Surface resolution in three-dimensional objects by inclusion of thin fill layers

• US 5,209,878 A
• Filed: 10/30/1990
• Issued: 05/11/1993
• Est. Priority Date: 10/30/1990
• Status: Expired due to Fees

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Jacobs, Paul J., Freed, Ray S., Evans, Herbert E., Smalley, Dennis R., Nguyen, Hop D., Schmidt, Kris A.
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US07/605,979
• Time in Patent Office: 924 Days
• Field of Search: 264/22, 264/40.1, 264/232, 264/255, 264/308, 264/340, 264/343, 425/135, 425/174.4, 425/375, 156/64, 156/242, 156/273.3, 156/273.5, 156/275.5, 156/307.1, 156/378, 156/379.6, 427/53.1, 427/54.1, 427/393.5, 427/407.1, 427/430.1, 118/407, 118/423, 118/428, 118/429, 118/620, 118/712, 250/432 R, 250/492.1, 364/468, 364/476, 364/522, 364/523, 365/106, 365/107, 365/119, 365/120, 365/126, 365/127, 430/270, 430/328, 430/331, 395/119
• US Class Current: 264/401
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G05B 2219/49013 Deposit layers, cured by scanning laser, stereo lithography SLA, prototyping
• CPC Class Codes: G05B 2219/49019 Machine 3-D slices, to build 3-D model, stratified object manufacturing SOM

Abstract

Methods and apparatus for reducing surface discontinuities, resulting from the formation of a three-dimensional object out of a plurality of stacked layers, during layer by layer stereolithographic formation of the three-dimensional object. The discontinuities between layers are reduced by utilizing formation and solidification of thin fill layers near the edges of thicker structural layers or by utilizing surface tension effects to smooth discontinuities between the structural layers by formation of meniscuses of building material and solidifying the meniscuses.

Claims

1. An improved stereolithographic method for forming a three-dimensional object on substantially a layer by layer basis from a material capable of selective physical transformation upon exposure to synergistic stimulation comprising the steps of forming successive layers of unsolidified material of desired thickness in preparation of forming layers of structure of said three-dimensional object and exposing said layers of unsolidified material to synergistic stimulation to form said layers of structure of said three-dimensional object, including forming a last layer of unsolidified material and exposing said last layer to synergistic stimulation to form a last layer of structure thereby completing formation of all layers of said three-dimensional object, the improvement comprising the step of:

reducing at least part of an up-facing surface discontinuity between two layers by selectively exposing said unsolidified building material within at least part of said discontinuity to synergistic stimulation wherein the synergistic stimulation impinges on a surface of said material with an orientation close to perpendicular prior to exposing said last layer of structure of said three-dimensional object.

52. The improved method of claim 1 wherein the step of reducing at least part of a surface discontinuity between two consecutive layers comprises selectively exposing said unsolidified building material within at least part of said discontinuity to synergistic stimulation to form at least one layer thinner than said thickness of said layers of structure.

53. The improved method of claim 52 additionally comprising the step of:

determining a configuration of the discontinuity to be reduced by comparing the difference between material to be cured by said two consecutive layers and the material desired to be cured within an object envelope, said object envelope descriptive of the desired object configuration.

54. The method of claim 1 wherein up-facing surface discontinuities exist between a plurality of layers and a wherein said step of reducing the up-facing surface discontinuity reduces a substantial number of said discontinuities.

2. An improved stereolithographic method for forming a three-dimensional object on substantially a layer by layer basis from a material capable of selective physical transformation upon exposure to synergistic stimulation, comprising the steps of forming successive layers of unsolidified material of desired thickness in preparation for forming layers of structure of said three-dimensional object and exposing said layers of unsolidified material to synergistic stimulation to form said layers of structure of said three-dimensional object, including forming a last layer of unsolidified material and exposing said last layer to synergistic stimulation to form a last layer of structure thereby completing formation of all layers of structure of said three-dimensional object, the improvement comprising the step of:

reducing at least part of a down-facing surface discontinuity between a first and a second layer by selectively exposing said unsolidified material within at least part of said discontinuity to synergistic stimulation prior to exposing said last layer of structure of said three-dimensional object but after a layer of material is formed in preparation for formation of said second layer of structure.

55. The method of claim 2 wherein down-facing surface discontinuities exist between a plurality of layers and a wherein said step of reducing the down-facing surface discontinuity reduces a substantial number of said discontinuities.

