Method and apparatus for production of three-dimensional objects by irradiation of photopolymers
First Claim
1. In the method of preparing three-dimensional objects from an uncured photopolymer by depositing the photopolymer in layers and treating it with radiation to form successive slices of an object of required configuration and joining said slices together, the improvement which comprises irradiating said uncured photopolymer by transmitting radiation through a transmittent flexible film in contact with the uncured photopolymer, said film being mechanically prevented from bulging during irradiation.
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Abstract
An improved method of preparing three-dimensional objects from uncured photopolymer by depositing the photopolymer in layers and treating it with radiation to convert the photopolymer into a cohesive structure capable of being at least partially unsupported includes irradiating the uncured photopolymer by transmitting radiation through a constrained radiation transmittent flexible film. Apparatus for performing the method is disclosed.
194 Citations
37 Claims
- 1. In the method of preparing three-dimensional objects from an uncured photopolymer by depositing the photopolymer in layers and treating it with radiation to form successive slices of an object of required configuration and joining said slices together, the improvement which comprises irradiating said uncured photopolymer by transmitting radiation through a transmittent flexible film in contact with the uncured photopolymer, said film being mechanically prevented from bulging during irradiation.
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4. An apparatus for producing of three-dimensional objects from photopolymer layer by layer by application of modulated radiation solidifying said photopolymer in required configuration, said apparatus comprising:
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(a) means for supporting an object; (b) deposition means for depositing onto said object a layer of photopolymer of desired thickness; (c) a transmittent flexible film said film covering said layer during irradiation; (d) irradiation means for solidifying at least a portion of said layer and attaching it to said object, said irradiation means including limiting means for obstructing bulging of said film during irradiation; and (e) separating means for separating said film from said object. - View Dependent Claims (5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. In the method of preparing a three-dimensional object from a photopolymer by depositing a layer of uncured photopolymer upon a layer of cured photopolymer, irradiating said layer of uncured photopolymer to cure it, and joining it to the previously cured layer to form an object, the improvement which comprises pushing uncured photopolymer onto the layer of the previously cured photopolymer by moving a flexible radiation transmittent film in a spreading fashion to spread the uncured photopolymer to form an uncured layer and to cover the layer with the film to protect it during irradiation;
- irradiating the uncured layer and, then separating said film from the layer.
- View Dependent Claims (21)
- 22. In the method of producing a three-dimensional object from photopolymer in successive portions by depositing uncured photopolymer in layers, irradiating the layers using irradiation means to form the successive portions, and attaching the successive portions to previously formed portions of the object or to object support means, the improvement which comprises depositing said layers directly onto a surface of said irradiation means spaced apart from said previously formed portions, and repositioning said object support means and said irradiation means for attachment of said successive portions to said previously formed portions.
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24. A method of producing a three-dimensional object from photopolymer in successive portions by depositing uncured photopolymer in a layer, irradiating the layer using irradiation means to form a successive portion, and attaching the successive portion to a previously formed portion of the object or to object support means, which comprises:
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(a) forming a portion of said object attached to object support means, (b) depositing a successive layer of uncured photopolymer directly onto said surface of said irradiation means spaced apart from a said previously formed portion, (c) irradiating said successive layer while it is spaced apart from said previously formed portion to form a successive portion, (d) attaching said successive portion to a said previously formed portion, and (e) separating said surface from said successive portion. - View Dependent Claims (25, 26, 27)
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28. A method of producing a three-dimensional object from photopolymer in successive portions by depositing uncured photopolymer in a layer, irradiating the layer using irradiation means to form a successive portion, and attaching the successive portion to a previously formed portion of the object or to object support means, which comprises:
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(a) forming a portion of said object attached to object support means, (b) depositing a successive layer of uncured photopolymer directly onto said surface of said irradiation means spaced apart from a said previously formed portion, (c) bringing said successive layer and a said previously formed portion into contact, (d) irradiating said successive layer to form a successive portion of said object and attach it to a said previously formed portion, and (e) separating said surface from said successive portion.
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29. An apparatus for producing a three-dimensional object from photopolymer in successive portions, said apparatus comprising:
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(a) object support means for supporting said object as it is formed, (b) irradiation means spaced apart from a previously formed portion of the object for successive irradiation of layers of uncured photopolymer to form successive portions of said object, said irradiation means having a surface, (c) separate photopolymer deposition means for successive deposition directly onto said surface of said irradiation means of said layers of uncured photopolymer, (d) positioning means for mutual repositioning of said object support means and said irradiation means for attachment of said successive portions to previously formed portions, and (e) separating means for separating said surface of said irradiation means and said formed portions of the object. - View Dependent Claims (30, 31, 32, 33, 34, 35, 36)
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37. In the method of producing a three-dimensional object from photopolymer in successive portions by depositing uncured photopolymer in layers, irradiating the layers using irradiation means to form the successive portions of the object, and attaching the successive portions to a previously formed portion of the object or to object support means, the improvement which comprises forming a portion of said object attached to object support means, depositing a successive layer of uncured photopolymer directly onto said surface of said irradiation means spaced apart from said previously formed portion of the object, irradiating said successive layer to form a successive portion, attaching said successive portion to a said previously formed portion, and then separating said surface from said successive portion.
Specification