Stereolithographic curl reduction

• US 6,048,188 A
• Filed: 06/30/1998
• Issued: 04/11/2000
• Est. Priority Date: 04/18/1988
• Status: Expired due to Fees

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Vinson, Wayne S., Freed, Raymond S., Smalley, Dennis R., Hull, Charles W., Lewis, Charles W., Spence, Stuart T.
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US09/106,950
• Time in Patent Office: 651 Days
• Field of Search: 264/40.1, 264/308, 264/401, 425/135, 425/174.4, 364/468.27, 700/120
• US Class Current: 425/135
• 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: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B44B 1/006 using computer control means
• CPC Class Codes: G01J 1/4257 applied to monitoring the characteristics of a beam, e.g. laser beam, headlamp beam monitoring arrangements for lasers in general H01S3/0014
• 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: G06T 17/00 Three dimensional [3D] modelling, e.g. data description of 3D objects
• CPC Class Codes: G06T 17/10 Constructive solid geometry [CSG] using solid primitives, e.g. cylinders, cubes
• CPC Class Codes: G06T 17/20 Finite element generation, e.g. wire-frame surface description, tesselation

Abstract

An improved stereolithography system for generating a three-dimensional object by creating a cross-sectional pattern of the object to 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, information defining the object being structurally specified to reduce curl, stress and distortion in the ultimately formed object, the 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. A stereolithographic distortion known as curl is defined, and several techniques to eliminate or reduce curl are described, including dashed line, bent line, secondary structure, rivets, and multi-pass techniques. In addition, a quantitative measurement of curl known as the curl factor, and a test part known as a quarter cylinder are described, which together can be used to measure the effectiveness of the above techniques in reducing curl.

Claims

1. An improved apparatus for forming at least a portion of a three-dimensional object from a material capable of solidification upon exposure to synergistic stimulation, the apparatus comprising a source of the synergistic stimulation and a control device controlling the exposure, wherein the improvement comprises:

an improvement to the control device characterized in that the control device is adapted to specify at least one critical region of the object,

to additionally expose any non-critical regions of the object using a first set of exposure parameters, and

to additionally expose the at least one critical region of the object using a second set of exposure parameters which differ from the first set, wherein the second set of exposure parameters are chosen to achieve reduced distortion of the object.

2. An apparatus for forming a three-dimensional object from a plurality of superposed laminae each formed by the selective solidification of a layer of a transformable medium by exposure to a synergistic stimulation, comprising:

a source of the layer of transformable medium, the layer being adjacent to a previously formed lamina of the object;

a source of synergistic stimulation; and

a control device operably connected to at least the source of synergistic stimulation, the control device controlling at least the exposure, wherein the control device is operable according to a prescribed program to apply at least one initial exposure of synergistic stimulation to the layer according to a first predetermined pattern to form an initial section of a subsequent lamina after the previously formed lamina, and to apply at least one further exposure of synergistic stimulation to the layer according to a second predetermined pattern to form a further section of the subsequent lamina at least partially adhering the subsequent lamina to the previously formed lamina to form the three-dimensional object, wherein adherence of the subsequent lamina and the previously formed lamina is specified to occur on the at least one further exposure.

3. An apparatus according to claim 2 wherein the control device is arranged to apply the exposure according to the second predetermined pattern which comprises at least one of the group consisting of secondary structure, rivets, breaks, and bends.

4. An apparatus according to claim 3 wherein the control device is arranged to apply the exposure according to the second predetermined pattern which comprises breaks in the exposure of about 5 to 50 mils in length resulting in solid sub-portions of about 40 to 300 mils in length which are isolated from each other by the breaks.

5. An apparatus according to claim 3 wherein the control device is arranged to apply the exposure according to the second predetermined pattern which comprises bends in the exposure resulting in gaps of about 5 to 50 mils in length and solid sub-portions of about 40 to 300 mils in length between the gaps.

6. An apparatus according to claim 3 wherein the control device is arranged to apply the exposure according to the second predetermined pattern which comprises breaks and further comprises exposing the material in the breaks at a lower exposure than the second exposure.

7. An apparatus according to claim 3 wherein the control device is arranged to apply the exposure according to the second predetermined pattern which further comprises offsetting at least one of any secondary structure, rivets, breaks, and bends formed on the subsequent lamina from at least one of any secondary structure, rivets, breaks, and bends an the previous lamina.

8. An apparatus according to claim 2 wherein the control device is arranged to apply the at least one initial exposure wherein the at least one initial exposure comprises at least two exposures.