3. An improved stereolithographic method for forming a three-dimensional object, having an exterior surface, on substantially a layer by layer basis from a material capable of selective physical transformation upon exposure to synergistic stimulation, comprising the steps of forming successive layers of unsolidified material of desired thickness in preparation for forming layers of structure of said three-dimensional object and exposing said layers of unsolidified material to synergistic stimulation to form said layers of structure of said three-dimensional object, including forming a last layer of unsolidified material and exposing said last layer to synergistic stimulation to form a last layer of structure thereby completing formation of all layers of said three-dimensional object, the improvement comprising the steps of:

selectively curing a layer of material of desired thickness to form at least a portion of an internal region of a layer of structure, said layer of structure having a z-range corresponding to said desired thickness; and

forming at least a portion of said exterior surface of said three-dimensional object from at least one fill layer which has a thicknesses less than said desired thickness, and wherein said at least portion of said exterior surface corresponds to said z-range, and wherein said at least one fill layer is formed prior to formation of said last layer of structure of said three-dimensional object.

56. The method of claim 3 wherein a plurality of layers are cured each having a desired z-range of a desired thickness and wherein the exterior surface corresponding to a substantial number of said desired z-ranges is at least partially formed from a number of fill layers.

4. A method for reducing a surface discontinuity between first and second structural layers of a three-dimensional object being stereolithographically formed, said discontinuity comprising a deviation between a down-facing region of a three-dimensional object surface and a desired object envelope, the down-facing region to comprise an end of a not yet formed first structural layer which is to contact at least in part the object envelope, and an extension region which is to comprise a portion of a lower surface of a not yet formed second structural layer which extends beyond the end of the first structural layer, and which is to contact, at least in part, the object envelope, the lower surface to contact at least in part an upper surface of the first structural layer, the method comprising the steps of:

containing a volume of flowable material, which material is capable of selective physical transformation upon exposure to synergistic stimulation, whereupon a working surface of the material is formed;

selectively exposing material at said working surface to a first exposure of said synergistic stimulation to form said first structural layer having a first cure depth;

selectively exposing material at the working surface to a second exposure of the synergistic stimulation to form a first fill layer, said fill layer being cured to a depth less than said first cure depth, said fill layer also having a first edge and a second edge and having an upper surface;

forming an untransformed layer of said material over at least a portion of said upper surface of said first structural layer, whereupon an upper surface of said untransformed layer defines, at least in part, a new working surface; and

selectively exposing material at the new working surface to a third exposure of the synergistic stimulation to form said second structural layer, wherein said lower surface of said second structural layer contacts at least in part said upper surface of said first fill layer.

5. The method of claim 4 wherein the first fill layer is formed edgewise and further comprising the step of selectively exposing material at the working surface to a fourth exposure of the synergistic stimulation, before the forming of said untransformed layer, to form a second fill layer situated edgewise relative to the working surface, having a first edge and a second edge, an upper surface, and a lower surface which is situated below the working surface, wherein said first edge of said second fill layer contacts, at least in part, said second edge of said first fill layer, and wherein said upper surface of said second fill layer contacts at least in part said lower surface of said second structural layer upon formation of said second structural layer.

6. The method of claim 4, wherein the first fill layer is formed lengthwise and further comprising the steps of:

selectively exposing the upper surface of the first fill layer to a fourth exposure of synergistic stimulation, wherein the fourth exposure occurs before the third exposure, and wherein at least a portion of the synergistic stimulation in the fourth exposure passes through the first fill layer to expose untransformed material situated below the lower surface of the first fill layer to form a second fill layer situated lengthwise relative to the working surface and having an upper surface which is situated below and contacts at least in part the lower surface of the first fill layer, and having a first edge which contacts at least in part the end of the first structural layer, and having a thickness less than the thickness of the first structural layer.

7. The method of claim 4 wherein the first fill layer is formed lengthwise and overlapping at least in part, the first structural layer.

8. The method of claim 7 further comprising the step of selectively exposing said material to a fourth exposure of the synergistic stimulation to form a second fill layer situated lengthwise, and overlapping, at least in part, the first structural layer, said second fill layer having a lower surface, and having a thickness less than the thickness of the first structural layer, whereupon the lower surface of said second fill layer contacts, at least in part, the upper surface of the first fill layer.

