

18. The apparatus of claim 16, wherein the UV light projector comprises an ultraviolet image projector.

19. The apparatus of claim 16, wherein the UV light projector comprises an ultraviolet laser.

20. The apparatus of claim 16, wherein the deposition unit deposits a plurality of different liquid body materials on the UV-transparent substrate according to signals received from the controller.