Apparatus and method for producing an object using stereolithography

• US 5,904,889 A
• Filed: 12/23/1996
• Issued: 05/18/1999
• Est. Priority Date: 04/25/1995
• Status: Expired due to Fees

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Wolff, Peter, Krug, Gabriele, Serbin, Jurgen
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US08/765,688
• Time in Patent Office: 876 Days
• Field of Search: 264/40.1, 264/40.7, 264/308, 264/401, 264/497, 425/135, 425/145, 425/174.4, 427/356, 427/358, 118/100, 118/120
• US Class Current: 264/401
• 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 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/194 during lay-up
• 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 40/00 Auxiliary operations or equipment, e.g. for material handling

Abstract

An apparatus for producing an object by stereolithography is provided with a tank (1) receiving a bath of liquid or powdery material which can be solidified by action of electromagnetic radiation. In known manner the apparatus comprises a support (4) for positioning the object relative to the surface (3) of the bath and a device (8) for solidifying a layer of the material (3) adjacent to the surface using electromagnetic radiation. In order to allow a precise adjustment of the layer thickness the apparatus comprises a supplying device (51) for supplying the solidifiable material (3), the supplying device extending transversely across the tank and having a discharge opening (53) at its bottom side in operational position, a channel extending in the interior thereof and communicating with the discharge opening (53), the channel being connected at one point with a pump (63) through a conduit (62).

Claims

1. A stereolithographic apparatus for producing a three-dimensional object, said apparatus comprising:

a tank for receiving a bath of a liquid or powdery material suitable for solidification using electromagnetic radiation, said bath having a bath surface;

a relatively moveable support for positioning said object in said bath relative to said bath surface so as to form a layer of said material adjacent to said bath surface;

a solidification device for solidifying said layer by directing electromagnetic radiation thereto;

a coating device for supplying said material to said bath, said coating device having a bottom side arranged above said bath surface in an operational position;

an adjustable discharge opening including a gap which is provided in and extends along said bottom side, said gap having a gap width, and including a spacing device for adjusting said gap width;

a channel formed within said coating device and communicating with said discharge opening; and

a pump communicating with said channel through a conduit for supplying said material to said adjustable discharge opening.

2. The apparatus of claim 1, further comprising a displacing mechanism for displacing said coating device in direction within a plane which is parallel to a plane of said bath surface, said displacing mechanism comprising a device for adjusting a displacing speed of said coating device.

3. The apparatus of claim 1, further comprising an elevational adjustment device for adjusting an elevation of said coating device above said bath surface.

4. The apparatus of claim 1, additionally comprising a conduit which communicates with said bath within said tank.

5. The apparatus of claim 1, further comprising control device connected to said pump for controlling a volume rate of the material discharged by said pump to be substantially constant.

6. The apparatus of claim 1, wherein said pump comprises a bellows pump having a stroke volume, said stroke volume being at least equal to a volume of said material which is required for applying a layer of said material, whereby said layer is applied in a single pump stroke.

7. The apparatus of claim 1, wherein said pump is a bellows pump having a stroke volume which is smaller than a volume of said material which is required for applying one layer of said material.

8. The apparatus of claim 7, further comprising an accumulator connected to said pump for maintaining constant a high feed pressure of said pump.

9. The apparatus of claim 1, further comprising means for mounting said pump to said coating device and means for moving said pump together with said coating device above said bath surface.

10. The apparatus of claim 1, further comprising a measuring device for detecting the level of the surface of an applied layer or of a surface of a reference component which is constructed together with said object within said bath of said material.

11. The apparatus of claim 1, wherein said coating device comprises a wiper.

12. A stereolithographic method for producing a three-dimensional object by solidiying successive layers of a material, said material being suitable for solidification when irradiated with electromagnetic radiation, comprising:

a) providing a bath of said material, said bath having a bath surface;

b) applying a layer of said material having a defined layer thickness including moving a supplying device above a support for the object or a previously solidified layer, said supplying device having a discharge gap provided at its bottom side facing said bath surface in an operational position, said discharge gap having a gap width;

c) solidifying said layer at places corresponding to said object including irradiating said layer with electromagnetic radiation;

d) repeating steps (b) and (c) a plurality of times to form the object from a plurality of solidified layers; and

e) controlling the thickness of at least one of said applied layers including controlling the gap width.

13. The method of claim 12, further comprising forming said bath in a tank and supplying said material from said tank to said supplying device using a pump.

14. The method of claim 12, further comprising moving said supplying device in a plane spaced from said bath surface to form a gap between said bath surface and said discharge gap which is greater than said layer thickness.

15. The method of claim 12, further comprising controlling a volume rate of the material delivered through the discharge gap over an entire moving range of said supplying device.

16. The method of claim 13, further comprising controlling said pump to withdraw an amount of material required for applying one layer, from said bath, in a single pumping step.

17. The method of claim 13, further comprising controlling said pump to withdraw an amount of said material required for applying one layer, from said bath, in a plurality of pumping steps.

18. The method of claim 12, further comprising smoothing said layer before applying said electromagnetic radiation thereto.

19. The method of claim 12, wherein the step of adjusting said layer thickness comprises controlling a moving speed of said supplying device.

20. The method of claim 12, wherein the step of adjusting said layer thickness comprises controlling a delivery pressure of said pump.

21. A stereolithographic method for producing a three-dimensional object by solidifying successive layers of a material, said material being suitable for solidification when irradiated with electromagnetic radiation, comprising:

a) providing a bath of said material, said bath having a bath surface;

b) applying a layer of said material, said layer having a defined layer thickness, including moving a supplying device above a support for the object or a previously solidified layer, said supplying device having a discharge gap provided at its bottom side facing said bath surface in an operational position, said discharge gap having an adjustable gap width; and

c) solidifying said layer at places corresponding to said object including irradiating said layer with electromagnetic radiation;

d) repeating steps b) and c) a plurality of times to form the three-dimensional object; and

wherein the method further comprises setting the defined layer thickness including adjusting the gap width.

22. The method of claim 21, further comprising moving said supplying device in a plane spaced from said bath surface to form a gap between said bath surface and said discharge gap which is greater than said layer thickness.

23. The method of claim 21, further comprising controlling the volume rate of the material delivered through the discharge gap over the entire moving range of said supplying device.

24. The method of claim 21, further comprising supplying said material from said bath to said supplying device using a pump and controlling the pump to withdraw an amount of material required for applying one layer, from said bath, in a single pumping step.

25. The method of claim 21, further comprising supplying said material from said bath to said supplying device using a pump and controlling the pump to withdraw an amount of said material required for applying one layer, from said bath, in a plurality of pumping steps.

26. The method of claim 21, further comprising smoothing said layer and before applying said electromagnetic radiation thereto.