Method and apparatus for creating three-dimensional objects by cross-sectional lithography
First Claim
Patent Images
1. A method, comprising:
- (a) providing an array of controllable pixel elements;
(b) providing a container having a medium therein capable of selective curing upon application of a stimulus;
(c) providing a window coupled with the container, such that the medium is operatively (d) providing a source of the stimulus;
(e) directing the stimulus and the array of pixel elements, such that a portion of the stimulus travels through the window of the container, wherein select regions of the medium are cured;
(f) displacing the cured select regions of the layer with respect to the surface of the window, such that a gap is formed between the window and the cured layer, and wherein additional uncured medium fills the gap;
(g) repeating (e) and (f) until a final layer is to be formed; and
(f) repeating (e) to form the final layer.
5 Assignments
0 Petitions
Accused Products
Abstract
A method and apparatus for creating a three-dimensional object by generating a cross-sectional pattern of energy of an object to be formed at a selected surface of a medium capable of altering its physical state in response to the energy projected or transmitted onto the selected layer. By impinging radiation, particle bombardment, or chemical reaction by a method controlled by a spatial light modulator, successive adjacent cross-sections of the object are rapidly formed and integrated together to provide a step-wise laminar build-up of the desired object creating a three dimensional manifestation from bitmap images of a series of cross-sections of a computer generated model.
285 Citations
51 Claims
-
1. A method, comprising:
-
(a) providing an array of controllable pixel elements;
(b) providing a container having a medium therein capable of selective curing upon application of a stimulus;
(c) providing a window coupled with the container, such that the medium is operatively (d) providing a source of the stimulus;
(e) directing the stimulus and the array of pixel elements, such that a portion of the stimulus travels through the window of the container, wherein select regions of the medium are cured;
(f) displacing the cured select regions of the layer with respect to the surface of the window, such that a gap is formed between the window and the cured layer, and wherein additional uncured medium fills the gap;
(g) repeating (e) and (f) until a final layer is to be formed; and
(f) repeating (e) to form the final layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
turning each of the plurality of pixel elements either ON or OFF, such that pixel elements turned ON reflect the stimulus into the medium, and pixel elements turned OFF deflect the stimulus away from the medium.
-
-
17. The method of claim 16, wherein a computer control system determines which pixel elements are turned ON or OFF.
-
18. The method of claim 1, wherein displacing the cured select regions of the layer away from the surface of the window further comprises:
-
providing an elevator platform upon which the cured layer rests; and
lowering the elevator platform following curing of the select regions of the layer.
-
-
19. The method of claim 1, wherein displacing the cured select regions of the layer with respect to the surface of the window further comprises:
-
providing an elevator platform having a target platform attached thereto, wherein the three dimensional object being formed adheres to the target platform; and
raising elevator platform away from the window.
-
-
20. The method of claim 19, wherein the window is substantially at the bottom of the container.
-
21. The method of claim 19, wherein the container further includes a recess within a base of the container.
-
22. The method of claim 21, wherein the window is mounted within the recess.
-
23. The method of claim 19, further comprising directing the stimulus through the window within the recess of the container.
-
24. A method, comprising:
-
providing at least one spatial light modulator, having a plurality of controlled pixel elements;
providing a container having a medium therein and a window within the container, wherein the medium is operatively positioned with respect to at least one surface of the window;
providing a source of stimulus;
iterating for i=1, 2, . . . , M, wherein M is the maximum number of layers to be formed, and wherein iteration I comprises;
if i≦
M, directing the stimulus and the pixel elements of the spatial light modulator, such that select pixel elements reflect the stimulus, directing the stimulus into an ith layer of the medium, wherein select regions of the ith layer are cured;
if i<
M, moving the cured ith layer with respect to the window, such that a gap is formed between the window and the cured ith layer, wherein the uncured medium fills the gap; and
ending iteration i.- View Dependent Claims (25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35)
-
-
36. An apparatus for forming a three dimensional object, comprising:
-
a container having a selectively curable medium therein;
a window coupled with the container, wherein the selectively curable medium is operatively positioned with respect to at least one surface of the window;
a source of stimulus, such that the stimulus is capable of curing the selectively curable medium;
a controllable array of pixel elements capable of selectively projecting the stimulus through the window to a layer of the selectively curable medium; and
a device capable of displacing a cured quantity of the selectively curable medium with respect to the window. - View Dependent Claims (37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51)
at least one lens between the array of pixel elements and the curable medium.
-
-
38. The apparatus of claim 37, wherein the at least one lens increases an image projected into the layer of selectively curable medium.
-
39. The apparatus of claim 37, wherein the at least one lens decreases an image projected into the layer of selectively curable medium.
-
40. The apparatus of claim 39, wherein the projected image decreased by the at least one lens is approximately 1 micron by 1 micron.
-
41. The apparatus of claim 36, wherein the window further comprises a separation agent on a surface contacting the selectively curable medium.
-
42. The apparatus of claim 41, wherein the separation agent on the surface of the window comprises a halogenated compound.
-
43. The apparatus of claim 36, wherein the window is mounted substantially near a top of the container.
-
44. The apparatus of claim 36, wherein the window is mounted substantially near a bottom of the container.
-
45. The apparatus of claim 36, wherein the window is mounted within a recess of the container.
-
46. The apparatus of claim 36, further including an opening between the window and the container.
-
47. The apparatus of claim 36, wherein the device capable of displacing a cured quantity comprises an elevator platform.
-
48. The apparatus of claim 47, wherein the elevator platform further includes a target platform.
-
49. The apparatus of claim 48, wherein the target platform is mounted to the elevator platform between the elevator platform and the window.
-
50. The apparatus of claim 48, wherein a first cured layer adheres to a surface of the target platform included with the elevator platform.
-
51. The method of claim 36, wherein the controllable array of pixel elements comprises a plurality of mirrored surfaces each independently pivotable from a first to a second position.
Specification