System and method for three dimensional model printing

• US 6,850,334 B1
• Filed: 01/18/2000
• Issued: 02/01/2005
• Est. Priority Date: 01/18/2000
• Status: Expired due to Term

• Current Assignee: Stratasys Incorporated
• Original Assignee: Objet Geometries
• Inventors: Gothait, Hanan
• Primary Examiner(s): HASKINS, TWYLER LAMB
• Application Number:
  US09/484,272
• Time in Patent Office: 1,841 Days
• Field of Search: 358/1.1, 358/1.2, 358/1.4, 700/119, 700/118, 700/98, 364/468.27, 264/40.1, 264/308
• US Class Current: 358/1.1
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• 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 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

A system and a method for printing of three-dimensional models and apparatus for controlling the height and thickness of the layers of interface material forming the 3-D models being printed, is provided. The method includes the steps of dispensing a pre-determined quantity of interface material from at least one printing head to form at least one interface layer; leveling the dispensed interface material to a pre-determined height; curing the leveled interface material; and repeating the steps of dispensing, leveling and curing thereby producing a plurality of interface layers to a configured pattern layer for forming the three-dimensional model.

Claims

1. A method for printing of a three-dimensional model, said method comprising the steps of:

dispensing a pre-determined quantity of interface material from at least one printing head to form at least one interface layer of photopolymer material including first and second interface material;

leveling the layer of photopolymer material including said first and second interface materials using a roller rotatable about an axis, the roller including a sensing device embedded within the roller operative to detect the contact of the roller with the interface materials;

curing the leveled photopolymer material including first and second interface materials; and

repeating said steps of dispensing, leveling and curing thereby producing a plurality of said at least one interface layer of photopolymer material to a configured pattern layer for forming the three-dimensional model.

2. The method according to claim 1, wherein said first and second interface materials are dispensed from first and second printing heads, respectively.

3. The method according to claim 2, further comprising the steps of:

curing said first interface material for a first period of time and at a first radiation wavelength; and

curing said second interface material for a second period of time and at a second radiation wavelength.

4. The method according to claim 1, wherein said step of leveling comprises the step of:

removing surplus material from a layer of dispensed photopolymer material utilizing the roller, such that the dispensed layer is leveled to a pre-determined height.

5. The method according to claim 4, wherein said step of leveling further comprises the step of:

cleaning the surplus material off said roller.

6. The method according to claim 5, wherein said step of leveling further comprises the step of:

curing the surplus material.

7. The method of claim 1, comprising providing an audible signal to indicate contact with an interface material.

8. A system for three-dimensional printing of a three-dimensional model, comprising:

at least one printing head for dispensing a pre-determined quantity of interface material to form at least one interface layer of photopolymer material including first and second interface material;

a leveling apparatus for removing surplus material from said at least one interface layer prior to curing, said leveling apparatus including at least a roller rotatable about an axis, the roller including a sensing device embedded within the roller operative to detect the contact of the roller with the interface materials;

a curing apparatus for curing the leveled interface layer; and

a controller connected to said leveling apparatus for controlling the height of each of said at least one interface layer.

9. The system according to claim 8 wherein said at least one printing head comprises first and second printing heads for dispensing firs t a nd second interface materials respectively from first and second dispenser connected thereto respectively.

10. The system according to claim 9 wherein said cu ring apparatus comprises:

a first cur ing apparatus for curing said first interface material for a first period of time and at a first radiation wavelength; and

a second curing apparatus for curing said second interface material for a second period of time and at a second radiation wavelength.

11. The system according to claim 8, wherein said interface layer is a photopolymer material curable by the application of ultra-violet or infra-red radiation.

12. The system according to claim 8, wherein said roller is rotatable about a longitudinal axis.

13. The system according to claim 8, and further comprising:

cleaning apparatus connected to said controller for cleaning said leveling apparatus; and

waste disposal apparatus for disposing of the waste interface material.

14. The system according to claim 13, wherein said waste disposal apparatus comprises curing apparatus using ultra-violet or infra-red radiation.

15. The system according to claim 12, wherein the outer circumferential surface of said roller comprises grinding material.

16. The system of claim 8, comprising a device to provide a signal to audibly indicate contact with an interface material.

17. Apparatus for controlling the finished height of interface layers deposited during the printing of a three-dimensional model, the apparatus comprising:

a roller rotatable about a longitudinal axis, the roller being operative to make contact with the deposited interface layers;

a sensing device embedded within the roller operative to detect the contact of the roller with the interface layers; and

a processor for processing the output from said sensing device.

18. The system according to claim 17, wherein the output from said sensing device is indicative of the height and width of interface material protruding above a pre-determined level.

19. The apparatus of claim 17, comprising a device to provide a signal to audibly indicate contact with the interface layers.

20. An apparatus for controlling the finished height of layers deposited during the printing of a three-dimensional model, the layers comprising photopolymer material, the apparatus comprising:

a roller, the roller to make contact with the deposited layer and remove surplus material from each layer such that the dispensed layer is leveled to a predetermined height; and

a device to provide a signal to indicate contact with the material.

21. The apparatus of claim 20, wherein the device is embedded within the roller.

22. The apparatus of claim 20, wherein the signal indicating contact with the material is audible.