Method and apparatus for production of high resolution three-dimensional objects by stereolithography

• US 6,600,965 B1
• Filed: 01/26/1999
• Issued: 07/29/2003
• 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: Smalley, Dennis R., Lewis, Charles W., Tarnoff, Harry L., Spence, Stuart T., Nguyen, Hop D., Harlow, Richard A., Remba, David Z., Vorgitch, Tom J., Albert, David J., Stinebaugh, Phil, Hull, Charles W.
• Primary Examiner(s): Gordon, Paul P.
• Application Number:
  US09/236,259
• Time in Patent Office: 1,645 Days
• Field of Search: 700/118, 700/119, 700/120, 264/402, 264/408, 264/497, 264/308, 264/401, 156/273.3, 156/379.6, 156/379.5, 345/419, 425/174.4
• US Class Current: 700/120
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2995/0073 smooth
• 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 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• 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 be 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 specially processed to reduce curl and distortion, and increase resolution, strength, accuracy, speed and economy of reproduction even for rather difficult object shapes, 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.

Claims

1. A method for forming a desired layer of a three-dimensional object, the object comprising a plurality of adhered laminae of a solidifiable medium, the method comprising:

manipulating coordinate data representing the three-dimensional object to provide modified coordinate data representing a desired layer of the three-dimensional object, the modified coordinate data including data specifying generation of skin; and

forming the desired layer of the three-dimensional object from the solidifiable medium in accordance with the modified coordinate data.

2. A method according to claim 1, wherein the data specifying the generation of skin includes data specifying generation of flat skin.

3. A method according to claim 1, wherein the data specifying the generation of skin includes data specifying generation of near-flat skin.

4. A method according to claim 1, wherein the data specifying the generation of skin includes data specifying generation of up-facing skin.

5. A method according to claim 1, wherein the data specifying the generation of skin includes data specifying generation of down-facing skin.

6. A method according to claim 1, wherein the data specifying the generation of skin includes data specifying generation of up-facing and down-facing skin.

7. A method for forming a desired layer of a three-dimensional object, the object comprising a plurality of adhered laminae of a solidifiable medium, the method comprising:

manipulating coordinate data representing the three-dimensional object to provide modified coordinate data representing a desired layer of the three-dimensional object, the modified coordinate data including data specifying generation of cross-hatch; and

forming the desired layer of the three-dimensional object from the solidifiable medium in accordance with the modified coordinate data.

8. A method for forming a desired layer of a three-dimensional object, the object comprising a plurality of adhered laminae of a solidifiable medium, the method comprising:

manipulating coordinate data representing the three-dimensional object to provide modified coordinate data representing a desired layer of the three-dimensional object, the modified coordinate data including data specifying ordering of vector blocks; and

forming the desired layer of the three-dimensional object from the solidifiable medium in accordance with the modified coordinate data.

9. A method for forming a desired layer of a three-dimensional object, the object comprising a plurality of adhered laminae of a solidifiable medium, the method comprising:

manipulating coordinate data representing the three-dimensional object to provide modified coordinate data representing a desired layer of the three-dimensional object, the modified coordinate data including data adjusted to compensate for a desired amount of scaling; and

forming the desired layer of the three-dimensional object from the solidifiable medium in accordance with the modified coordinate data.

10. A method for forming a desired layer of a three-dimensional object, the object comprising a plurality of adhered laminae of a solidifiable medium, the method comprising:

manipulating coordinate data representing the three-dimensional object to provide modified coordinate data representing a desired layer of the three-dimensional object, the modified coordinate data including data specifying generation of a fill parameter; and

forming the desired layer of the three-dimensional object from the solidifiable medium in accordance with the modified coordinate data.

11. A method for forming a desired layer of a three-dimensional object, the object comprising a plurality of adhered laminae of a solidifiable medium, the method comprising:

manipulating coordinate data representing the three-dimensional object to provide modified coordinate data representing a desired layer of the three-dimensional object, the modified coordinate data including data specifying generation of a layer boundary; and

forming the desired layer of the three-dimensional object from the solidifiable medium in accordance with the modified coordinate data.

12. A method according to claim 11, wherein the data specifying the generation of a layer boundary further includes data specifying the generation of multiple boundaries.

13. An apparatus for forming a desired layer of a three-dimensional object, the object comprising a plurality of adhered laminae of a solidifiable medium, the apparatus comprising:

a computer configured to manipulate coordinate data representing the three-dimensional object to provide modified coordinate data representing a desired layer of the three-dimensional object, the modified coordinate data including data adjusted to compensate for a desired amount of scaling; and

stimulation means for forming the desired layer of the three-dimensional object from the solidifiable medium in accordance with the modified coordinate data.

14. An apparatus for forming a desired layer of a three-dimensional object, the object comprising a plurality of adhered laminae of a solidifiable medium, the apparatus comprising:

a computer configured to manipulate coordinate data representing the three-dimensional object to provide modified coordinate data representing a desired layer of the three-dimensional object, the modified coordinate data including data specifying generation of a fill parameter; and

stimulation means for forming the desired layer of the three-dimensional object from the solidifiable medium in accordance with the modified coordinate data.

15. An apparatus for forming a desired layer of a three-dimensional object, the object comprising a plurality of adhered laminae of a solidifiable medium, the apparatus comprising:

a computer configured to manipulate coordinate data representing the three-dimensional object to provide modified coordinate data representing a desired layer of the three-dimensional object, the modified coordinate data including data specifying generation of a layer boundary; and

stimulation means for forming the desired layer of the three-dimensional object from the solidifiable medium in accordance with the modified coordinate data.