9. A method for reducing a surface discontinuity between first and second structural layers of a three-dimensional object being stereolithographically formed from a flowable material capable of selective physical transformation upon exposure to synergistic stimulation, said discontinuity comprising a deviation between a down-facing region of said three-dimensional object surface and a desired object envelope, the down-facing region comprising an end of an already-formed first structural layer which contacts at least in part the envelope, and an extension region comprising a portion of a lower surface of a not yet formed second structural layer, the lower surface of said second structural layer, after formation, contacting at least in part an upper surface of the first structural layer, and the second structural layer having an end which extends beyond the end of the first structural layer by the extension region, which end contacts at least in part the object envelope, wherein the first and second structural layers have thicknesses, the method comprising:

coating over at least a portion of said first structural layer with a layer of desired thickness of said flowable building material in preparation for formation of said second structural layer;

selectively exposing said coating of flowable building material to synergistic stimulation to form at least a portion of said second structural layer; and

selectively exposing, at least in part, the extension region of the second structural layer to synergistic stimulation to expose material situated below the extension region of the second structural layer to form a first fill layer.

10. The method of claim 9 wherein the fill layer is formed edgewise and the fill layer has a first edge, and wherein said first edge contacts, at least in part, the end of the first structural layer.

11. The method of claim 10 further comprising the step of selectively exposing, at least in part, the extension region to an additional exposure of synergistic stimulation to expose material situated below the extension region to form a second fill layer situated edgewise relative to the working surface and contacting at least in part said first fill layer.

12. The method of claim 9 wherein the first fill layer is formed lengthwise.

13. The method of claim 12 further comprising the step of selectively exposing at least in part the upper surface of the extension region to an additional exposure of the synergistic stimulation to form a second fill layer, below said extension region, situated lengthwise relative to the working surface, and having an upper surface which contacts, at least in part, a lower surface of said first fill layer.

14. A method for reducing a surface discontinuity between first and second structural layers of a three-dimensional object being stereolithographically formed from a flowable material capable of selective physical transformation upon exposure to synergistic stimulation, said discontinuity comprising a deviation between an up-facing region of a three-dimensional object surface and a desired object envelope, the up-facing region comprising an end of an already-formed first structural layer, and an extension region comprising at least part of an upper surface of an already-formed second structural layer, the first structural layer having a lower surface which contacts at least in part the upper surface of the second structural layer, and the second structural layer having an end which extends beyond the end of the first structural layer by the extension region, which end contacts at least in part the envelope, wherein the first and second structural layers have thicknesses, the method comprising:

selectively exposing said material to synergistic stimulation to form a first fill layer having a thickness less than the thickness of the first structural layer.

15. The method of claim 14 wherein a lower surface of the first fill layer contacts, at least in part, the extension region of the second structural layer and a first edge of said first fill layer contacts at least in part said end of said first structural layer.

16. The method of claim 15 wherein the first fill layer is formed lengthwise and further comprising the steps of selectively exposing said material to an additional exposure of synergistic stimulation to form a second fill layer situated lengthwise, and having a lower surface which contacts, at least in part, the upper surface of the first fill layer, and having a first edge which contacts, at least in part, the first end of the first structural layer, and having a thickness less than the thicknesses of the first structural layer.

17. The method of claim 14 wherein said first fill layer is formed edgewise.

18. The method of claim 17 wherein a first edge of said first fill layer contacts, at least in part, the end of the first structural layer.

19. The method of claim 18 further comprising the step of selectively exposing said material to form a second fill layer situated edgewise, and having a first edge which contacts, at least in part, a second edge of said first fill layer, and having a lower surface which contacts, at least in part, the extension region of the second structural layer.

20. A method for reducing a surface discontinuity between first and second structural layers of a three-dimensional object being stereolithographically formed from a flowable material capable of selective physical transformation upon exposure to synergistic stimulation, said discontinuity comprising a deviation between an up-facing region of a three-dimensional object surface and a desired object envelope, the up-facing region to comprise an end of a not yet formed first structural layer, an extension region comprising at least a portion of an upper surface of an already-formed second structural layer, the second structural layer having an end which is to extend beyond the end of the first structural layer by the extension region, and which ends contacts at least in part the envelope, wherein the second structural layer has an upper surface which is to contact, at least in part, a lower surface of the first structural layer, the second structural layer having an upper surface situated at about a working surface of said flowable material, the method comprising:

forming a first layer of said flowable material over at least part of said extension region in preparation for forming a first fill layer; and

selectively exposing said first layer of said material to synergistic stimulation to form a first fill layer having a lower surface which contacts, at least in part, the extension region of the second structural layer.

