Method and apparatus for production of three-dimensional objects

• US 5,534,104 A
• Filed: 05/25/1994
• Issued: 07/09/1996
• Est. Priority Date: 10/07/1992
• Status: Expired due to Fees

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: EOS GmbH Electro Optical Systems
• Inventors: Reichle, Johannes, Langer, Hans J.
• Primary Examiner(s): Simmons, David A.
• Assistant Examiner(s): SELLS, JAMES D
• Application Number:
  US08/244,498
• Time in Patent Office: 776 Days
• Field of Search: 156/272.2, 156/273.3, 156/273.5, 156/275.5, 156/290, 156/307.1, 156/359, 156/379.6, 264/401, 264/308, 264/DIG. 59, 425/174.4, 427/510, 427/581, 427/586
• US Class Current: 156/275.5
• CPC Class Codes: B29C 37/005 Compensating volume or shape change during moulding, in general
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: Y10S 264/59 Processes in which a partial cure is involved

Abstract

In a method for producing a three-dimensional object by successive solidification of superposed layers of the object a deformation of the object caused by shrinkage during the solidification shall be reduced. To this end first of all respective partial regions (6a . . . 6k) of a layer are solidified and simultaneously connected with underlying partial regions of the previously solidified layer to form multilayered cells and thereafter adjacent partial regions of the same layer are interconnected by solidifying narrow connecting regions (8a . . . 8p). The intermediate regions (7) between the individual partial regions are solidified by post-curing.

Claims

1. A method for producing a three-dimensional object by solidifying successive layers of said object within a bath of a liquid material by directing electromagnetic radiation onto said material,

said method comprising

a) solidifying partial regions of said layer so as to leave narrow liquid intermediate regions between adjacent ones of said partial regions while at the same time connecting said partial regions to corresponding partial regions of a previously solidified layer so as to form multilayered cells,

b) interconnecting adjacent ones of said partial regions of said layer by solidifying narrow connecting regions bridging said intermediate regions in the form of connecting webs, and

c) thereafter solidifying said intermediate regions between said partial regions for completing the solidification of said object.

2. The method of claim 1,

comprising solidifying said connecting regions after expiry of a waiting time corresponding to at least a defined shrinkage of said partial regions.

3. The method of claim 2,

wherein said waiting time is between 5 and 100 seconds, preferably about 10 seconds.

4. The method of claim 1,

comprising forming said connecting regions between adjacent ones of said cells after solidifying said partial regions of each of said layers.

5. The method of claim 1,

comprising forming said connecting webs between said cells in a number of said layers which is lower than the total number of layers of said cells.

6. The method of claim 4,

comprising forming one or more of said connecting regions between adjacent ones of said partial regions.

7. The method of claim 1,

comprising connecting said partial regions at the periphery of said object for enclosing said intermediate regions.

8. The method of claim 1,

comprising solidifying said intermediate regions after solidification of said partial regions of all layers of said object.

9. The method of claim 1,

wherein said narrow intermediate regions have a width which is in the order of 1/20 to 1/200, preferably about 1/100 of a dimension of said partial regions.

10. The method of claim 7,

comprising completely solidifying the lowermost and topmost layer for forming a completely closed surface of said object in cooperation with said interconnections of said partial regions at said boundary of the said object.