Method for supporting an object made by means of stereolithography or another rapid prototype production method

• US 5,595,703 A
• Filed: 03/10/1995
• Issued: 01/21/1997
• Est. Priority Date: 03/10/1994
• Status: Expired due to Term

• Current Assignee: Materialise Naamloze Vennootschap
• Original Assignee: Materialise Naamloze Vennootschap
• Inventors: Pauwels, Johan, Swaelens, Bart, Vancraen, Wilfried
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US08/402,525
• Time in Patent Office: 683 Days
• Field of Search: 264/236, 264/255, 264/308, 264/401, 264/497, 156/272.8, 156/273.3, 156/273.5, 156/275.5, 156/307.1, 427/508, 427/510, 427/512, 427/553, 427/554, 427/555
• US Class Current: 264/401
• CPC Class Codes: A61B 17/58 for osteosynthesis, e.g. bone plates, screws , setting implements or the like A61B17/14, A61B17/16 take precedence
• CPC Class Codes: A61F 2/30942 for designing or making customized prostheses, e.g. using templates, CT or NMR scans, finite-element analysis or CAD-CAM techniques
• CPC Class Codes: A61F 2002/30602 Shaft made of a bundle of anchoring rods or bristles, e.g. fasciculate shaft
• CPC Class Codes: A61F 2002/30912 made of expanded metal, e.g. diamond mesh or metal nets having lozenge-shaped apertures
• CPC Class Codes: A61F 2002/30952 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2002/30962 using stereolithography
• CPC Class Codes: B22F 10/12 by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
• CPC Class Codes: B22F 10/47 characterised by structural features
• 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: G03F 7/0037 Production of three-dimensional images
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A method of supporting an object made by stereolithography or another rapid prototype production method, in which a support is provided with at least one supporting structure which is airier than a supporting structure made of solid standing walls, including those made with notches at the top and/or at the bottom. The supporting structure can be made airy by using walls of which at least a number are provided with openings over a major part of their surface.

Claims

1. A method of supporting an object made by sterolithography or another rapid prototype production method comprising:

creating at least one supporting structure adapted to support an object to be made with each supporting structure constituting an open framework made up of supporting elements that are interconnected at spaced locations such that each supporting structure has an outer surface provided with openings over a substantial portion thereof.

2. The method according to claim 1, further comprising erecting the supporting elements, which define walls of the supporting structure, with the walls intersecting at spaced locations where each wall includes material.

3. The method according to claim 1, further comprising creating the walls with enlarged openings such that each wall is defined by bars that are interconnected only in junction zones.

4. The method according to claim 3, further comprising widening the bars towards the object.

5. The method according to claim 3, further comprising arranging each of the bars diagonal to an associated longitudinal axis of the supporting structure.

6. The method according to claim 3, further comprising creating a supporting structure wherein at least one edge of a predetermined number of said walls does not have any openings.

7. The method according to claim 1, further comprising arranging the supporting elements farther away from each other near a lower end of the supporting structure than adjacent the object.

8. The method according to claim 1, further comprising providing said supporting structure with plurality of lower supporting elements and, directly under the object, raised rods which support a bottom face of the object.

9. The method according to claim 1, comprising forming the supporting elements as a set of hollow columns.

10. The method according to claim 1, further comprising erecting said supporting elements as columns which widen toward the object.

11. The method according to claim 1, comprising forming the supporting structure of layers or groups of layers which are sequentially formed in a first direction and then in a second direction which is angled with respect to said first direction.

12. The method according to claim 11, comprising forming the supporting structure with said second direction perpendicular to said first direction.

13. The method according to claim 3, further comprising arranging a plurality of said bars transverse to an associated longitudinal axis of the supporting structure.