Use of a support liquid to manufacture three-dimensional objects

• US 5,573,721 A
• Filed: 02/16/1995
• Issued: 11/12/1996
• Est. Priority Date: 02/16/1995
• Status: Expired due to Fees

• Current Assignee: Hercules Incorporated (Ashland Global Holdings, Inc.)
• Original Assignee: Hercules Incorporated (Ashland Global Holdings, Inc.)
• Inventors: Gillette, Paul C.
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US08/389,514
• Time in Patent Office: 635 Days
• Field of Search: 264/40.1, 264/40.7, 264/255, 264/298, 264/308, 264/401, 425/135, 425/145, 425/174.4, 156/64, 156/272.8, 156/273.3, 156/273.5, 156/275.5, 156/307.1, 156/378, 156/379.6, 156/538, 427/8, 427/356, 427/358, 427/510, 427/512, 427/553, 427/554, 427/555, 118/100, 118/120, 118/423, 118/428, 118/429, 118/500, 118/620, 118/712, 73/293, 73/305, 73/319, 73/322.5, 250/432 R, 250/492.1, 250/577, 340/619, 340/623, 340/624, 359/350, 364/468, 364/476, 365/106, 365/107, 395/119
• US Class Current: 264/401
• CPC Class Codes: B29C 2791/001 Shaping in several steps
• CPC Class Codes: B29C 41/12 Spreading-out the material on a substrate , e.g. on the surface of a liquid
• CPC Class Codes: B29C 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: Y10T 156/17 Surface bonding means and/or assemblymeans with work feeding or handling means

Abstract

A system is provided for producing a three dimensional object from a reactive liquid medium capable of being solidified. The object is constructed from many successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation. A reservoir contains both the reactive liquid medium and an underlying supporting, substantially immiscible, non-reactive liquid medium. To begin forming the object, a platform within the reservoir is initially positioned at a depth equal to the thickness of a first layer to be solidified, and continues to support the object being constructed. The synergistic source radiates toward the reactive liquid medium and imaging apparatus defining a three dimensional object of required configuration selectively controls the size and shape of that part of a new two dimensional layer to be solidified. At least part of the new layer is solidified, after which a further layer is applied. This sequence is repeated until all of the solidified layers define the three dimensional object being constructed. In another embodiment, a first part of the new two dimensional layer of the reactive liquid medium is solidified, then all unreacted reactive liquid medium is removed from the reservoir and replaced with a new layer of the reactive liquid medium having a substantially uniform thickness and generally coplanar with and equivalent to the thickness of the first part solidified earlier. Then the second part of the new two dimensional layer of the reactive liquid medium corresponding to the replacement liquid medium is solidified.

Claims

1. Apparatus for producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said system comprising:

a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

platform means for supporting the object being constructed;

control means for providing coordinate information to enable definition of a three dimensional object of required configuration;

a source of synergistic stimulation for solidifying at least part of a two dimensional layer at the surface of the reactive liquid medium;

imaging means responsive to said control means for selectively controlling the size and shape of that part of the two dimensional layer of the reactive liquid medium to be solidified; and

replenishment means operable for providing a further two dimensional layer of the reactive liquid medium overlying the two dimensional solidified layer substantially at the surface of the reactive liquid medium;

wherein said imaging means includes;

optical means intermediate said source of synergistic stimulation and the surface of the reactive liquid medium; and

including;

means for maintaining the surface of the reactive liquid medium at a focal plane which is a substantially constant distance from said imaging optical means; and

wherein said maintaining means includes;

means for sensing changes from the desired height of the surface of the reactive liquid medium relative to said imaging optical means; and

means responsive to said sensing means for adjusting the height of the reactive liquid medium in said reservoir when the height of the surface of the reactive liquid medium falls below the desired height or rises above the desired height.

2. Apparatus as set forth in claim 1

wherein said height adjusting means includes:

operative means for replenishing the non-reactive liquid medium in said reservoir when the height of the surface of the reactive liquid medium falls below a desired height and for withdrawing excess non-reactive liquid medium from said reservoir when the height of the surface of the reactive liquid medium tends to increase above the desired height.

4. Apparatus as set forth in claim 1

wherein said height adjusting means includes:

means for adjusting the volume of the non-reactive liquid medium in said reservoir.