9. An apparatus according to claim 2 wherein the control device is arranged to apply at least one non-uniform exposure.

10. An apparatus according to claim 2 wherein the source of synergistic stimulation is a beam of synergistic stimulation.

11. An apparatus according to claim 10 wherein the control device is arranged to apply the exposure which includes exposure of the material to the beam of synergistic stimulation including tracing at least one vector with at least one pass of the beam.

12. An apparatus according to claim 11 wherein the control device is arranged to apply the exposure according to the second predetermined pattern which additionally comprises offsetting at least one of any secondary structure, rivets, breaks, and bends formed by a first pass of the beam from at least one of any secondary structure, rivets, breaks, and bends formed by an adjacent pass of the beam.

13. An improved stereolithography apparatus, comprising:

a control device operably connected to at least a source of synergistic stimulation, wherein the synergistic stimulation transforms a transformable medium by exposure to the synergistic stimulation, and wherein the control device controls at least the exposure and is operable according to a prescribed program to apply at least one initial exposure of synergistic stimulation to a layer of the transformable medium according to a first predetermined pattern to form an initial section of a subsequent lamina after a previously formed lamina, and to apply at least one further exposure of synergistic stimulation to the layer according to a second predetermined pattern to form a further section of the subsequent lamina at least partially adhering the subsequent lamina to the previously formed lamina, wherein adherence of the subsequent lamina and the previously formed lamina is specified to occur on the at least one further exposure.

14. An improved apparatus according to claim 13, wherein the control device is arranged to apply the exposure according to the second predetermined pattern which comprises at least one of the group consisting of secondary structure, rivets, breaks, and bends.

15. An improved apparatus according to claim 14 wherein the control device is arranged to apply the exposure according to the second predetermined pattern which comprises breaks in the exposure of about 5 to 50 mils in length resulting in solid sub-portions of about 40 to 300 mils in length which are isolated from each other by the breaks.

16. An improved apparatus according to claim 14 wherein the control device is arranged to apply the exposure according to the second predetermined pattern which comprises bends in the exposure resulting in gaps of about 5 to 50 mils in length and solid sub-portions of about 40 to 300 mils in length between the gaps.

17. An improved apparatus according to claim 14 wherein the control device is arranged to apply the exposure according to the second predetermined pattern which comprises breaks and further comprises exposing the material in the breaks at a lower exposure than the second exposure.

18. An improved apparatus according to claim 14 wherein the control device is arranged to apply the exposure according to the second predetermined pattern which additionally comprises offsetting at least one of any secondary structure, rivets, breaks, and bends formed on the subsequent lamina from at least one of any secondary structure, rivets, breaks, and bends on the previous lamina.

19. An improved apparatus according to claim 13, wherein the control device is arranged to apply the at least one initial exposure wherein the at least one initial exposure comprises at least two exposures.

20. An improved apparatus according to claim 13, wherein the control device is arranged to apply at least one non-uniform exposure.

21. An improved apparatus according to claim 13, wherein the source of synergistic stimulation is a beam of synergistic stimulation.

22. An improved apparatus according to claim 21 wherein the control device is arranged to apply the exposure which includes exposure of the material to the beam of synergistic stimulation including tracing at least one vector with at least one pass of the beam.

23. An improved apparatus according to claim 22 wherein the control device is arranged to apply the exposure according to the second predetermined pattern which additionally comprises offsetting at least one of any secondary structure, rivets, breaks, and bends formed by a first pass of the beam from at least one of any secondary structure, rivets, breaks, and bends formed by an adjacent pass of the beam.

24. An apparatus for forming a three-dimensional object from a plurality of superposed laminae each formed by the selective solidification of a layer of a transformable medium by exposure to a synergistic stimulation, comprising:

a source of the layer of transformable medium, the layer being adjacent to a previously formed lamina of the object;

a source of synergistic stimulation; and

a control device operably connected to at least the source of synergistic stimulation, the control device controlling at least the exposure, wherein the control device is operable according to a prescribed program to apply at least one initial exposure of synergistic stimulation to the layer according to a first predetermined pattern to form at least a portion of a subsequent lamina adjacent to the previously formed lamina of the object to form the three-dimensional object wherein the first predetermined pattern comprises at least one of the group consisting of secondary structure, rivets, breaks, and bends.

25. An apparatus according to claim 24 wherein the control device is arranged to apply the at least one initial exposure wherein the at least one initial exposure comprises at least two exposures.