21. The method of claim 20 wherein the first fill layer is formed edgewise and a first edge of the first fill layer contacts, at least in part, the end of the yet to be formed first structural layer.

22. The method of claim 20 wherein the first fill layer is formed edgewise and further comprising the step of selectively exposing said material to an additional exposure of synergistic stimulation to form a second edgewise fill layer having a lower surface which contacts, at least in part, the extension region of the second structural layer, and having an edge which contacts, at least in part, an edge of the first fill layer.

23. The method of claim 20 further comprising the steps of:

forming a second layer of untransformed material over at least part of said upper surface of said second structural layer; and

selectively exposing said second layer to a second exposure of synergistic stimulation to form said first structural layer, wherein said thickness of said first structural layer is greater than the thickness of said first fill layer.

24. The method of claim 23, further comprising the steps of:

forming a third layer of flowable material over at least part of said extension region; and

selectively exposing said third layer of flowable material to a third exposure of said synergistic stimulation, prior to forming said second layer of flowable material, to form a second fill layer adjacent to said first fill layer, and having a thickness which is less than the thickness of said first structural layer.

25. A method for reducing a surface discontinuity between first and second structural layers of a three-dimensional object being stereolithographically formed, said discontinuity comprising a deviation between a region of a three-dimensional object surface and a desired object envelope, the region to comprise an end of a not yet formed first structural layer, and an extension region, the extension region to comprise at least a portion of a surface of a not yet formed second structural layer, the second structural layer to have an end which is to extend beyond an end of the first structural layer by the extension region, the ends to contact at least in part the envelope, the surface of the first structural layer to contact, at least in part, a surface of the first structural layer, and the first and second structural layers to have thicknesses, the method comprising the following steps:

containing a volume of flowable material, the material capable of selective physical transformation upon exposure to synergistic stimulation;

selectively exposing said material to a first exposure to said synergistic stimulation to form a first selected one of said first and second structural layers;

selectively exposing said material to a second exposure of said synergistic stimulation to form a first fill layer having a first portion which contacts, at least in part, a portion of said first selected one; and

selectively exposing said material to a third exposure to said synergistic stimulation, to form a second selected one of said first and second structural layers which is different from said first selected one, wherein a time order of exposure is one of the first exposure followed by the second exposure followed by the third exposure or the first exposure followed by the third exposure followed by the second exposure.

26. The method of claim 25 wherein said formation of said second selected one occurs after formation of said first fill layer, and said first fill layer will contact, at least in part, a portion of said second selected one after formation.

27. The method of claim 25 wherein said formation of said second selected one occurs before formation of said first fill layer, and said first fill layer contacts, at least in part, a portion of said second selected one.

28. A method for reducing a surface discontinuity between first and second structural layers of a three-dimensional object being stereolithographically formed from a flowable material capable of selective physical transformation upon exposure to synergistic stimulation, said discontinuity comprising a deviation between a region of a three-dimensional object surface and a desired object envelope, the region to comprise an end of a not yet formed first structural layer, and an extension region, the extension region to comprise at least a portion of a surface of a not yet formed second structural layer, the second structural layer to have an end which is to extend beyond an end of the first structural layer by the extension region, the ends to contact, at least in part, the envelope, the surface of the second structural layer to contact, at least in part, a surface of the first structural layer, the method comprising the following steps:

selectively exposing flowable material to a first exposure of said synergistic stimulation to form a first selected one of said first and second structural layers out of said material;

forming a meniscus in said region which at least in part reduces said discontinuity;

selectively exposing said meniscus, at least in part, to a second exposure of said synergistic stimulation whereupon said meniscus substantially transforms, wherein said exposure of said meniscus occurs prior to formation of a last layer of structure of said three-dimensional object;

forming a coating of said flowable material over at least a portion of an upper surface of said first selected one, said upper surface comprising one of said surfaces of said first and second structural layers; and

selectively exposing said coating to a third exposure of said synergistic stimulation to form a second selected one of said first and second structural layers which is different from said first selected one.

29. The method of claim 28 wherein said first selected one is said second structural layer.

30. The method of claim 28 wherein the steps of forming the meniscus and selectively exposing the meniscus are repeated at least one to further reduce said discontinuity.

