System, apparatus, and method for resin level maintenance in a stereo-lithography device

• US 8,298,472 B2
• Filed: 08/09/2010
• Issued: 10/30/2012
• Est. Priority Date: 08/09/2009
• Status: Active Grant

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Inventors: Schlienger, Max Eric, Withey, Paul Anthony
• Primary Examiner(s): Sole, Joseph Del
• Assistant Examiner(s): Brown, II, David N
• Application Number:
  US12/853,007
• Publication Number:
  US 20110049767A1
• Time in Patent Office: 813 Days
• Field of Search: 425/174.4, 425/375, 425/449, 264/308, 264/401, 264/497
• US Class Current: 264/497
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/321 Feeding
• 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

Abstract

A system includes a stereo-lithography device having a primary fluid vessel having an amount of a photo-curable fluid therein. The system includes a leveling reservoir fluidly coupled to the primary fluid vessel, where a fluid level in the leveling reservoir is vertically positionable. The system further includes a controller that maintains a pre-determined level of the photo-curable fluid in the primary fluid vessel by vertically positioning the fluid level in the leveling reservoir.

Claims

1. A system, comprising:

a stereo-lithography device having a primary fluid vessel having an amount of a photo-curable fluid therein;

a leveling reservoir fluidly coupled to the primary fluid vessel, wherein a fluid level in the leveling reservoir is vertically positionable; and

a controller structured to maintain a pre-determined level of the photo-curable fluid in the primary fluid vessel by vertically positioning the fluid level in the leveling reservoirs;

a replenishment reservoir selectively fluidly coupled with the primary fluid vessel, wherein the controller is further structured to transfer fluid between the replenishment reservoir and the primary fluid vessel; and

wherein the leveling reservoir is vertically moveable, and wherein the leveling reservoir is moved to a default position prior to an operation of the stereo-lithography device to manufacture a layer of a component, and wherein the replenishment reservoir is moved such that a level of the photo-curable fluid in the primary fluid vessel is at the pre-determined level prior to the operation of the stereo-lithography device to manufacture the layer of the component.

2. The system of claim 1, wherein the pre-determined level of the photo-curable fluid in the primary fluid vessel corresponds to a focal plane of an optical device of the stereo-lithography device.

3. The system of claim 1, wherein the controller is further structured to transfer fluid between the replenishment reservoir and the primary fluid vessel in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

4. The system of claim 1, wherein the pre-determined level is changed in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

5. The system of claim 1, wherein the pre-determined level is changed in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

8. The system of claim 1, further comprising a controllable piston that positions the fluid level in the leveling reservoir.

6. A system, comprising:

a stereo-lithography device having a primary fluid vessel having an amount of a photo-curable fluid therein;

a leveling reservoir fluidly coupled to the primary fluid vessel, wherein a fluid level in the leveling reservoir is vertically positionable; and

a controller structured to maintain a pre-determined level of the photo-curable fluid in the primary fluid vessel by vertically positioning the fluid level in the leveling reservoir;

a replenishment reservoir selectively fluidly coupled with the primary fluid vessel, wherein the controller is further structured to transfer fluid between the replenishment reservoir and the primary fluid vessel, wherein the pre-determined level is changed in response to the stereo-lithography device completing a layer of a component being manufactured by the device; and

wherein the leveling reservoir is vertically moveable, and wherein the leveling reservoir is moved to a default position prior to an operation of the stereo-lithography device to manufacture the layer of the component, and a level of replenishment fluid in the replenishment reservoir is vertically positioned such that the level of the photo-curable fluid in the primary fluid vessel is at the pre-determined level prior to the operation of the stereo-lithography device to manufacture the layer of the component.

7. The system of claim 6, wherein the default position comprises a position determined in response to the pre-determined level.

11. The system of claim 6, wherein the pre-determined level of the photo-curable fluid in the primary fluid vessel corresponds to a focal plane of an optical device of the stereo-lithography device.

12. The system of claim 6, wherein the controller is further structured to transfer fluid between the replenishment reservoir and the primary fluid vessel in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

13. The system of claim 6, wherein the pre-determined level is changed in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

14. The system of claim 6, further comprising a controllable piston that positions the fluid level in the leveling reservoir.

9. A system, comprising:

a stereo-lithography device having a primary fluid vessel having an amount of a photo-curable fluid therein;

a leveling reservoir fluidly coupled to the primary fluid vessel, wherein a fluid level in the leveling reservoir is vertically positionable;

a controller structured to maintain a pre-determined level of the photo-curable fluid in the primary fluid vessel by vertically positioning the fluid level in the leveling reservoir; and

further comprising a pressurizing pump that controls an overpressure on the leveling reservoir, wherein the amount of the overpressure positions the fluid level in the leveling reservoir.

15. The system of claim 9, wherein the pre-determined level of the photo-curable fluid in the primary fluid vessel corresponds to a focal plane of an optical device of the stereo-lithography device.

16. The system of claim 9, further comprising a replenishment reservoir selectively fluidly coupled with the primary fluid vessel, wherein the controller is further structured to transfer fluid between the replenishment reservoir and the primary fluid vessel.

17. The system of claim 16, wherein the controller is further structured to transfer fluid between the replenishment reservoir and the primary fluid vessel in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

18. The system of claim 16, wherein the pre-determined level is changed in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

19. The system of claim 9, wherein the pre-determined level is changed in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

20. The system of claim 9, further comprising a controllable piston that positions the fluid level in the leveling reservoir.

10. A system, comprising:

a stereo-lithography device having a primary fluid vessel having an amount of a photo-curable fluid therein;

a leveling reservoir fluidly coupled to the primary fluid vessel, wherein a fluid level in the leveling reservoir is vertically positionable and wherein the leveling reservoir is vertically moveable; and

a controller structured to maintain a pre-determined level of the photo-curable fluid in the primary fluid vessel by vertically positioning the fluid level in the leveling reservoir.

21. The system of claim 10, wherein the pre-determined level of the photo-curable fluid in the primary fluid vessel corresponds to a focal plane of an optical device of the stereo-lithography device.

22. The system of claim 10, further comprising a replenishment reservoir selectively fluidly coupled with the primary fluid vessel, wherein the controller is further structured to transfer fluid between the replenishment reservoir and the primary fluid vessel.

23. The system of claim 22, wherein the controller is further structured to transfer fluid between the replenishment reservoir and the primary fluid vessel in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

24. The system of claim 22, wherein the pre-determined level is changed in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

25. The system of claim 10, wherein the pre-determined level is changed in response to the stereo-lithography device completing a layer of a component being manufactured by the device.

26. The system of claim 10, further comprising a controllable piston that positions the fluid level in the leveling reservoir.