26. An apparatus according to claim 25 wherein the control device is arranged to apply the initial exposure according to the first predetermined pattern which comprises breaks and applies a further exposure that exposes the material in the breaks at a lower exposure than the initial exposure.

27. An apparatus according to claim 24 wherein the control device is arranged to apply at least one non-uniform exposure.

28. An apparatus according to claim 24 wherein the control device is arranged to apply the initial exposure according to the first predetermined pattern which comprises breaks in the exposure of about 5 to 50 mils in length resulting in solid sub-portions of about 40 to 300 mils in length that are isolated from each other by the breaks.

29. An apparatus according to claim 24 wherein the control device is arranged to apply the initial exposure according to the first predetermined pattern which comprises bends in the exposure resulting in gaps of about 5 to 50 mils in length and solid sub-portions of about 40 to 300 mils in length between the gaps.

30. An apparatus according to claim 24 wherein the control device is arranged to apply the initial exposure according to the first predetermined pattern which comprises at least one of the group consisting of secondary structure, rivets, breaks, and bends and additionally offsets at least one of any secondary structure, rivets, breaks, and bends formed on the subsequent lamina from at least one of any secondary structure, rivets, breaks, and bends on the previous lamina.

31. An apparatus according to claim 24 wherein the source of synergistic stimulation is a beam of synergistic stimulation.

32. An apparatus according to claim 31 wherein the control device is arranged to apply the exposure which includes exposure of the material to the beam of synergistic stimulation including tracing at least one vector with at least one pass of the beam.

33. An apparatus according to claim 32 wherein the control device is arranged to apply the exposure according to the first predetermined pattern which comprises at least one of the group consisting of secondary structure, rivets, breaks, and bends and additionally offsets at least one of any secondary structure, rivets, breaks, and bends formed by a first pass of the beam from at least one of any secondary structure, rivets, breaks, and bends formed by an adjacent pass of the beam.

34. An improved stereolithography apparatus, comprising:

a control device operably connected to at least a source of synergistic stimulation, wherein the synergistic stimulation transforms a transformable medium by exposure to the synergistic stimulation, and wherein the control device controls at least the exposure and is operable according to a prescribed program to apply at least one initial exposure of synergistic stimulation to a layer of the transformable medium according to a first predetermined pattern wherein the first predetermined pattern comprises at least one of the group consisting of secondary structure, rivets, breaks, and bends.

35. An improved apparatus according to claim 34 wherein the control device is arranged to apply the at least one initial exposure wherein the at least one initial exposure comprises at least two exposures.

36. An improved apparatus according to claim 35 wherein the control device is arranged to apply the initial exposure according to the first predetermined pattern which comprises breaks and applies a further exposure that exposes the material in the breaks at a lower exposure than the initial exposure.

37. An improved apparatus according to claim 34 wherein the control device is arranged to apply at least one non-uniform exposure.

38. An improved apparatus according to claim 34 wherein the control device is arranged to apply the initial exposure according to the first predetermined pattern which comprises breaks in the exposure of about 5 to 50 mils in length resulting in solid sub-portions of about 40 to 300 mils in length that are isolated from each other by the breaks.

39. An improved apparatus according to claim 34 wherein the control device is arranged to apply the initial exposure according to the first predetermined pattern which comprises bends in the exposure resulting in gaps of about 5 to 50 mils in length and solid sub-portions of about 40 to 300 mils in length between the gaps.

40. An improved apparatus according to claim 34 wherein the control device is arranged to apply the initial exposure according to the first predetermined pattern which comprises at least one of the group consisting of secondary structure, rivets, breaks, and bends and additionally offsets at least one of any secondary structure, rivets, breaks, and bends formed on the subsequent lamina from at least one of any secondary structure, rivets, breaks, and bends on the previous lamina.

41. An improved apparatus according to claim 34, wherein the source of synergistic stimulation is a beam of synergistic stimulation.

42. An improved apparatus according to claim 41 wherein the control device is arranged to apply the exposure which includes exposure of the material to the beam of synergistic stimulation including tracing at least one vector with at least one pass of the beam.

43. An improved apparatus according to claim 42 wherein the control device is arranged to apply the initial exposure according to the first predetermined pattern which comprises at least one of the group consisting of secondary structure, rivets, breaks, and bends and additionally offsets at least one of any secondary structure, rivets, breaks, and bends formed by a first pass of the beam from at least one of any secondary structure, rivets, breaks, and bends formed by an adjacent pass of the beam.