57. The method of claim 29 wherein the time order of exposure is specified to be the first exposure followed by the third exposure followed by the second exposure.

58. The method of claim 57 wherein the step of forming the meniscus comprises the step of separating an upper surface of said second selected one from a material surface.

59. The method of claim 58 wherein the step of separating comprises raising at least said second selected one above said material surface.

31. An improved stereolithographic apparatus for forming a three-dimensional object on substantially a layer by layer basis from a material capable of selective physical transformation upon exposure to synergistic stimulation comprising means for forming successive layers of unsolidified material of desired thickness in preparation for forming layers of structure of said three-dimensional object and means for exposing said layers of unsolidified material to synergistic stimulation to form said layers of structure of said three-dimensional object, including means for forming a last layer of unsolidified material and means for exposing said last layer to synergistic stimulation to form a last layer of structure thereby completing formation of all layers of said three-dimensional object, the improvement comprising:

means for reducing at least part of an up-facing surface discontinuity between two layers by selectively exposing said unsolidified building material within at least part of said discontinuity to synergistic stimulation wherein said synergistic stimulation impinges on a surface of said material with an orientation close to perpendicular prior to exposing said last layer of structure of said three-dimensional object.

60. The apparatus of claim 31 wherein the means for forming the layers is the means for forming the last layer and the means for exposing said layers is the means for exposing said last layer.

32. An apparatus for reducing a surface discontinuity between first and second structural layers of a three-dimensional object being stereolithographically formed comprising a deviation between a down-facing region of a three-dimensional object surface and a desired object envelope, the down-facing region to comprise an end of a not yet formed first structural layer which is to contact at least in part the object envelope, and an extension region which is to comprise a portion of a lower surface of a not yet formed second structural layer, the lower surface to contact at least in part an upper surface of the first structural layer, the second structural layer to have an end which is to extend beyond the end of the first structural layer, and which is to contact, at least in part, the object envelope, comprising:

a container containing a volume of flowable material, which material is capable of selective physical transformation upon selective exposure to synergistic stimulation, whereupon a working surface of the material is formed;

at least one computer programmed to modify a building representation, wherein said building representation specifies a first exposure of said synergistic stimulation to form said first structural layer having a first cure depth, to specify selectively exposing material at the working surface to a second exposure of the synergistic stimulation to form a first fill layer, said fill layer having a first edge and a second edge and having an upper surface and being cured to a depth less than said first cure depth;

wherein said at least one computer is further programmed to specify selectively exposing material to a third exposure of synergistic stimulation to form said second structural layer, wherein said lower surface of said second structural layer contacts at least in part said upper surface of said first fill layer, in accordance with said building representation;

recoating means for forming an untransformed layer of said material over said upper surface of said first structural layer and said upper surface of said first fill layer; and

forming means for selectively exposing material to said synergistic stimulation in accordance with said building representation.

33. The apparatus of claim 32 wherein said at least one computer programmed to modify said building representation specifies formation of the first fill layer edgewise and is further programmed to modify said building representation to specify selectively exposing material at the working surface to a fourth exposure of the synergistic stimulation, before said third exposure, to form a second fill layer situated edgewise, having an upper surface, a first edge, and a second edge, wherein one of said first or second edges of said second fill layer contact said first one of said first or second edges of said first fill layer, at least in part, and wherein said upper surface of said second fill layer contacts, at least in part, said lower surface of said second structural layer upon formation of said second structural layer.

34. The apparatus of claim 32 wherein said at least one computer programmed to modify said building representation specifies formation of the first fill layer lengthwise and overlapping, at least in part, the first structural layer.

35. The apparatus of claim 34 wherein said at least one computer is further programmed to modify said building representation to specify selectively exposing said material to a fourth exposure of the synergistic stimulation to form a second fill layer situated lengthwise, and overlapping, at least in part, the first structural layer, said second fill layer having an upper surface and a lower surface, and having a thickness less than the thickness of the first structural layer, whereupon the lower surface of said second fill layer contacts, at least in part, the upper surface of the first fill layer.

65. The apparatus of claim 32 wherein said at least one computer programmed to modify said building representation specifies formation of the first fill layer lengthwise and is further programmed to modify said building representation to specify selectively exposing at least a portion of the upper surface of the first fill layer to a fourth exposure of synergistic stimulation, before said third exposure, to form a second fill layer situated lengthwise, and having an upper surface which contacts at least in part the lower surface of the first fill layer, and having a thickness less than said first thickness.

