Rapid prototyping method and apparatus with simplified build preparation for production of three dimensional objects
First Claim
1. A stereolithographic method of forming a three-dimensional object from a plurality of adhered laminae by exposing successive layers of a material to prescribed stimulation, comprising:
- providing data representing an object to be formed;
providing answers to a series of questions, including answers to stereolithographic machine type, recoating device, material type, and data file units;
automatically determining a group of styles to be used in forming the object, wherein the determination is derived based on the answers provided, the styles including build styles and support styles;
forming a layer of material according to at least one of the styles of the group, wherein the layer is formed in preparation for forming a successive lamina of the object, the layer in the object being formed according to at least one selected build style that includes geometric features;
exposing the material to the prescribed stimulation to form a successive lamina of the object, wherein the exposure is performed according to at least one of the styles of the group; and
repeating the acts of forming and exposing a plurality of times in order to form the object from a plurality of laminae.
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Abstract
A rapid prototyping and manufacturing (e.g. stereolithography) method and apparatus for making three-dimensional objects with simplified correlation of building parameters with object data. Object data is preferably correlated to (1) object build parameters that are used in solidifying object portions of layers of the material, (2) recoating parameters that are used in forming layers of material that include object data, (3) support build parameters that are used in solidifying support portions of layers of the material, (4) recoating parameters that are used in forming layers of material that include support data but no object data, and (5) parameters for use in generating a support structure that will be used to support the object during its formation. A style file is identified with each set of parameters. An algorithm (i.e. style wizard) is used to select among a plurality of styles of each type. The algorithm derives successively narrowing groups of compatible styles, for a particular build, based on answers to a series of questions until a final singular group of compatible styles is identified. This final group of styles is used in the formation of the object. This process results in fewer errors in deriving groups of styles and increases the probability of successful build processes.
47 Citations
23 Claims
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1. A stereolithographic method of forming a three-dimensional object from a plurality of adhered laminae by exposing successive layers of a material to prescribed stimulation, comprising:
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providing data representing an object to be formed; providing answers to a series of questions, including answers to stereolithographic machine type, recoating device, material type, and data file units; automatically determining a group of styles to be used in forming the object, wherein the determination is derived based on the answers provided, the styles including build styles and support styles; forming a layer of material according to at least one of the styles of the group, wherein the layer is formed in preparation for forming a successive lamina of the object, the layer in the object being formed according to at least one selected build style that includes geometric features; exposing the material to the prescribed stimulation to form a successive lamina of the object, wherein the exposure is performed according to at least one of the styles of the group; and repeating the acts of forming and exposing a plurality of times in order to form the object from a plurality of laminae. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. An apparatus for forming a three-dimensional object from a plurality of adhered laminae by exposing successive layers of a material to prescribed stimulation, comprising:
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a memory for receiving data representing an object; a memory for receiving answers to a series of questions, including answers to stereolithographic machine types, recoating device, material type and data file units; a computer programmed to automatically determine a group of styles to be used in forming the object based on the answers provided, the styles including build styles and support styles; a coating system for forming a layer of material, according to a style forming part of the group, adjacent to any last formed layer of material in preparation for forming a subsequent lamina of the object; an exposure system for selectively applying prescribed stimulation to the layer, according to the object data and a style forming part of the group, to form a successive lamina of the object; and a control computer programmed to operate the coating system and the exposure system in order to form the object from a plurality of adhered laminae.
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19. An apparatus for forming a three-dimensional object from a plurality of adhered laminae by exposing successive layers of a material to prescribed stimulation, comprising:
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means for receiving data representing an object; means for receiving answers to a series of questions, including answers to machine type, recoating device, material type and data file units; means for automatically determining a group of styles to be used in forming the object based on the answers provided, the styles including build styles and support styles; means for forming a layer of material, according to a style forming part of the group, adjacent to any last formed layer of a material in preparation for forming a subsequent lamina of the object; means for selectively applying prescribed stimulation to the layer, according to the object data and a style forming part of the group, to form a successive lamina of the object; and means for repeating the acts of forming and for selectively applying prescribed stimulation in order to form the object from a plurality of adhered laminae.
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20. A stereolithographic method of forming a three-dimensional object from a plurality of adhered laminae by exposing successive layers of a material to stimulation, comprising:
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providing data representing an object to be formed; providing responses to a series of prompts, including responses to machine type, recoating device, material type and data file units; at least in part automatically determining a group of styles to be used in forming the object, wherein the determination is derived based on the responses provided, the styles including build styles and support styles; forming a layer of material according to at least one of the styles of the group, wherein the layer is formed in preparation for forming a successive lamina of the object; exposing the material to the stimulation to form a successive lamina of the object, wherein the exposure is performed according to at least one of the styles of the group; and repeating the acts of forming and exposing a plurality of times in order to form the object from a plurality of laminae. - View Dependent Claims (21)
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22. Forming at least one lamina according to at least one style, comprising:
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providing data representing a lamina to be formed; providing a response to at least one prompt; at least in part automatically determining the at least one style to be used in forming the lamina; and forming the at least one lamina. - View Dependent Claims (23)
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Specification