Optical molding process

• US 5,609,814 A
• Filed: 11/20/1995
• Issued: 03/11/1997
• Est. Priority Date: 03/22/1993
• Status: Expired due to Term

• Current Assignee: Sony Corporation (Sony Group Corp.)
• Original Assignee: Sony Corporation (Sony Group Corp.)
• Inventors: Takano, Yoichi
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US08/560,152
• Time in Patent Office: 477 Days
• Field of Search: 264/308, 264/401, 156/273.3, 156/273.5, 156/275.5, 156/307.1, 427/510, 427/512, 427/553, 427/554, 427/555
• US Class Current: 264/401
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29K 2995/0073 smooth

Abstract

An optical molding process for obtaining a three-dimensional resin model by scanning a surface of a photocurable resin liquid held in a photocurable resin liquid tank by a light beam to cure the same and successively building up the scanned and cured layers on an elevator. When the molding of one constant-height section layer is ended and the elevator is made to descend, the overflow of the photocurable resin liquid from the photocurable resin liquid tank to an overflow tank is temporarily blocked and then after the blocking of the overflow is lifted, the next constant-height section layer is molded.

Claims

1. An optical molding process for obtaining a three-dimensional resin model comprising the steps of:

providing a photocurable resin liquid tank having a supply of photocurable resin liquid therein and an elevator in the photocurable resin liquid tank;

scanning a surface of the photocurable resin liquid accommodated in the photocurable resin liquid tank with a light beam to cure a first three-dimensional layer of the photocurable resin liquid between the surface of the photocurable resin liquid and the elevator;

arranging an overflow tank in flow communication with said photocurable resin liquid tank;

blocking temporarily an overflow of the photocurable resin liquid from the photocurable resin liquid tank to said overflow tank;

making the elevator descend;

releasing blocking of the overflow of the photocurable resin liquid from the photocurable resin liquid tank to said overflow tank; and

molding a next three-dimensional constant-height section layer on said first three-dimensional layer after releasing said blocking of the overflow.

2. An optical molding process as recited in claim 1, said step of making the elevator descend comprising steps of:

making the elevator descend to a depth greater than a thickness of the constant-height section layer to be next molded; and

making the elevator ascend to a thickness position of the constant-height section layer.

3. An optical molding process as recited in claim 1, comprising the further steps of:

providing a conduit for recirculating resin liquid from the overflow tank back to the resin liquid tank;

recirculating resin liquid from the overflow tank back to the resin liquid tank;

stopping recirculation between the photocurable resin liquid tank and the overflow tank during said step of blocking the overflow.

4. An optical molding process as recited in claim 2, comprising the further steps of:

providing a conduit for recirculating resin liquid from the overflow tank back to the resin liquid tank;

recirculating resin liquid from the overflow tank back to the resin liquid tank;

stopping recirculation between the overflow tank and the photocurable resin liquid tank during said step of blocking the overflow.

6. An optical molding process as recited in claim 1, said step of making the elevator descend comprising steps of:

making the elevator descend to a depth greater than a thickness of the constant-height section layer to be next molded; and

making the elevator ascend to a thickness position of the constant-height section layer.

5. An optical molding process for obtaining a three-dimensional resin model comprising the steps of:

providing a photocurable resin liquid tank having a supply of photocurable resin liquid therein and an elevator in the photocurable resin liquid tank;

scanning a surface of the photocurable resin liquid accommodated in the photocurable resin liquid tank with a light beam to cure a three-dimensional layer of the photocurable resin liquid between the surface of the photocurable resin liquid and the elevator;

arranging an overflow tank in flow communication with said photocurable resin liquid tank;

restricting temporarily an overflow of the photocurable resin liquid from the photocurable resin liquid tank to an overflow tank;

making the elevator descend;

decreasing said restricting of the overflow; and

molding a next constant-height three-dimensional section layer after

decreasing said restricting of the overflow.

7. An optical molding process as recited in claim 5, comprising the further steps of:

providing a conduit for recirculating resin liquid from the overflow tank back to the resin liquid tank;

recirculating resin liquid from the overflow tank back to the resin liquid tank;

restricting recirculation between the overflow tank and the photocurable resin liquid tank during said step of restricting the overflow.