Stereolithography method and apparatus employing various penetration depths
First Claim
1. An improved stereolithographic method for producing a three-dimensional object by forming layers of material curable in response to synergistic stimulation adjacent to previously formed layers of material and successively curing the layers of material by exposing the layers of material to a pattern of synergistic stimulation correspond to successive cross-section of the three-dimensional object, the improvement comprising the steps of:
- curing at least a portion of a first layer of a three-dimensional object, said portion being cured using a first exposure of synergistic stimulation having a first penetration depth; and
curing said portion of the first layer using at least a second exposure of synergistic stimulation having a second penetration depth wherein the first and second penetration depths are different.
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Accused Products
Abstract
An improved stereolithographic apparatus (SLA) and an improved method for generating a part from curable material. The invention utilizes control and/or knowledge of depths of penetration of actinic radiation into a vat of photopolymer to determine and/or control and/or produce desirable characteristics associated with the creation of parts. From a predictive point of view, these desirable characteristics may include determination of cure depth from a given exposure, determination cure width, determination of required minimum surface angle (MSA), determination of optimum skin fill spacing, the strength of cross sections of partially polymerized material, amount of curl type distortion, and necessary overcure to attain adhesion between layers, etc. These determinations can lead to the use of particular building techniques to insure adequate part formation. From the controlling and producing point of view, the penetration depths can be controlled to obtain optimized characteristics for a given layer thickness, maximized speed of drawing, minimized print through, maximized strength, minimum curl and other distortions, and maximum resolution, etc. An important aspect of the present invention is the integration of resin characteristics, with the depth of penetration associated with the particular resin being used and the wavelength(s) of actinic radiation being used to solidify it, and with the intensity profile of the beam of actinic radiation as it strikes the resin surface.
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Citations
44 Claims
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1. An improved stereolithographic method for producing a three-dimensional object by forming layers of material curable in response to synergistic stimulation adjacent to previously formed layers of material and successively curing the layers of material by exposing the layers of material to a pattern of synergistic stimulation correspond to successive cross-section of the three-dimensional object, the improvement comprising the steps of:
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curing at least a portion of a first layer of a three-dimensional object, said portion being cured using a first exposure of synergistic stimulation having a first penetration depth; and curing said portion of the first layer using at least a second exposure of synergistic stimulation having a second penetration depth wherein the first and second penetration depths are different. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. An improved stereolithography method for producing a three-dimensional object by forming layers of material curable in response to synergistic stimulation adjacent to previously formed layers of material and successively curing the layers of material by exposing the layers of material to a pattern of synergistic stimulation corresponding to successive cross-section of the three-dimensional object, the improvement comprising the steps of:
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curing at least a portion of a first layer of the three-dimensional object, said portion being cured using a first exposure of synergistic stimulation having a first penetration depth; and curing said portion of the first layer using a second exposure of synergistic stimulation having a second penetration depth wherein the second penetration depth is greater than the first penetration depth. - View Dependent Claims (12, 13)
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14. An improved stereolithographic method for producing a three-dimensional object by forming layers of material curable in response to synergistic stimulation adjacent to previously formed layers of material and successively curing the layers of material by exposing the layers of material to a pattern of synergistic stimulation corresponding to successive cross-sections of the three-dimensional object, the improvement comprising the steps of:
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curing at least a portion of a first layer of a three-dimensional object, said portion being cured using at least a first exposure of synergistic stimulation having a first penetration depth wherein said first exposure causes a depth of cure of the portion to be less than a cure depth required to cause sufficient adhesion to cause curl distortion; and curing said portion of the first layer using at least one additional exposure of synergistic stimulation having at least one additional penetration depth wherein an additional exposure insures adhesion of said portion of said first layer to a previously cured layer and wherein an additional penetration depth is greater than the first penetration depth. - View Dependent Claims (15, 16)
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17. An improved stereolithographic method for producing a three-dimensional object by forming layers of material curable in response to synergistic stimulation adjacent to previously formed layers of material and successively curing the layers of material by exposing the layers of material to a pattern of synergistic stimulation corresponding to successive cross-sections of the three-dimensional object, the improvement comprising the steps of:
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curing at least a portion of a first layer of a three-dimensional object, having a layer thickness, said portion being cured using a first exposure of synergistic stimulation having a first penetration depth which causes a depth of cure of the portion to be less than the layer thickness; and curing said portion of the first layer using at least one additional exposure of synergistic stimulation having at least one additional penetration depth wherein the additional exposure results in a cure depth greater than the layer thickness and wherein an additional penetration depth is greater than the first penetration depth. - View Dependent Claims (18, 19)