36. An apparatus for reducing a surface discontinuity between first and second structural layers of a three-dimensional object being stereolithographically formed comprises a deviation between a down-facing region of said three-dimensional object surface and a desired object envelope, the down-facing region comprising an end of an already-formed first structural layer which contacts at least in part the object envelope, and an extension region comprising a portion of a lower surface of a not yet formed second structural layer, after formation the lower surface of said second structural layer contacting at least in part an upper surface of the first structural layer, and the second structural layer having an end which extends beyond the end of the first structural layer by the extension region, which end contacts at least in part the object envelope, wherein the first and second structural layers have thicknesses, comprising:

at least one computer programmed to modify a building representation, wherein said building representation specifies coating over said first structural layer with a layer of desired thickness of said flowable building material in preparation for formation of said second structural layer and specifies selective exposure of said coating to said synergistic stimulation to form at least part of said second structural layer, to specify selectively exposing, at least in part, the extension region of the second structural layer to synergistic stimulation to expose material situated below the extension region to form a first fill layer; and

forming means for selectively exposing said material to said synergistic stimulation in accordance with said modified building representation.

37. The apparatus of claim 36 wherein said at least one computer programmed to modify said building representation specifies formation of the first fill layer edgewise and is further programmed to modify said building representation to specify selectively exposing at least in part the upper surface of the extension region to an additional exposure of the synergistic stimulation sufficient to expose material situated below the extension region of the second structural layer to form a second fill layer situated edgewise relative to the working surface and contacting at least in part said first fill layer and said second structural layer.

38. The apparatus of claim 36 wherein said at least one computer programmed to modify said building representation specifies formation of the first fill layer lengthwise.

39. The apparatus of claim 38 wherein said at least one computer is further programmed to modify said building representation to specify selectively exposing at least in part the extension region to an additional exposure of synergistic stimulation to expose material situated below the extension region of the second structural layer to form a second fill layer situated lengthwise relative to the working surface, and having an upper surface which contacts, at least in part, a lower surface of said first fill layer.

40. An apparatus for reducing a surface discontinuity between first and second structural layers of a three-dimensional object being stereolithographically formed, said discontinuity comprising a deviation between an up-facing region of a three-dimensional object surface and a desired object envelope, the up-facing region comprising an end of an already-formed first structural layer, and an extension region comprising at least part of an upper surface of an already-formed second structural layer, the first structural layer having a lower surface contacting at least in part the upper surface of the second structural layer, and the second structural layer having an end which extends beyond the end of the first structural layer by the extension region, which end contacts at least in part the object envelope, wherein the first structural layer has an upper surface at about a working surface of flowable material capable of selective physical transformation upon exposure to synergistic stimulation, wherein the first and second structural layers have thicknesses, comprising:

at least one computer programmed to modify a building representation to specify selectively exposing said material to a first exposure of the synergistic stimulation to form a first fill layer having a thickness less than the thicknesses of the first and second structural layers; and

forming means for selectively exposing said material to said synergistic stimulation in accordance with said modified building representation.

41. The apparatus of claim 40 wherein said at least one computer programmed to modify said building representation specifies formation of the first fill layer lengthwise and is further programmed to modify said building representation to specify selectively exposing said material to a second exposure of synergistic stimulation to form a second fill layer situated lengthwise, and having a lower surface which contacts, at least in part, the upper surface of the first fill layer, and having a first edge which contacts, at least in part, the first end of the first structural layer, and having a thickness less than the thicknesses of the first structural layer.

42. The apparatus of claim 40 wherein said at least one computer programmed to modify said building representation specifies formation of the first fill layer edgewise.

43. The apparatus of claim 42 wherein said at least one computer is programmed to modify said building representation to specify selectively exposing said material to form a second fill layer situated edgewise, and having a first surface which contacts, at least in part, a second edge of said first fill layer, and having a lower surface which contacts, at least in part, the extension region of the second structural layer.