6. Apparatus as set forth in claim 4

wherein said volume adjusting means includes:

piston means in fluid communication with the non-reactive liquid medium in said reservoir and movable in response to said sensing means between a first position for reducing the volume of the non-reactive liquid medium in the reservoir when the height of the surface of the reactive liquid medium falls below the desired height and a second position for increasing the volume of the non-reactive liquid medium the reservoir when the height of the surface of the reactive liquid medium tends to increase above the desired height.

8. Apparatus as set forth in claim 1

wherein said height adjusting means includes:

displacement mass means within said reservoir movable between first and second spaced positions in at least one of the reactive liquid medium and the non-reactive liquid medium, said displacement mass means being movable in response to changes in the level of the surface of the reactive liquid medium such that the surface of the reactive liquid medium is maintained at the focal plane.

3. Apparatus for producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said system comprising:

a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

platform means for supporting the object being constructed;

control means for providing coordinate information to enable definition of a three dimensional object of required configuration;

a source of synergistic stimulation for solidifying at least part of a two dimensional layer at the surface of the reactive liquid medium;

imaging means responsive to said control means for selectively controlling the size and shape of that part of the two dimensional layer of the reactive liquid medium to be solidified; and

replenishment means operable for providing a further two dimensional layer of the reactive liquid medium overlying the two dimensional solidified layer substantially at the surface of the reactive liquid medium;

means for maintaining the surface of the reactive liquid medium at a focal plane which is a substantially constant distance from said imaging optical means;

wherein said maintaining means includes;

operative means for replenishing the non-reactive liquid medium in said reservoir when the height of the surface of the reactive liquid medium falls below a desired height and for withdrawing excess non-reactive liquid medium from said reservoir when the height of the surface of the reactive liquid medium tends to increase above the desired height.

5. Apparatus as set forth in claim 3

wherein said maintaining means includes:

means for adjusting the volume of the non-reactive liquid medium in said reservoir.

7. Apparatus as set forth in claim 3 including:

piston means in fluid communication with the non-reactive liquid medium in said reservoir and operable to increase the volume of the non-reactive liquid medium in said reservoir when the height of the surface of the reactive liquid medium falls below the desired eighth and to tend to decrease the volume of the non-reactive liquid medium in said reservoir when the height of the surface of the reactive liquid medium increases above the desired height.

9. Apparatus for producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said system comprising:

a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

platform means for supporting the object being constructed;

control means for providing coordinate information to enable definition of a three dimensional object of required configuration;

a source of synergistic stimulation for solidifying at least part of a two dimensional layer at the surface of the reactive liquid medium;

imaging means responsive to said control means for selectively controlling the size and shape of that part of the two dimensional layer of the reactive liquid medium to be solidified; and

replenishment means operable for providing a further two dimensional layer of the reactive liquid medium overlying the two dimensional solidified layer substantially at the surface of the reactive liquid medium;

wherein said replenishment means is positioned in a plane intermediate said imaging means and the surface of the reactive liquid medium and movable across the surface of the reactive liquid medium; and

wherein said imaging means includes a programmable array operable for projecting an image onto that part of the new two dimensional layer of the reactive liquid medium overlying the object to be solidified; and

control means for moving the image across the new two dimensional layer in unison with said replenishment means.

10. Apparatus for producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said system comprising:

a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

platform means for supporting the object being constructed;

control means for providing coordinate information to enable definition of a three dimensional object of required configuration;

a source of synergistic stimulation for solidifying at least part of a two dimensional layer at the surface of the reactive liquid medium;

imaging means responsive to said control means for selectively controlling the size and shape of that part of the two dimensional layer of the reactive liquid medium to be solidified; and

replenishment means operable for providing a further two dimensional layer of the reactive liquid medium overlying the two dimensional solidified layer; and

including;

barrier means for confining the reactive liquid medium within an enclosed area in said reservoir and movable for altering the size of the enclosed area of the reactive liquid medium so as to maintain a thickness thereof equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified.

11. Apparatus as set forth in claim 10 including:

sensor means for measuring the thickness of the reactive liquid medium;

wherein said barrier is movable in response to said sensor means so as to maintain the thickness of the reactive liquid medium so as to be equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified.