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20. An improved stereolithographic method for producing a three-dimensional object by forming layers of material curable in response to synergistic stimulation adjacent to previously formed layers of material and successively curing the layers of material by exposing the layers of material to a pattern of synergistic stimulation corresponding to successive cross-sections of the three-dimensional object, the improvement comprising the steps of:
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curing at least a portion of a first layer of a three-dimensional object, said portion being cured using a first exposure of synergistic stimulation having a first penetration depth wherein said exposure causes the depth of cure of the portion to be less than that required to cause adhesion between the portion of the first layer and a previously cured layer; and curing said portion of the first layer using an additional exposure of synergistic stimulation having a second penetration depth wherein the additional exposure insures adhesion of said portion of said first layer to the previously cured layer and wherein the second penetration depth is greater than the first penetration depth. - View Dependent Claims (21, 22)
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23. An improved stereolithography apparatus for producing a three-dimensional object by forming layers of material curable in response to synergistic stimulation adjacent to previously formed layers of material and successively curing the layers of material by exposing the layers of material to a pattern of synergistic stimulation corresponding to successive cross-sections of the three-dimensional object, the improvement comprising:
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means for curing at least a portion of a first layer of a three-dimensional object, said portion being cured using a first exposure of synergistic stimulation having a first penetration depth; and means for curing said portion of the first layer using at least a second exposure of synergistic stimulation having a second penetration depth wherein the first and second penetration depths are different. - View Dependent Claims (24, 25, 26, 27, 28, 29, 30, 31, 32)
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33. An improved stereolithographic apparatus for producing a three-dimensional object by forming layers of material curable in response to synergistic stimulation adjacent to previously formed layers of material and successively curing the layers of material by exposing the layers of material to a pattern of synergistic stimulation corresponding to successive cross-sections of the three-dimensional object, the improvement comprising:
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means for curing at least a portion of a first layer of the three-dimensional object, said portion being cured using a first exposure of synergistic stimulation having a first penetration depth; and means for curing said portion of the first layer using a second exposure of synergistic stimulation having a second penetration depth wherein the second penetration depth is greater than the first penetration depth. - View Dependent Claims (34, 35)
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36. An improved stereolithographic apparatus for producing a three-dimensional object by forming layers of material curable in response to synergistic stimulation adjacent to previously formed layers of material and successively curing the layers of material by exposing the layers of material to a pattern of synergistic stimulation corresponding to successive cross-sections of the three-dimensional object, the improvement comprising:
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means for curing at least a portion of a first layer of a three-dimensional object, said portion being cured using at least a first exposure of synergistic stimulation having a first penetration depth wherein said first exposure causes a depth of cure of the portion to be less than a cure depth required to cause sufficient adhesion to cause curl distortion; and means for curing said portion of the first layer using at least one additional exposure of synergistic stimulation having at least one additional penetration depth wherein an additional exposure insures adhesion of said portion of said first layer to a previously cured layer and wherein an additional penetration depth is greater than the first penetration depth. - View Dependent Claims (37, 38, 41)
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39. An improved stereolithographic apparatus for producing a three-dimensional object by forming layers of material curable in response to synergistic stimulation adjacent to previously formed layers of material and successively curing the layers of material by exposing the layers of material to a pattern of synergistic stimulation corresponding to successive cross-sections of the three-dimensional object, the improvement comprising:
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means for curing at least a portion of a first layer of a three-dimensional object, having a layer thickness, said portion being cured using a first exposure of synergistic stimulation having a first penetration depth which causes a depth of cure of the portion to be less than the layer thickness; and means for curing said portion of the first layer using at least one additional exposure of synergistic stimulation having at least one additional penetration depth wherein an additional exposure results in a cure depth greater than the layer thickness and wherein an additional penetration depth is greater than the first penetration depth. - View Dependent Claims (40)
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42. An improved stereolithographic apparatus for producing a three-dimensional object by forming layers of material curable in response to synergistic stimulation adjacent to previously formed layers of material and successively curing the layers of material by exposing the layers of material to a pattern of synergistic stimulation corresponding to successive cross-sections of the three-dimensional object, the improvement comprising:
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means for curing at least a portion of a first layer of a three-dimensional object, said portion being curing using a first exposure of synergistic stimulation having a first penetration depth wherein said exposure causes the depth of cure of the portion to be less than that required to cause adhesion between the portion of the first layer and a previously cured layer; and means for curing said portion of the first layer using an additional exposure of synergistic stimulation having a second penetration depth wherein the additional exposure insures adhesion of said portion of said first layer to the previously cured layer and wherein the second penetration depth is greater than the first penetration depth. - View Dependent Claims (43, 44)
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Specification