Rapid prototyping apparatus and method of rapid prototyping

• US 7,128,866 B1
• Filed: 10/12/1999
• Issued: 10/31/2006
• Est. Priority Date: 10/12/1998
• Status: Expired due to Fees

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: Dicon A/S
• Inventors: Henningsen, Henning
• Primary Examiner(s): Del Sole, Joseph S.
• Assistant Examiner(s): Luk, Emmanuel S.
• Application Number:
  US09/807,394
• Time in Patent Office: 2,576 Days
• Field of Search: 425/174, 425/174.4, 264/1.24, 264/1.26, 264/1.37, 264/1.38, 264/462, 264/461, 264/463, 264/485, 264/488, 264/492, 264/497, 264/1.36, 264/460, 264/401
• US Class Current: 264/401
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• 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

Abstract

The invention relates to a rapid prototyping apparatus for the manufacturing of three dimensional objects by additive treatment of cross sections comprising a wholly or partially light-sensitive material, said apparatus comprising at least one light source for illumination of a cross section of the light-sensitive material by at least one spatial light modulator of individually controllable light modulators, wherein at least one light source is optically coupled with a plurality of light guides arranged with respect to the spatial light modulator arrangement in such a manner that each light guide illuminates a sub-area of the cross section.

According to the invention, it is possible to obtain a significant simplification of an RP design system, just as the apparatuses designed are essentially capable of creating prototypes of any size, according to the invention.

Claims

1. Rapid prototyping apparatus for the manufacturing of three dimensional objects by additive treatment of cross sections comprising a wholly or partially light-sensitive material, said apparatus comprising at least one light source for illumination of a cross section of the light-sensitive material by at least two spatial light modulators of individually controllable light modulators, wherein the at least one light source is optically coupled to a plurality of light guides arranged with respect to the spatial light modulator arrangement in such a manner that each light guide illuminates a sub-area of the cross section.

2. Rapid prototyping apparatus of claim 1 wherein each spatial modulator arrangement comprises transmissive light valves.

3. Rapid prototyping apparatus of claim 2 wherein said apparatus comprises a first lens arrangement, said first lens arrangement comprising at least one micro lens arranged with respect to each light valve in such a manner that that the emitted light by the light guide focuses on or in proximity of the optical axis of the individual light valves.

4. Rapid prototyping apparatus of claim 2 further comprising a second lens arrangement, said second lens arrangement comprising at least one micro lens arranged between the light valves and an illumination surface in such a manner that light transmitted through channels of the individual light valves is suitably focused on the illumination surface.

5. Rapid prototyping apparatus of claim 1 wherein optical fibers constitute the optical light guides.

6. Rapid prototyping apparatus of claim 1 wherein the at least one light sources is made of a short arc gap lamp.

7. Rapid prototyping apparatus of claim 2 wherein the individual light valves are arranged in rows in a transverse direction of a surface at a given mutual distance, said rows being mutually displaced in the transverse direction.

8. Rapid prototyping apparatus of claim 7 wherein the rows are arranged in such a manner that the projection of each individual light valve in the transverse direction on the surface results in a number of illumination points at a given mutual distance in the transverse direction.

9. Rapid prototyping apparatus of claim 1 wherein surface profiles of the spatial modulator arrangements are arranged on one or more exposure heads, said exposure heads and an illumination surface being designed to make a relative movement, said rapid prototyping apparatus being provided with a control circuitry for control of the spatial light modulator arrangements in dependency of the movement between the exposure head and the illumination surface.

10. Rapid prototype apparatus of claim 1 further comprising an exposure head comprising a bar whose relative movement over an illumination surface consists of one single progressing movement in a transverse direction of the bar.

11. Rapid prototyping apparatus of claim 1 further comprising an illumination device between the spatial light modulator arrangement and an illumination surface comprising optical means for spreading light beams emitted by the light modulator arrangement over the illumination surface.

12. Rapid prototyping apparatus according to claim 1 wherein the modulator arrangement comprises the spatial light modulators including at least one of LCD, PDLC, PLZT, FELCD and Kerr cells.

13. Rapid prototyping apparatus of claim 1 wherein the modulator arrangement comprises reflective electromechanical light valves.

14. Rapid prototyping apparatus of claim 13 wherein the light guides are arranged with respect to the modulator arrangement in such a manner that optical energy furnished to each subset of light valves does not vary significantly once the subsets of light valves illuminate adjacent sub-areas in close proximity to each other on an illumination surface.

18. Rapid prototyping apparatus of claim 5 wherein said optical fibers are multi mode fibers.

19. Rapid prototyping apparatus of claim 13 wherein said reflective electromechanical light valves comprise DMD.

20. Rapid prototyping apparatus of claim 1, wherein the plurality of light guides is disposed between the light source and the spatial light modulators.

15. Method of manufacturing three dimensional objects by means of a rapid prototyping apparatus where a wholly or partially light-sensitive material is treated by at least one light source illuminating a cross section of the material by at least two modulator arrangements of individually controllable light modulators, wherein at least one light source is optically coupled with a plurality of light guides arranged with respect to the spatial light modulator arrangement in such a manner that each light guide illuminates a sub-area of the cross section.

16. Method of claim 15 wherein a wholly or partially light-sensitive material is placed in a layer on a plate in a container and subsequently exposed to an RP apparatus prior to creating a new layer on top of the previous layer.

17. Method of claim 15 wherein an RP apparatus is provided with a computer-aided design program wherein a 3D representation of the desired prototype is converted into files containing a cross section of the prototype and wherein the contents of the files are used to control the spatial light modulator arrangement.

21. Rapid prototyping apparatus for the manufacturing of three dimensional objects by additive treatment of cross sections comprising a wholly or partially light-sensitive material, said apparatus comprising at least one light source for illumination of a cross section of the light-sensitive material by at least one spatial light modulator of individually controllable light modulators, wherein the at least one light source is optically coupled to a plurality of light guides arranged with respect to the spatial light modulator arrangement in such a manner that each light guide illuminates a sub-area of the cross section, wherein the plurality of light guides is disposed between the light source and the spatial light modulators.