Vibrationally enhanced stereolithographic recoating
First Claim
1. An improved apparatus for forming a three-dimensional object substantially layer by layer from a medium capable of solidification upon exposure to synergistic stimulation, comprising means for providing a working surface of unsolidified liquid building material, means for forming successive layers of unsolidified liquid building material of desired thickness in preparation for forming layers of structure of said object, and means for selectively exposing said layers of liquid building material to synergistic stimulation to form said layers of structure of said object, the improvement comprising means for inducing vibrational energy which is configured to induce vibrational energy into the unsolidified liquid building material at the working surface, and to allow the unsolidified liquid building material to flow and form a coating of substantially uniform thickness over at least one of said layers of structure of said object.
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Abstract
Methods and apparatus for providing a vibrational enhancement to the recoating process in stereolithography are disclosed. The formation of a thin layer of building material over a previous layer of structure of a partially completed three-dimensional object, in preparation for formation of an additional layer of structure, is enhanced by the use of vibrational energy imparted to the building medium. In a first preferred apparatus, vibration is induced into the surface of the material by a plurality of vibrating needles that penetrate below the working surface to a sufficient depth to ensure adequate coupling but not deep enough to come into contact with the surface of the partially completed part. In a second preferred apparatus, vibration is coupled directly to the object support. The vibrational energy is then transmitted through the part to the surface of the building material. In a first preferred method the partially completed object is overcoated with material and vibration is used to reduce the coating thickness. In a second preferred method, the partially completed object is undercoated with material and vibration is used to increase the coating thickness.
70 Citations
12 Claims
- 1. An improved apparatus for forming a three-dimensional object substantially layer by layer from a medium capable of solidification upon exposure to synergistic stimulation, comprising means for providing a working surface of unsolidified liquid building material, means for forming successive layers of unsolidified liquid building material of desired thickness in preparation for forming layers of structure of said object, and means for selectively exposing said layers of liquid building material to synergistic stimulation to form said layers of structure of said object, the improvement comprising means for inducing vibrational energy which is configured to induce vibrational energy into the unsolidified liquid building material at the working surface, and to allow the unsolidified liquid building material to flow and form a coating of substantially uniform thickness over at least one of said layers of structure of said object.
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4. An improved stereolithographic apparatus for forming a three-dimensional object substantially layer by layer from a medium capable of solidification upon exposure to synergistic stimulation, comprising means for providing a working surface of unsolidified stereolithographic building material, means for forming successive layers of unsolidified stereolithographic building material of desired thickness in preparation for forming layers of structure of said object, and means for selectively exposing said layers of building material to synergistic stimulation to form said layers of structure of said object, the improvement comprising means for inducing vibrational energy which is configured to induce vibrational energy into the unsolidified liquid building material at the working surface, and to allow the unsolidified liquid building material to flow and form a coating of substantially uniform thickness over at least one of said layers of structure of said object;
- wherein said means for inducing vibrational energy comprises at least one vibrational needle.
- View Dependent Claims (5, 6)
- 7. An improved stereolithographic apparatus for forming a three-dimensional object substantially layer by layer from a medium capable of solidification upon exposure to synergistic stimulation, comprising means for providing a working surface of unsolidified stereolithographic building material, means for forming successive layers of unsolidified stereolithographic building material of desired thickness in preparation for forming layers of structure of said object, and means for selectively exposing said layers of building material to synergistic stimulation to form said layers of structure of said object, the improvement comprising means for inducing vibrational energy which is configured to induce vibrational energy into the unsolidified liquid building material at the working surface, and to allow the unsolidified liquid building material to flow and form a coating of substantially uniform thickness over at least one of said layers of structure of said object, wherein said means for inducing vibrational energy is coupled to said object through solid material.
Specification