Elevator and method for tilting solid image build platform for reducing air entrainment and for build release

• US 8,465,689 B2
• Filed: 07/05/2011
• Issued: 06/18/2013
• Est. Priority Date: 01/17/2007
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Sperry, Charles R., McNamara, Dennis F. Jr., Scott, Suzanne M., Hull, Charles W., Mojdeh, Mehdi
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US13/176,190
• Publication Number:
  US 20110272857A1
• Time in Patent Office: 714 Days
• Field of Search: 264/308, 264/334, 264/401
• US Class Current: 264/401
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• 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

Abstract

A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build. The invention also provides for tilting the build elevator to reduce air entrainment and for releasing the build from the image plane.

Claims

1. A method for facilitating release of a build object on a build platform in a solid imaging device from an image plane in the solid imaging device, said method comprising the steps of:

a) solidifying solid image build material on the image plane to the build object to define a layer of the build object;

b) tilting with respect to the image plane the build platform to lift one edge of the build object off the image plane, wherein tilting of the build platform is performed while lifting the build object from the image plane; and

c) repeating steps (a) and (b) for at least one additional layer of the build object.

2. The method of claim 1 wherein the steps (a) through (b) are repeated, alternately lifting a first and a second edge.

3. The method of claim 1 wherein said image plane further comprises a flexible build material transport surface on a rigid surface transparent to solid imaging radiation and said method further comprises the steps of adhering the transport surface to the rigid surface, contacting a layer of build material on the build material transport surface opposite the rigid surface with the build, and imaging the layer to solidify the layer, and wherein said step of tilting the build platform lifts one edge of the build off the transport surface.

4. The method of claim 3 further comprising the steps of lifting the build off the transport surface and thereafter releasing the transport surface from the rigid surface.

5. The method of claim 1 wherein tilting the build platform to lift one edge of the build object breaks an attractive force between the cured build material and the surface to which it is adhered.

6. The method of claim 5 wherein the surface to which the cured build material is adhered is a transport film.

7. The method of claim 1 further comprising horizontally displacing the build platform relative to the image plane while tilting the build platform.

8. The method of claim 7 wherein horizontally displacing the build platform avoids at least one of distorting, bending, or tearing features of the build object.