Selective deposition modeling method and apparatus for forming three-dimensional objects and supports

• US 7,077,638 B2
• Filed: 11/26/2003
• Issued: 07/18/2006
• Est. Priority Date: 09/27/1995
• Status: Expired due to Fees

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Lockard, Michael S., Merot, Christian M., Bedal, Bryan J. L., Fedchenko, Richard P., Pang, Thomas H., Almquist, Thomas A., That, Dinh Ton, Thayer, Jeffrey S., Earl, Jocelyn M., Smalley, Dennis R., Hull, Charles W., Leyden, Richard N., Kerekes, Thomas A.
• Primary Examiner(s): Mackey, James P.
• Application Number:
  US10/724,370
• Publication Number:
  US 20040075196A1
• Time in Patent Office: 965 Days
• Field of Search: 425/174.4, 425/375, 425/447, 425/449, 264/401, 264/308
• US Class Current: 425/174.4
• CPC Class Codes: B29C 41/12 Spreading-out the material on a substrate , e.g. on the surface of a liquid
• CPC Class Codes: B29C 41/36 Feeding the material on to the mould, core or other substrate
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• 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 variety of support structures and build styles for use in Rapid Prototyping and Manufacturing systems are described wherein particular emphasis is given to Thermal Stereolithography, Fused Deposition Modeling, and Selective Deposition Modeling systems, and wherein a 3D modeling system is presented which uses multijet dispensing and a single material for both object and support formation.

Claims

1. An apparatus for forming a three-dimensional object in successive layers from a build material and a support material on a supporting platform in accordance with data defining the object, comprising:

a dispenser mounted on the apparatus,

a controller mounted on the apparatus and connected to the dispenser for controlling relative movement of the dispenser and the platform, the controller causing the build material to be dispensed according to a build style and the support material to be dispensed according to a support style, the build style specifying and forming the object with supports selected one from the group consisting of checkerboard supports, column supports, arch supports, line supports and combinations thereof;

the dispenser having a plurality of orifices extending in a direction angled to a scan direction and being selectively activatable in accord with data supplied to the dispenser relating to the formation of each layer; and

a source of flowable build material and flowable support material connected to the dispenser for selective deposition from the orifices thereof onto the supporting platform, at least the flowable build material further being a radiation-curable material.

2. The apparatus according to claim 1 further comprising means for supplying radiation to cure each layer of selectively-deposited, radiation-curable build material.

3. The apparatus according to claim 1 wherein the flowable build material is a photopolymer.

4. The apparatus according to claim 3 wherein the flowable build material comprises a photoinitiator.

5. The apparatus according to claim 2 wherein the means for supplying radiation further comprises a source of ultraviolet (UV) radiation to cure at least the flowable build material.

6. The apparatus according to claim 1 wherein the selectively deposited flowable build material and support material are deposited on the supporting platform, the dispenser and the platform being operable to move in an angled direction to each other.

7. The apparatus according to claim 1 wherein the dispenser further comprises at least one multi-jet ink jet dispensing head.

8. The apparatus according to claim 1 wherein the column supports are one selected from the group consisting of offset column supports, column supports with shelving, N-by-N column supports define in terms of drop width, N-by-N column supports defined in terms of pixels and combinations thereof.

9. The apparatus according to claim 1 wherein the checkerboard supports are drop-on/drop-off checkerboard supports.

10. The apparatus according to claim 1 wherein the line supports are one selected from the group consisting of straight-line supports, curved line supports, broken line supports and combinations thereof.

11. The apparatus according to claim 1 wherein the dispenser moves transverse to the scan direction.

12. The apparatus of claim 1 further comprising the support style specifying supports with shelving on at least part of a layer.

13. The apparatus of claim 1 further comprising the controller provides a build style that specifies a higher drop density ratio for down-facing or up facing surfaces than for interior regions of the object.

14. The method of claim 1 wherein the build style specifies forming an interior region of the object with supports selected one from the group consisting of checkerboard supports, column supports, arch supports, line supports and combinations thereof.

15. The apparatus according to claim 11 wherein the controller provides a build style that forms the object through raster scanning.

16. The apparatus according to claim 1 wherein the controller specifies the use of a water soluble material to build supports.