Apparatus for production of three-dimensional objects by stereolithography

• US 4,575,330 A
• Filed: 08/08/1984
• Issued: 03/11/1986
• Est. Priority Date: 08/08/1984
• Status: Expired due to Term

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: UVP, Inc.
• Inventors: Hull, Charles W.
• Primary Examiner(s): TENTONI, LEO B
• Application Number:
  US06/638,905
• Time in Patent Office: 580 Days
• Field of Search: 425/162, 425/174, 425/174.4, 425/425, 264/22, 264/183, 264/40.1, 430/269, 156/38, 156/58, 156/275.5, 365/107, 365/119, 365/127
• US Class Current: 425/174.4
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0833 using actinic light
• CPC Class Codes: B29C 2035/0844 using X-ray
• CPC Class Codes: B29C 2035/0877 using electron radiation, e.g. beta-rays
• CPC Class Codes: B29C 35/0866 using particle radiation
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: G03F 7/0037 Production of three-dimensional images
• CPC Class Codes: G03F 7/70416 2.5D lithography
• CPC Class Codes: G05B 2219/49013 Deposit layers, cured by scanning laser, stereo lithography SLA, prototyping
• CPC Class Codes: G05B 2219/49017 DTM desktop manufacturing, prototyping
• CPC Class Codes: G09B 25/00 Models for purposes not provided for in G09B23/00, e.g. full-sized devices for demonstration purposes model vehicles, tracks therefor, models in the nature of toys A63H
• CPC Class Codes: G09B 25/02 of industrial processes; of machinery

Abstract

A system for generating three-dimensional objects by creating a cross-sectional pattern of the object to be formed at a selected surface of a fluid medium capable of altering its physical state in response to appropriate synergistic stimulation by impinging radiation, particle bombardment or chemical reaction, successive adjacent laminae, representing corresponding successive adjacent cross-sections of the object, being automatically formed and integrated together to provide a step-wise laminar buildup of the desired object, whereby a three-dimensional object is formed and drawn from a substantially planar surface of the fluid medium during the forming process.

Claims

1. A system for producing a three-dimensional object from a fluid medium capable of solidification when subjected to prescribed synergistic stimulation, said system comprising:

means for drawing upon and forming successive cross-sectional laminae of said object at a two-dimensional interface; and

means for moving said cross-sections as they are formed and building up said object in step wise fashion, whereby a three-dimensional object is extracted from a substantially two-dimensional surface.

2. An improved system for producing a three-dimensional object from a fluid medium capable of solidification when subjected to prescribed synergistic stimulation, said system comprising:

a body of fluid medium capable of transforming its physical state in response to synergistic stimulation;

object support means immersed within said fluid medium for supporting a three-dimensional object to be formed;

translational means for selectively moving said object support means progressively away from a designated surface of said fluid medium; and

reaction means capable of altering the physical state of said fluid medium and operating in a prescribed pattern upon said designated surface of said fluid medium to provide a thin solid lamina at said surface representing a corresponding cross-sectional lamina of said three-dimensional object to be formed,

whereby successive adjacent laminae are provided to form said three-dimensional object on said object support means as said translational means moves said support means away from said designated surface.

3. A system as set forth in claim 2, and further including:

programmed control means for varying the graphic pattern of said reaction means operating upon said designated surface of said fluid medium.

4. A system as set forth in claim 2, wherein said reaction means includes:

a beam of impinging radiation.

5. A system as set forth in claim 2, wherein said reaction means includes:

an electron beam.

6. A system as set forth in claim 2, wherein said reaction means includes:

a beam of high energy particles.

7. A system as set forth in claim 2, wherein said reaction means includes:

a beam of light.

8. A system as set forth in claim 2, wherein said reaction means includes:

x-rays.

9. A system as set forth in claim 2, wherein said reaction means includes:

a beam of ultraviolet light.

10. A system as set forth in claim 2, wherein said reaction means includes:

a jet of a reactive chemical to induce solidification of said fluid medium.

11. A system as set forth in claim 2, wherein said reaction means includes:

a patterned mask overlying said designated surface for selectively applying a chemical to induce solidification of said fluid medium.

12. A system as set forth in claim 2, wherein said reaction means includes:

a patterned mask overlying said designated surface for selectively exposing said surface to synergistic stimulation.

13. A system as set forth in claim 2, wherein said reaction means includes:

a patterned mask overlying said designated surface for selectively exposing said surface to radiation.

14. A system as set forth in claim 2, wherein said translational means moves said object as it is formed away from said designated surface and further into said fluid medium.

15. A system as set forth in claim 2, wherein said translational means moves said object as it is formed away from said surface and out of said fluid medium.

