Method for production of three-dimensional objects by stereolithography

• US 5,762,856 A
• Filed: 06/07/1995
• Issued: 06/09/1998
• Est. Priority Date: 08/08/1984
• Status: Expired due to Term

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Hull, Charles W.
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US08/480,596
• Time in Patent Office: 1,098 Days
• Field of Search: 264/236, 264/308, 264/401, 425/174.4, 156/58, 156/242, 156/272.8, 156/273.3, 156/273.5, 156/275.5, 156/307.1, 156/379.6, 156/538, 427/510, 427/512, 427/554, 427/555, 118/423, 118/428, 118/429, 118/500, 118/620, 250/432 R, 250/492.1, 364/468, 364/476, 365/106, 365/107, 365/119, 365/120, 365/126, 365/127, 395/119
• US Class Current: 264/401
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0833 using actinic light
• CPC Class Codes: B29C 2035/0844 using X-ray
• CPC Class Codes: B29C 2035/0877 using electron radiation, e.g. beta-rays
• CPC Class Codes: B29C 35/0866 using particle radiation
• CPC Class Codes: B29C 41/20 incorporating preformed parts or layers, e.g. moulding inserts or for coating articles
• 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
• 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: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G03F 7/0037 Production of three-dimensional images
• CPC Class Codes: G03F 7/70416 2.5D lithography
• CPC Class Codes: G05B 2219/49013 Deposit layers, cured by scanning laser, stereo lithography SLA, prototyping
• CPC Class Codes: G05B 2219/49017 DTM desktop manufacturing, prototyping
• CPC Class Codes: G09B 25/00 Models for purposes not provided for in G09B23/00, e.g. full-sized devices for demonstration purposes model vehicles, tracks therefor, models in the nature of toys A63H
• CPC Class Codes: G09B 25/02 of industrial processes; of machinery
• CPC Class Codes: Y10T 156/17 Surface bonding means and/or assemblymeans with work feeding or handling means

Abstract

A system for generating three-dimensional objects by creating a cross-sectional pattern of the object to be formed at a selected surface of a fluid medium capable of altering its physical state in response to appropriate synergistic stimulation by impinging radiation, particle bombardment or chemical reaction, successive adjacent laminae, representing corresponding successive adjacent cross-sections of the object, being automatically formed and integrated together to provide a step-wise laminar buildup of the desired object, whereby a three-dimensional object is formed and drawn from a substantially planar surface of the fluid medium during the forming process.

Claims

1. A method of producing a three-dimensional object from a medium capable of solidification upon exposure to prescribed radiation, said method comprising the steps of:

a. providing data representing the three-dimensional object;

b. providing said medium, said medium having a surface;

c. forming a layer of medium in preparation for forming a lamina of said object;

d. exposing said layer of medium to said prescribed radiation to form said lamina integral with any previously formed lamina;

e. repeating steps (c) and (d) a plurality of times to form said three-dimensional object from a plurality of solidified and adhered laminae; and

f. changing the orientation of at least one of the laminae relative to the surface prior to formation of a subsequent lamina.

2. A method of producing a three-dimensional object from a medium capable of solidification when subjected to synergistic stimulation, said method comprising the steps of:

a. forming a layer of medium in preparation for forming a lamina of said object, said layer of medium having a surface;

b. exposing said surface of medium to said synergistic stimulation to form said lamina integral with any previously formed lamina;

c. repeating steps (a) and (b) a plurality of times to form said three-dimensional object from a plurality of solidified and adhered laminae;

d. changing the orientation of at least one of the laminae relative to the surface prior to formation of a subsequent lamina.

3. The method of claim 2 wherein the object is formed on a moveable platform.

4. The method of claim 3 wherein the step of changing the orientation of at least one of the laminae comprises the step of changing the orientation of the platform.

5. The method of claim 2 wherein the medium is a photopolymer and said synergistic stimulation is light.

6. The method of claim 5 wherein the synergistic stimulation is UV light.

7. A method of producing a three-dimensional object from a solidifiable medium, said method comprising the steps of:

a. providing data representing the three-dimensional object;

b. providing said medium;

c. solidifying said medium to form a lamina integral with any previously formed lamina;

d. repeating step (c) a plurality of times to form said three-dimensional object from a plurality of solidified and adhered laminae; and

e. changing the orientation of at least one of the formed laminae prior to formation of a subsequent lamina.

8. The method of claim 7 wherein the medium is a photopolymer.

9. A method of producing a three-dimensional object, including a pre-existing first part, from a medium capable of solidification upon exposure to prescribed radiation, said method comprising the steps of:

a. providing data representing the three-dimensional object,

b. providing said medium;

c. locating the first part, to which at least one lamina is to be added, relative to said medium;

d. forming a layer of medium in preparation for forming a lamina of said object;

e. exposing said layer of medium to said prescribed radiation to form said lamina integral with said first part and any previously formed laminae; and

f. repeating steps (d) and (e) a plurality of times to form said dimensional object.

10. The method of claim 9 wherein the medium is a photopolymer.

11. A method of producing a three-dimensional object, including a pre-existing first part, from a medium capable of solidification upon exposure to synergistic stimulation, said method comprising the steps of:

a. providing data representing the three-dimensional object;

b. providing said medium;

c. locating the first part, to which at least one lamina is to be added, relative to said medium;

d. forming a layer of medium in preparation for forming a lamina of said object;

e. exposing said layer of medium to said synergistic stimulation to form said lamina integral with said part and any previously formed laminae; and

f. repeating steps (d) and (e) a plurality of times to form said three-dimensional object.

12. The method of claim 11 wherein the medium is a photopolymer.

13. A method of producing a three-dimensional object, including pre-existing a first part, said method comprising the steps of:

a. providing data representing the three-dimensional object;

b. providing solidifiable medium;

c. providing a first part to which at least one lamina is to be added;

d. forming a lamina of said object, integral with said part and any previously formed laminae; and

e. repeating step (e) a plurality of times to form said three-dimensional object.

14. The method of claim 13 wherein the medium is a photopolymer.