12. Apparatus for producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said system comprising:

a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

platform means for supporting the object being constructed;

control means for providing coordinate information to enable definition of a three dimensional object of required configuration;

a source of synergistic stimulation for solidifying at least part of a two dimensional layer at the surface of the reactive liquid medium;

imaging means responsive to said control means for selectively controlling the size and shape of that part of the two dimensional layer of the reactive liquid medium to be solidified;

replenishment means operable for providing a further two dimensional layer of the reactive liquid medium overlying the two dimensional solidified layer; and

means for controlling the molecular alignment within the reactive liquid medium during exposure thereof to synergistic stimulation.

13. Apparatus as set forth in claim 12

wherein said controlling means includes:

a movable pressure barrier proximate the layer of the reactive liquid medium for inducing molecular alignment within the reactive liquid medium.

14. Apparatus for producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said apparatus comprising:

a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

platform means for supporting the object being constructed within the reservoir, said platform means having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

control means for providing coordinate information to enable definition of a three dimensional object of required configuration;

a source of synergistic stimulation for solidifying at least part of a two dimensional layer at the surface of the reactive liquid medium;

imaging means response to said control means for selectively controlling the size and shape of that part of the two dimensional layer of the reactive liquid medium to be solidified and operable in two successive operations to solidify a first part of a further two dimensional layer of the reactive liquid medium and, thereafter, to solidify a second part of the further two dimensional layer of the reactive liquid medium; and

replenishment means operable for providing the further two dimensional layer of the reactive liquid medium overlying the two dimensional solidified layer substantially at the surface of the reactive liquid medium after solidification of the preceding two dimensional layer of the reactive liquid medium;

means for removing from said reservoir all unreacted reactive liquid medium after solidification of the first part of the further two dimensional layer of the reactive liquid medium;

said replenishment means being operable for replacing the reactive liquid medium removed after solidification of the first part of the further two dimensional layer of the reactive liquid medium with a new layer of the reactive liquid medium having a substantially uniform thickness and generally coplanar with and equivalent to the thickness of the first solidified part.

15. Apparatus as set forth in claim 14 including:

a first source of reactive liquid medium;

a second source of reactive liquid medium; and

mixing means for selectively connecting said first source to said replenishment means and said second source to said replenishment means.

16. Apparatus as set forth in claim 15

wherein said first source contains a first composition of the reactive liquid medium;

and

wherein said second source contains a second composition of the reactive liquid medium, the second composition being different from the first composition.

18. Apparatus as set forth in claim 15

wherein said first source contains a first composition of the reactive liquid medium;

and

wherein said second source contains a second composition of the reactive liquid medium, the second composition being different from the first composition.

17. Apparatus for producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said apparatus comprising:

a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

platform means for supporting the object being constructed within the reservoir, said platform means having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

control means for providing coordinate information to enable definition of a three dimensional object of required configuration;

a source of synergistic stimulation for solidifying at least part of a two dimensional layer at the surface of the reactive liquid medium;

imaging means responsive to said control means for selectively controlling the size and shape of that part of the two dimensional layer of the reactive liquid medium to be solidified;

a first source of reactive liquid medium;

a second source of reactive liquid medium;

mixing means for selectively connecting said first source to said replenishment means and said second source to said replenishment means;

replenishment means operable for providing the further two dimensional layer of the reactive liquid medium overlying the two dimensional solidified layer substantially at the surface of the reactive liquid medium after solidification of the preceding two dimensional layer of the reactive liquid medium; and

means for removing from said reservoir all unreacted reactive liquid medium after solidification of the first part of the further two dimensional layer of the reactive liquid medium.

19. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying at least part of the new two dimensional layer of the reactive liquid medium;

(g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed;

wherein step (g) includes the step of;

(h) adjusting the thickness of the further layer of the reactive liquid medium to achieve the further layer of step (g); and

wherein the reactive liquid medium is confined within an enclosed area in the reservoir; and

wherein step (h) includes the step of;

(i) altering the size of the enclosed area of the further layer of the reactive liquid medium so as to maintain a thickness thereof equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified.

20. A method as set forth in claim 19

wherein step (h) includes the steps of:

(i) providing a movable barrier within the reservoir for at least partially restraining the reactive liquid medium such that the reactive liquid medium is confined within the enclosed area which is smaller than that of the reservoir; and

(j) moving the movable barrier so as to maintain the thickness of the further layer of the reactive liquid medium so as to be equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified.