16. A system as set forth in claim 2, wherein exposure to said reaction means at said designated surface is through a second non-reactive medium.

17. A system as set forth in claim 2, and further including:

a container for said fluid medium, wherein exposure of said designated surface to said reaction means is through the bottom of said container and a second non-reactive medium adjacent said designated surface.

18. A system as set forth in claim 17, wherein said second non-reactive medium is heavy water.

19. A system as set forth in claim 17, wherein said second non-reactive medium is ethylene glycol.

20. A system as set forth in claim 2, and further including:

rotational means, supplementing said translational means for altering the orientation of said object relative to said designated surface at which laminae are being formed.

21. A system as set forth in claim 2, wherein the level of said fluid medium locating said designated surface is variable.

22. A system as set forth in claim 2, wherein the level of said fluid medium locating said designated surface is maintained constant.

23. A system as set forth in claim 2, wherein said translational means has multiple degrees of freedom of movement.

24. A system as set forth in claim 4, wherein precise focus of said beam of impinging radiation upon said designated surface is maintained.

25. A system as set forth in claim 2, wherein said prescribed pattern is formed upon said designated surface by radiation emanating from the face of a cathode ray tube.

26. A system as set forth in claim 2, wherein said prescribed pattern is formed by light directly emanating from a phosphor image.

27. A system for directly producing a three-dimensional object as it is designed by a computer, comprising:

deriving graphic image output from said computer, said graphic image defining successive adjacent cross-sections of the three-dimensional object designed by said computer;

means for drawing upon and forming successive cross-sections, corresponding to said computer designed cross-sections of said object, at a two-dimensional interface; and

means for moving said cross-sections as they are formed and building up said object in a stepwise fashion, whereby the three-dimensional object designed by said computer is automatically extracted from a substantially two-dimensional surface.

28. An improved system for producing a three-dimensional object from a fluid medium capable of altering its physical state when subjected to prescribed radiation, said system comprising:

a body of fluid medium capable of altering its physical state;

means for forming said three-dimensional object from said fluid medium by irradiating a designated surface of said medium to provide integrated, successive surface laminae at said surface, said laminae together defining said three-dimensional object.

29. An improved system for producing a three-dimensional object from a fluid medium, said system comprising:

a body of fluid medium capable of altering its physical state in response to prescribed radiation;

a radiation source for impinging said prescribed radiation in a selected pattern upon a designated surface of said fluid medium to provide only at said surface a thin solid lamina representing a cross-sectional lamina of a three-dimensional object to be formed; and

means for combining successive adjacent laminae to form said three-dimensional object from said fluid medium.

30. A system as set forth in claim 29, wherein said radiation source includes:

a beam of impinging radiation.

31. A system as set forth in claim 29, wherein said radiation source includes:

an electron beam.

32. A system as set forth in claim 29, wherein said radiation source includes:

a beam of high energy particles.

33. A system as set forth in claim 29, wherein said radiation source includes:

a beam of light.

34. A system as set forth in claim 29, wherein said radiation source includes:

a beam of ultraviolet light.

35. A system as set forth in claim 29, wherein said radiation source includes:

x-rays.

36. A system as set forth in claim 29, wherein said radiation source and pattern includes:

a patterned mask overlying said designated surface for selectively exposing said surface to synergistic stimulation.

37. A system as set forth in claim 29, wherein said radiation source and pattern includes:

a patterned mask overlying said designated surface selectively exposing said surface to radiation.

38. A system as set forth in claim 29, wherein exposure to said prescribed radiation at said designated surface is through a second non-reactive medium.

39. A system as set forth in claim 29, and further including:

a container for said fluid medium, wherein exposure of said designated surface to said prescribed radiation is through the bottom of said container and a second non-reactive medium adjacent said designated surface.

40. A system as set forth in claim 39, wherein said second non-reactive medium is heavy water.

41. A system as set forth in claim 39, wherein said second non-reactive medium is ethylene glycol.

42. A system as set forth in claim 39, wherein the level of said fluid medium locating said designated surface is maintained constant.

43. A system as set forth in claim 39, wherein said translational means has multiple degrees of freedom of movement.

44. A system as set forth in claim 39, wherein precise focus of said prescribed radiation upon said designated surface is maintained.

45. A system as set forth in claim 39, wherein said selected pattern is formed upon said designted surface by radiation emanating from the face of a cathode ray tube.

46. A system as set forth in claim 39, wherein said selected pattern is formed by light directly emanating from a phosphor image.

47. A system as set forth in claim 39, and further including:

programmed control means for varying the pattern of said impinging radiation upon said designated surface of said fluid medium.