Method of and apparatus for making a three-dimensional object by stereolithography
First Claim
1. A method of constructing a three-dimensional object, comprising:
- a. forming a layer of a solidifiable medium adjacent to any previously formed cross-section of the three-dimensional object in preparation for forming a successive cross-section of the three-dimensional object;
b. selectively exposing the layer of medium to prescribed stimulation to form the successive cross-section of the three-dimensional object; and
c. repeating (a) and (b) a plurality of times to construct the three-dimensional object from a plurality of adhered cross-sections, wherein (a) further comprises forming at least a first portion of a first cross-section with a first pattern comprising a plurality of lines of exposure and forming at least a second portion of a second cross-section with a second pattern comprising a plurality of lines of exposure, the second pattern being different from the first pattern, and wherein at least some of the lines of the first pattern expose the medium in a tighter configuration near a boundary of the first cross-section and a looser configuration further away from the boundary of the first cross-section.
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Accused Products
Abstract
An improved method for stereolithographically making an object by alternating the order in which similar sets of vectors are exposed over two or more layers. In another method, a pattern of tightly packed hexagonal tiles are drawn. Each tile is isolated from its neighboring tiles by specifying breaks of unexposed material between the tiles. Using an interrupted scan method, vectors are drawn with periodic breaks along their lengths. In another method, modulator and scanning techniques are used to reduce exposure problems associated with the acceleration and deceleration of the scanning system when jumping between vectors or changing scanning directions. In another method, a capability for automatically inserting vents an drains into a three-dimensional object representation is provided.
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Citations
27 Claims
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1. A method of constructing a three-dimensional object, comprising:
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a. forming a layer of a solidifiable medium adjacent to any previously formed cross-section of the three-dimensional object in preparation for forming a successive cross-section of the three-dimensional object;
b. selectively exposing the layer of medium to prescribed stimulation to form the successive cross-section of the three-dimensional object; and
c. repeating (a) and (b) a plurality of times to construct the three-dimensional object from a plurality of adhered cross-sections, wherein (a) further comprises forming at least a first portion of a first cross-section with a first pattern comprising a plurality of lines of exposure and forming at least a second portion of a second cross-section with a second pattern comprising a plurality of lines of exposure, the second pattern being different from the first pattern, and wherein at least some of the lines of the first pattern expose the medium in a tighter configuration near a boundary of the first cross-section and a looser configuration further away from the boundary of the first cross-section. - View Dependent Claims (4, 5, 6, 7, 8, 9, 10)
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2. A method of constructing a three-dimensional object, comprising:
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a. forming a layer of a solidifiable medium adjacent to any previously formed cross-section of the three-dimensional object in preparation for forming a successive cross-section of the three-dimensional object;
b. selectively exposing the layer of medium to prescribed stimulation to form the successive cross-section of the three-dimensional object; and
c. repeating (a) and (b) a plurality of times to construct the three-dimensional object from a plurality of adhered cross-sections, wherein (a) further comprises forming at least a first portion of a first cross-section with a first pattern comprising a plurality of lines of exposure and forming at least a second portion of a second cross-section with a second pattern comprising a plurality of lines of exposure, the second pattern being different from the first pattern, and wherein at least some of the lines of the first pattern expose the medium in a looser configuration near a boundary of the first cross-section and a tighter configuration further away from the boundary of the first cross-section. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17)
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3. A method of constructing a three-dimensional object, comprising:
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a. forming a layer of a solidifiable medium adjacent to any previously formed cross-section of the three-dimensional object in preparation for forming a successive cross-section of the three-dimensional object;
b. selectively exposing the layer of medium to prescribed stimulation to form the successive cross-section of the three-dimensional object;
c. repeating (a) and (b) a plurality of times to construct the three-dimensional object from a plurality of adhered cross-sections; and
d. waiting at least a predetermined period of time after exposure of at least a critical portion of at least one layer prior to beginning formation of a next layer. - View Dependent Claims (18, 19, 20)
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21. A method of constructing a three-dimensional object, comprising:
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a. forming a layer of a solidifiable medium adjacent to any previously formed cross-section of the three-dimensional object in preparation for forming a successive cross-section of the three-dimensional object;
b. selectively exposing the layer of medium to prescribed stimulation to form the successive cross-section of the three-dimensional object;
c. repeating (a) and (b) a plurality of times to construct the three-dimensional object from a plurality of adhered cross-sections;
d. waiting at least a predetermined period of time after exposure of at least a critical portion of at least one layer prior to formation of a next layer. - View Dependent Claims (22, 23, 24, 25, 26, 27)
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Specification