44. An apparatus for reducing a surface discontinuity between first and second structural layers of a three-dimensional object being stereolithographically formed from a flowable material capable of selective physical transformation upon exposure to synergistic stimulation, said discontinuity comprising a deviation between an up-facing region of a three-dimensional object surface and a desired object envelope, the up-facing region to comprise an end of a not yet formed first structural layer, an extension region comprising at least a portion of an upper surface of an already-formed second structural layer, the second structural layer having an end which is to extend beyond the end of the first structural layer by the extension region, and which ends contacts at least in part the object envelope, wherein the second structural layer has an upper surface which is to contact, at least in part, a lower surface of the first structural layer, the second structural layer having an upper surface situated at about a working surface of flowable material, comprising:

at least one computer programmed to modify a building representation to specify forming a coating of said flowable material over at least part of said extension region in preparation for forming a first fill layer and selectively exposing said material to a first exposure of synergistic stimulation to form said first fill layer, and having a lower surface which contacts, at least in part, the extension region of the second structural layer;

coating means for forming a coating over previously formed layers in accordance with said modified building representation; and

forming means for selectively exposing said material to said synergistic stimulation in accordance with said modified building representation.

45. The apparatus of claim 44 wherein said at least one computer programmed to modify said building representation specifies formation of the first fill layer edgewise and is programmed to further modify said building representation to specify selectively exposing said material to a second exposure of the synergistic stimulation to form a second fill layer edgewise having a lower surface which contacts, at least in part, the extension region of the second structural layer, and having an edge which contacts, at least in part, an edge of the first fill layer.

46. The apparatus of claim 44 wherein said building representation specifies formation of a second coating, at least in part, over said first fill layer in said second structural layer in preparation for formation of said first structural layer and wherein said building representation specifies formation of said first structural layer over said second structural layer.

47. The apparatus of claim 46

wherein said at least one computer is programmed to modify said building representation to specify forming a third coating of said flowable material over said extension region prior to forming said second coating and specifies selectively exposing said third coating of said flowable material to a third exposure of said synergistic stimulation before formation of the first structural layer to form a second fill layer having a thickness which is less than the thickness of said first structural layer.

48. An apparatus for reducing a surface discontinuity between a first and second structural layer of a three-dimensional object being stereolithographically formed said discontinuity comprising a deviation between a region of a three-dimensional object surface and a desired object envelope, the region to comprise an end of a not yet formed first structural layer, and an extension region, the extension region to comprise at least a portion of a surface of a not yet formed second structural layer, the second structural layer to have an end which is to extend beyond an end of the first structural layer by the extension region, the ends to contact at least in part the object envelope, the surface of the second structural layer to contact, at least in part, a surface of the first structural layer, and the first and second structural layers to have thicknesses, comprising:

a container containing a volume of flowable material, the material being capable of selective physical transformation upon exposure to synergistic stimulation;

at least one computer programmed to modify a building representation, wherein said building representation specifies a first exposure of said synergistic stimulation to form a first selected one of said first and second structural layers in accordance with a building representation, to specify selectively exposing said material to a second exposure of said synergistic stimulation to form a first fill layer having a first portion which contacts, at least in part, a portion of said first selected one; and

wherein said building representation specifies selectively exposing said material to a third exposure of said synergistic stimulation, to form a second selected one of said first and second structural layers which is different from said first selected one, wherein said modified building representation specifies a time order of exposure to be one of the first exposure followed by the second exposure followed by the third exposure or the first exposure followed by the third exposure followed by the second exposure; and

forming means for selectively exposing said material to said synergistic stimulation in accordance with said modified building representation.

49. An apparatus for reducing a surface discontinuity between first and second structural layers of a three-dimensional object being stereolithographically formed from a flowable material capable of selective physical transformation upon exposure to synergistic stimulation, said discontinuity comprising a deviation between a region of a three-dimensional object surface and a desired object envelope, the region to comprise an end of a not yet formed first structural layer, and an extension region, the extension region to comprise at least a portion of a surface of a not yet formed second structural layer, the second structural layer to have an end which is to extend beyond an end of the first structural layer by the extension region, the ends to contact, at least in part, the object envelope, the surface of the second structural layer to contact, at least in part, a surface of the first structural layer, comprising:

at least one computer programmed to modify said building representation, wherein said building representation specifies a first exposure of said synergistic stimulation to form a first selected one of said first and second structural layers out of said material, to specify selectively exposing a meniscus of said material to a second exposure of said synergistic stimulation whereupon at least a portion of said meniscus substantially transforms, and wherein said building representation further specifies selectively exposing said flowable material to a third exposure of said synergistic stimulation to form a second selected one of said first and second structural layers which is different from said first selected one;

recoating means for forming a coating of untransformed material over an upper surface of said first selected one;

meniscus forming means for forming a meniscus of said flowable material in said region which at least in part reduces said discontinuity; and

at least one forming means for selectively exposing material to said synergistic stimulation in accordance with said modified building representation to transform said material to form said layers and to transform said meniscus to reduce said discontinuity.

