Rapid prototyping and manufacturing system and method
First Claim
1. A method for producing three-dimensional objects from a liquid resin by curing selected portions of the liquid resin layer-by-layer, wherein a layer is defined along an x-axis and an y-axis and wherein a layer thickness is defined along a z-axis, the method comprising:
- a) moving a recoater along the y-axis across a working surface of the liquid resin, wherein the recoater is operatively connected to a controller; and
b) adjusting the recoater about a theta axis as the recoater moves along the y-axis, wherein the theta axis is parallel to the y-axis.
3 Assignments
0 Petitions
Accused Products
Abstract
A stereolithography apparatus having a resin vat with resupply containers in one-way flow communication and a leveling container in two-way how communication, an automatic offload cart to remove and replace build support platforms, an elevator assembly for supporting and releasably retaining a build platform removably attached to the stereolithography apparatus frame such that elevator forks supporting the build platform can be released into the vat and removed from the stereolithography apparatus with the vat, and a recoater assembly and recoater blade for mapping the resin surface in the vat and applying a fresh coating of resin to a cross-section being built in the vat.
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Citations
20 Claims
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1. A method for producing three-dimensional objects from a liquid resin by curing selected portions of the liquid resin layer-by-layer, wherein a layer is defined along an x-axis and an y-axis and wherein a layer thickness is defined along a z-axis, the method comprising:
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a) moving a recoater along the y-axis across a working surface of the liquid resin, wherein the recoater is operatively connected to a controller; and b) adjusting the recoater about a theta axis as the recoater moves along the y-axis, wherein the theta axis is parallel to the y-axis. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method for producing three-dimensional objects from a liquid resin by curing selected portions of the liquid resin layer-by-layer, wherein a layer is defined along an x-axis and an y-axis and wherein a layer thickness is defined along a z-axis, the method comprising:
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a) providing a housing having a frame, a container of liquid resin within the housing, a source of energy for curing selected portions of the liquid resin, a build platform within the container to support the three-dimensional object, an elevator for moving the build platform along the z-axis, a recoater extending generally along the x-axis for leveling a working surface of the liquid resin in the container, and a controller operatively connected to the source of energy, the elevator, and the recoater; b) determining a distance between a portion of a recoater and the working surface of the liquid resin in the container at multiple locations along the x-axis and y-axis, wherein the distances for the respective locations define predetermined data for adjustment of the recoater; c) moving a recoater along the y-axis across the working surface of the liquid resin to level the working surface for at least one layer of the liquid resin from which selected portions are cured to define a layer of the three-dimensional object; and d) adjusting the recoater about a theta axis as the recoater moves along the y-axis in response to the predetermined data, wherein the theta axis is parallel to the y-axis and wherein adjusting the recoater about the theta axis keeps the recoater generally parallel to the working surface of the liquid resin. - View Dependent Claims (13, 14, 15, 16)
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17. A method for producing three-dimensional objects from a liquid resin by curing selected portions of the liquid resin layer-by-layer, wherein a layer is defined along an x-axis and an y-axis and wherein a layer thickness is defined along a z-axis, the method comprising:
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a) moving a recoater along the y-axis across a working surface of the liquid resin, wherein the recoater is operatively connected to a controller; b) adjusting the recoater about a theta axis as the recoater moves along the y-axis, wherein the theta axis is parallel to the y-axis; and c) raising and lowering the recoater along the z-axis as the recoater moves along the y-axis to maintain a constant distance at each end of the recoater from the working surface of the liquid resin. - View Dependent Claims (18, 19, 20)
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Specification