Stereolithographic apparatus

• US 7,785,093 B2
• Filed: 05/21/2008
• Issued: 08/31/2010
• Est. Priority Date: 10/08/2004
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Stonesmith, Matthew K., Reynolds, Gary L., Reichental, Abraham N., Holmboe, Scott B., Hull, Charles W.
• Primary Examiner(s): EWALD, MARIA VERONICA
• Application Number:
  US12/124,591
• Publication Number:
  US 20080217818A1
• Time in Patent Office: 832 Days
• Field of Search: 425/174.4, 425/375, 425/185, 264/308, 264/401, 264/113, 264/497
• US Class Current: 425/185
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29L 2031/7532 Artificial members, protheses
• 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 70/00 Materials specially adapted for additive manufacturing

Abstract

An improved stereolithography apparatus for forming three-dimensional objects using multiple chambered resin vats and a quick disconnect mounting system to permit concurrent use of multiple photopolymer build materials and easy change over of resin vats is disclosed. The apparatus permits easy change over from multiple chambered vat use to single chamber vat use and vice versa or change over between multiple chambered vats.

Claims

1. An apparatus for forming three dimensional objects from solidifiable liquid material in response to energy applied to a working surface of the material, the apparatus comprising:

a. a frame;

b. a source of energy mounted to the frame for applying energy to the solidifiable liquid material, wherein the source of energy is controlled based upon data representative of the three-dimensional objects;

c. a removable container for holding the solidifiable liquid material, wherein the removable container is removable from the frame of the apparatus;

d. a platform on which the three dimensional objects are formed, the platform being movably supported by at least one elevator leg and lowerable into the solidifiable liquid material within the container; and

e. a z-stage stepper motor mounted to the frame that raises and lowers a mounting plate, wherein the at least one elevator leg is connected to the mounting plate with a quick disconnect locking device that allows the at least one elevator leg to be disconnectable from the mounting plate so that the at least one elevator leg and platform are removable with the container holding the solidifiable liquid material.

2. The apparatus according to claim 1 wherein the at least one elevator leg comprises two elevator legs and an elevator frame.

3. The apparatus according to claim 2 wherein the two elevator legs are connected with an elevator leg locking bar.

4. The apparatus according to claim 1 wherein the mounting plate is secured to a mounting block that is raised and lowered by the z-stage stepper motor.

5. The apparatus according to claim 1, wherein the quick disconnect locking device comprises a locking lever pivotally mounted to the mounting plate and movable between a locked position contacting and holding the at least one elevator leg and an unlocked position in which the at least one elevator leg can be removed from the mounting plate.

6. The apparatus according to claim 5, wherein the at least one elevator leg comprises two elevator legs that are connected with an elevator leg locking bar, and wherein the locking lever presses against the locking bar to lock the two elevator legs to the mounting plate.

7. The apparatus according to claim 1, wherein the container comprises multiple chambers holding different solidifiable liquid material.

8. The apparatus according to claim 1, wherein the source of energy comprises at least one of a UV laser and a visible light digital light projector.

9. The apparatus according to claim 8, wherein the solidifiable liquid material comprises a photopolymer resin.

10. An apparatus for forming three dimensional objects from solidifiable liquid material layer by layer in response to energy applied to a working surface of the material, the apparatus comprising:

a. a frame;

b. a removable container having a solidifiable liquid material for forming three dimensional objects, the container being removable from the frame; and

c. a platform on which three dimensional objects are formed, the platform being movably supported by at least one elevator leg and lowerable into the container of solidifiable liquid material, the at least one elevator leg being disconnectable from a mounting plate that is raised and lowered relative to the frame, wherein the at least one elevator leg is disconnectable from the mounting plate by at least one quick release lever to permit removal of the container, the at least one elevator leg, and the platform from the frame.

11. The apparatus according to claim 10 wherein the at least one elevator leg comprises two elevator legs and an elevator frame.

12. The apparatus according to claim 11 wherein the two elevator legs are connected with an elevator leg locking bar.

13. The apparatus according to claim 10 wherein the mounting plate is secured to a mounting block that is raised and lowered by a z-stage stepper motor.