21. A method as set forth in claim 19

wherein the reactive liquid medium is confined within an enclosed area in the reservoir;

and

wherein step (g) includes the steps of;

(h) lowering the platform to an operating depth such that an uppermost surface of the object being formed is below the surface of the reactive liquid medium and such that a quantity of the reactive liquid medium overlying the object is at least equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified;

(i) raising the platform until the uppermost surface of the object being formed rises above the surface of the reactive liquid medium;

(j) drawing a doctor blade across the upper surface of the object being formed and parallel thereto and at a uniform distance therefrom, the uppermost surface of the object being formed being a distance below the doctor blade equal to the desired layer thickness for the next layer to be formed, thereby removing excess amounts of the reactive liquid medium from the upper surface of the object to result in a substantially uniform thickness overlying the object;

(k) from the position assumed by the platform as a result of step (g) for the formation of the most recently solidified layer, lowering the platform by a distance which is substantially equal to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

(l) altering the size of the enclosed area of the further layer of the reactive liquid medium to maintain a thickness thereof equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified.

22. A method as set forth in claim 21

wherein step (j) includes the steps of:

(m) providing a movable barrier within the reservoir for at least partially restraining the reactive liquid medium such that the reactive liquid medium is confined within an enclosed area which is less than that of the reservoir; and

(n) moving the movable barrier so as to maintain the thickness of the further layer of the reactive liquid medium to be equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified.

23. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying at least part of the new two dimensional layer of the reactive liquid medium;

(g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed;

wherein step (d) includes the step of;

(h) positioning the imaging means intermediate the source of synergistic stimulation and the reactive liquid medium and spaced from the surface of the reactive liquid medium; and

further including the step of

(i) maintaining the surface of the reactive liquid medium at a focal plane which is a substantially constant distance from the imaging means; and

wherein step (i) includes the step of;

(j) replenishing the reactive liquid medium in the reservoir when the height of the surface of the reactive liquid medium falls below a desired height and withdrawing excess reactive liquid medium from the reservoir when the height of the surface of the reactive liquid medium tends to increase above the desired height.

24. A method as set forth in claim 23

wherein step (i) includes the steps of:

(j) sensing changes from an established level of the surface of the reactive liquid medium relative to the imaging optics; and

(k) in response to the changes sensed in step (j), replenishing the reactive liquid medium in the reservoir when the height of the surface of the reactive liquid medium falls below the desired height and withdrawing excess reactive liquid medium from the reservoir when the height of the surface of the reactive liquid medium tends to increase above the desired height.

25. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying at least part of the new two dimensional layer of the reactive liquid medium;

(g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed;

wherein step (d) includes the step of;

(h) positioning the imaging means intermediate the source of synergistic stimulation and the reactive liquid medium and spaced from the surface of the reactive liquid medium; and

wherein the method further includes the step of;

(i) maintaining the surface of the reactive liquid medium at a focal plane which is a substantially constant distance from the imaging means; and

wherein step (i) includes the step of;

(j) adjusting the volume of the non-reactive liquid medium in the reservoir.

26. A method as set forth in claim 25

wherein step (j) includes the steps of:

(i) reducing the volume of the non-reactive liquid medium in the reservoir when the height of the surface of the reactive liquid medium falls below the desired height; and

(k) increasing the volume of the non-reactive liquid medium the reservoir when the height of the surface of the reactive liquid medium tends to increase above the desired height.

27. A method as set forth in claim 25

wherein step (i) includes the steps of:

(j) sensing changes from an established level of the surface of the reactive liquid medium relative to the imaging optics; and

(k) in response to changes in the level of the surface of the reactive liquid medium sensed in step (j), operating a piston in fluid communication with the non-reactive liquid medium in the reservoir to tend to increase the volume of the non-reactive liquid medium in the reservoir when the height of the surface of the reactive liquid medium falls below the desired height and to tend to decrease the volume of the non-reactive liquid medium in the reservoir when the height of the surface of the reactive liquid medium increases above the desired height.

28. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying at least part of the new two dimensional layer of the reactive liquid medium;

(g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed;

wherein step (d) includes the step of;

(h) positioning the imaging means intermediate the source of synergistic stimulation and the reactive liquid medium and spaced from the surface of the reactive liquid medium; and

wherein the method further includes the steps of;

(i) maintaining the surface of the reactive liquid medium at a focal plane which is a substantially constant distance from the imaging means;

(j) providing displacement mass means within the reservoir operable for movement between first and second spaced positions in at least one of the reactive liquid medium and the non-reactive liquid medium; and

(k) moving the displacement mass means in response to changes in the level of the surface of the reactive liquid medium such that the surface of the reactive liquid medium is maintained at a focal plane which is a substantially constant distance from the imaging optical means.

29. A method as set forth in claim 28

wherein step (h) includes the step of:

(i) sensing changes from an established level of the surface of the reactive liquid medium relative to the imaging optics.

30. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying at least part of the new two dimensional layer of the reactive liquid medium;

(g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed;

wherein step (g) includes the steps of;

(h) providing an extrusion die having an elongated slot extending across the surface of the reactive liquid medium at a uniform distance;

(i) causing flow of the reactive liquid medium from a source thereof through the elongated slot; and

(j) translating the extrusion die across the surface of the reactive liquid medium; and

wherein the method includes the step of;

(k) withdrawing excess reactive liquid medium from the reservoir when the height of the surface of the reactive liquid medium tends to increase above a desired height.

32. A method as set forth in claim 30 including the step of:

(1) providing an auxiliary reservoir adjacent the reservoir for receiving excess reactive liquid medium from the reservoir during step (k).

34. A method as set forth in claim 32 including the step of:

(m) providing displacement mass means within the reservoir operable for movement between first and second spaced positions in at least one of the reactive liquid medium and the non-reactive liquid medium; and

(n) moving the displacement mass means in response to changes in the level of the surface of the reactive liquid medium such that the surface of the reactive liquid medium is maintained at a focal plane which is a substantially constant distance from the imaging optical means.

37. A method as set forth in claim 32

wherein step (k) includes the step of

(m) adding non-reactive liquid medium to the reservoir so as to displace reactive liquid medium and cause it to overflow into the auxiliary reservoir.

31. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying at least part of the new two dimensional layer of the reactive liquid medium;

(g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed;

wherein step (g) includes the steps of;

(h) providing an extrusion die having an elongated slot extending across the surface of the reactive liquid medium at a uniform distance;

(i) causing flow of the reactive liquid medium from a source thereof through the elongated slot; and

(j) translating the extrusion die across the surface of the reactive liquid medium; and

wherein the method includes the step of;

(k) withdrawing excess reactive liquid medium from the reservoir when the thickness of the reactive liquid medium tends to increase beyond a desired thickness.

33. A method as set forth in claim 31 including the step of:

(1) providing an auxiliary reservoir adjacent the reservoir for receiving excess reactive liquid medium from the reservoir during step (k).

36. A method as set forth in claim 33

wherein step (k) includes the step of

(m) adding non-reactive liquid medium to the reservoir so as to displace reactive liquid medium and cause it to overflow into the auxiliary reservoir.

35. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying at least part of the new two dimensional layer of the reactive liquid medium;

(g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed;

wherein step (g) includes the steps of;

(h) providing an extrusion die having an elongated slot extending across the surface of the reactive liquid medium at a uniform distance;

(i) causing flow of the reactive liquid medium from a source thereof through the elongated slot; and

(j) translating the extrusion die across the surface of the reactive liquid medium; and

wherein the method includes the steps of;

(k) sensing changes in the height of the surface of the reactive liquid medium from a desired height thereof;

(l) providing displacement mass means within the reservoir movable between first and second spaced positions in at least one of the reactive liquid medium and the non-reactive liquid medium; and

(m) moving the displacement mass means from the first position to the second position in response to changes in the level of the surface of the reactive liquid medium detected in step (k) such that the surface of the reactive liquid medium is maintained at a focal plane which is a substantially constant distance from the imaging optical means.

38. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying at least part of the new two dimensional layer of the reactive liquid medium;

(g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed;

wherein step (g) includes the steps of;

(h) providing an extrusion die having an elongated slot extending across the surface of the reactive liquid medium at a uniform distance;

(i) causing flow of the reactive liquid medium from a source thereof through the elongated slot; and

(j) translating the extrusion die across the surface of the reactive liquid medium; and

wherein the method includes the step of;

(k) heating at least one of the reactive liquid medium and the non-reactive liquid medium to control the viscosity thereof.

39. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying at least part of the new two dimensional layer of the reactive liquid medium;

(g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed;

wherein steps (d), (f) and (g) include the steps of;

(h) positioning the dispenser means in a plane intermediate the imaging means and the surface of the reactive liquid medium; and

(i) from an imaging means including a programmable array, projecting an image onto that part of the new two dimensional layer of the reactive liquid medium overlying the object to be solidified; and

(j) moving the imaging means across the new two dimensional layer in unison with the dispenser means.

40. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying at least part of the new two dimensional layer of the reactive liquid medium;

(g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed;

wherein step (g) includes the steps of;

(h) removing from the reservoir all unreacted reactive liquid medium after step (f); and

(i) adding a new layer of reactive liquid medium overlying the surface of the non-reactive liquid medium.

41. The method of claim 40 wherein step (i) includes the steps of:

(j) adding a new layer of reactive liquid medium having a composition different from the preceding layer.

42. The method of claim 40 wherein step (i) includes the steps of:

(j) adding a new layer of reactive liquid medium having a composition the same as the preceding layer.

43. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying at least part of the new two dimensional layer of the reactive liquid medium;

(g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed;

wherein step (g) includes the step of;

(h) controlling the molecular alignment within the reactive liquid medium during exposure to synergistic stimulation.

44. The method of claim 43 wherein step (h) includes the step of:

(i) applying pressure to the layer of the reactive liquid medium by a movable pressure barrier to induce molecular alignment within the reactive liquid medium.

45. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to he solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying at least part of the new two dimensional layer of the reactive liquid medium;

(g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed;

wherein the object being formed has a bottom and at least one upstanding wall defining an interior region; and

including the step of;

(h) forming the upstanding wall with a displacement hole therethrough adjacent the bottom to enable flow of the non-reactive liquid medium into the interior region.

46. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying a first part of the new two dimensional layer of the reactive liquid medium;

(g) after step (f), removing from the reservoir all unreacted reactive liquid medium;

(h) replacing the reactive liquid medium removed in step (g) with a new layer of the reactive liquid medium having a substantially uniform thickness and generally coplanar with and equivalent to the thickness of the first part solidified in step (f);

(i) solidifying a second part of the new two dimensional layer of the reactive liquid medium corresponding to the replacement liquid medium of step (h);

(j) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and

repeating steps (c) through (j) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed.

47. The method of claim 46

wherein the further layer of the reactive liquid medium provided in step (j) is of a composition different from the preceding layer.

48. The method of claim 46

wherein the further layer of the reactive liquid medium provided in step (j) is of a composition the same as the preceding layer.

49. The method of claim 46

wherein the first part of the new two dimensional layer of the reactive liquid medium solidified in step (f) is of a composition different from the second part of the new two dimensional layer of the reactive liquid medium solidified in step (i).

50. The method of claim 46

wherein the first part of the new two dimensional layer of the reactive liquid medium solidified in step (f) is of the same composition as the second part of the new two dimensional layer of the reactive liquid medium solidified in step (i).

51. A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of:

(a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium;

(b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir;

(c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified;

(d) operating imaging means for selectively controlling the size and shape of that part of a further two dimensional layer of the reactive liquid medium to be soldified;

(e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration;

(f) solidifying the further two dimensional layer of the reactive liquid medium;

(g) after step (f), removing from the reservoir all unreacted reactive liquid medium;

(h) replacing the reactive liquid medium removed in step

(g) with a new layer of the reactive liquid medium having a substantially uniform thickness and overlying the preceding solidified layer of the reactive liquid medium;

(i) solidifying the new two dimensional layer of the reactive liquid medium corresponding to the replacement liquid medium of step (h); and

repeating steps (c) through (i) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed.

52. The method of claim 51

wherein the further layer of the reactive liquid medium provided in step (i) is of a composition different from the preceding layer.

53. The method of claim 51

wherein the further layer of the reactive liquid medium provided in step (i) is of a composition the same as the preceding layer.