66. The apparatus of claim 49 wherein said at least one computer is programmed to specify performing said first exposure followed by said third exposure followed by said second exposure.

67. The apparatus of claim 49, wherein the meniscus forming means is adapted to separate an upper surface of said second selected one from a material surface.

68. The apparatus of claim 67 wherein the meniscus forming means is adapted to raise at least said second selected one above said material surface.

69. The apparatus of claim 68 wherein the first structural layer is below the second structural layer and the at least one computer is programmed to specify the first structural layer as the second selected one and the second structural layer as the first selected one.

50. A method for forming a three-dimensional object from a material capable of selective physical transformation upon exposure to synergistic stimulation, comprising the steps of:

modifying an object representation, specifying, at least in part, a first layer of the object adjacent to a second layer in the object, said first and second layers specified to have thicknesses, and specified to form a surface which includes a deviation from a desired object envelope, to obtain a modified object representation further specifying forming a third layer, specified to have a thickness less than the thickness of said first and second layers, and attaching said third layer to at least one of said first or second layers of said object to reduce said deviation;

successively forming layers of said material; and

selectively exposing said layers of material to said synergistic stimulation in accordance with said modified object representation to obtain said three-dimensional object.

51. An apparatus for forming a three-dimensional object from a material capable of selective physical transformation upon exposure to synergistic stimulation, comprising:

at least one computer programmed to modify an object representation specifying, at least in part, a first layer of the object adjacent to a second layer of the object, said first and second layers specified to have thicknesses, and specified to form a region which comprises a deviation from a desired object envelope, to obtain a modified object representation further specifying forming a third layer, specified to have a thickness less than the thicknesses of said first and second layers, and attaching said third layer to at least one of said first or second layers to reduce said deviation;

means for successively forming layers of said material; and

means for selectively exposing said layers of material to said synergistic stimulation in accordance with said modified object representation to form said three-dimensional object.

61. An improved stereolithographic apparatus for forming a three-dimensional object on substantially a layer by layer basis from a material capable of selective physical transformation upon exposure to synergistic stimulation comprising means for forming successive layers of unsolidified material of desired thickness in preparation for forming layers of structure of said three-dimensional object and means for exposing said layers of unsolidified material to synergistic stimulation to form said layers of structure of said three-dimensional object, including means for forming a last layer of unsolidified material and means for exposing said last layer to synergistic stimulation to form a last layer of structure thereby completing formation of all layers of said three-dimensional object, the improvement comprising:

means for reducing at least part of a down-facing surface discontinuity between a first and a second layer by selectively exposing said unsolidified building material within at least part of said discontinuity to synergistic simulation prior to exposing said last layer of structure of said three-dimensional object but after a layer of material is formed in preparation for formation of said second layer.

62. The apparatus of claim 61 wherein the means for forming the layers is the means for forming the layer and the means for exposing said layers is the means for exposing said last layer.

63. An improved stereolithographic apparatus for forming a three-dimensional object, having an exterior surface, on substantially a layer by layer basis from a material capable of selective physical transformation upon exposure to synergistic stimulation, comprising means for forming successive layers of unsolidified material of desired thickness, including a last layer, in preparation for forming layers of structure of said three-dimensional object and means for exposing said layers of unsolidified material to synergistic stimulation to form said layers of said three-dimensional object, including formation of a last layer of structure thereby completing formation of all layers of said three-dimensional object, the improvement comprising:

means for selectively exposing a layer of material of desired thickness to form at least a portion of an internal region of a layer of structure, said layer of structure having a z-range corresponding to said desired thickness; and

means for forming at least a portion of said exterior surface of said three-dimensional object from at least one fill layer which has a thicknesses less than said desired thickness, and wherein said at least portion of said exterior surface corresponds to said z-range.

64. The apparatus of claim 63 wherein said means for selectively exposing exposes a plurality of layers each having a desired z-range of a desired thickness and wherein the exterior surface corresponding to a substantial number of said desired z-ranges and wherein said means for forming forms at least a portion of said exterior surface from a number of fill layers.