Method and apparatus for making three-dimensional objects from multiple solidifiable materials

• US 8,801,418 B2
• Filed: 01/30/2012
• Issued: 08/12/2014
• Est. Priority Date: 01/31/2011
• Status: Active Grant

• Current Assignee: Gulf Filtration Systems Inc. (Desktop Metal, Inc.)
• Original Assignee: Gulf Filtration Systems Inc. (Desktop Metal, Inc.)
• Inventors: El-Siblani, Ali, Shkolnik, Alexandr
• Primary Examiner(s): SANDERS, JAMES M
• Application Number:
  US13/361,803
• Publication Number:
  US 20120195994A1
• Time in Patent Office: 925 Days
• Field of Search: 425/174.4, 425/375, 264/401
• US Class Current: 425/174.4
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/236 for motion in a direction within the plane of a layer
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29C 64/357 Recycling
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• 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
• CPC Class Codes: B33Y 40/20 Post-treatment, e.g. curing, coating or polishing

Abstract

Methods and apparatuses for making three-dimensional objects from multiple solidifiable materials is shown and described. Multiple solidifiable material container assemblies are provided for holding different solidifiable materials. Relative movement between the solidifiable material container assemblies and a build platform allows the solidifiable materials to be switched as an object is built. Several exemplary cleaning stations are provided for removing residual solidifiable materials from the surface of the three-dimensional object as it is built to better ensure smooth transitions between materials on the finished object.

Claims

1. An apparatus for manufacturing a three-dimensional object by solidifying multiple solidifiable materials, comprising:

a first solidifiable material source comprising a first container having a transparent bottom and containing the first solidifiable material;

a pattern generator selected from a digital light projector and a linear solidification device;

a second solidifiable material source comprising a second container having a transparent bottom and containing the second solidifiable material, wherein the second solidifiable material source is spaced apart from the first solidifiable material source in a first direction defining a first axis and the second solidifiable material is different from the first solidifiable material; and

a build platform movable along a second direction defining a second axis, wherein the build platform and the pattern generator are fixed relative to one another along the first axis, thereby maintaining a fixed registration between the build platform and the pattern generator along the first axis, the first and second containers are translatable along the first axis relative to the build platform such that a select one of the first and second containers is alignable with the pattern generator along the first axis at a given time, and during an object solidification operation, the pattern generator projects solidification energy through at least one of the first container transparent bottom and the second container transparent bottom.

2. The apparatus of claim 1, wherein the build platform is movable along the first axis relative to each of the first solidifiable material source and the second solidifiable material source.

3. The apparatus of claim 1, further comprising a cleaning station between the first solidifiable material source and the second solidifiable material source.

4. The apparatus of claim 3, wherein the cleaning station comprises at least one enclosure with an interior that is selectively maintainable at a sub-atmospheric pressure.

5. The apparatus of claim 1, wherein the first container bottom comprises a first rigid or semi-rigid transparent solidification substrate, and during the object solidification operation the at least one pattern generator projects solidification energy through the first rigid or semi-rigid transparent solidification substrate and moves in a third direction defining a third axis, and as the at least one pattern generator moves in the third direction, the first rigid or semi-rigid transparent solidification substrate tilts.

6. The apparatus of claim 1, wherein the pattern generator is a linear solidification device.

7. The apparatus of claim 6, wherein the linear solidification device comprises a laser source in optical communication with a rotating light reflector.

8. The apparatus of claim 1, wherein the pattern generator is a digital light projector.

9. The apparatus of claim 1, wherein the first container bottom comprises a first rigid or semi-rigid transparent solidification substrate, and the first rigid or semi-rigid transparent solidification substrate is curved in a third direction along a third axis.

10. The apparatus of claim 1, wherein the first container bottom includes a first rigid or semi-rigid transparent solidification substrate having a resilient coating.

11. The apparatus of claim 10, wherein the pattern generator comprises a laser source in optical communication with a rotating light deflector.

12. The apparatus of claim 1, wherein the first container bottom is resilient.

13. The apparatus of claim 12, wherein the first container comprises first resilient sidewalls attached to the first container bottom.

14. The apparatus of claim 12, wherein the second container bottom is resilient.

15. The apparatus of claim 14, wherein the first container comprises first resilient sidewalls attached to the first container bottom and the second container comprises second resilient sidewalls attached to the second container bottom.

16. The apparatus of claim 1, wherein the first container bottom comprises a first rigid or semi-rigid transparent solidification substrate.

17. The apparatus of claim 16, further comprising a first transparent coating on the first rigid or semi-rigid transparent solidification substrate.

18. The apparatus of claim 16, wherein the second container bottom comprises a second rigid or semi-rigid transparent solidification substrate.

19. The apparatus of claim 18, further comprising a first transparent coating on the first rigid or semi-rigid transparent solidification substrate and a second transparent coating on the second rigid or semi-rigid transparent solidification substrate.

20. The apparatus of claim 1, wherein the first container is tiltable to relative to the build platform.

21. The apparatus of claim 20, wherein the second container is tiltable relative to the build platform.

22. The apparatus of claim 1, wherein the first container bottom comprises a first rigid or semi-rigid transparent solidification substrate, and the first container further comprises a first film stretched against the first rigid or semi-rigid solidification substrate.

23. The apparatus of claim 22, wherein the first container comprises a first inner frame and a first outer frame, and a portion of the first film is disposed between the first inner frame and the first outer frame.

24. The apparatus of claim 22, wherein the second container bottom comprises a second rigid or semi-rigid transparent solidification substrate, and the second container further comprises a second film stretched against the second rigid or semi-rigid solidification substrate.

25. The apparatus of claim 24, wherein the first container comprises a first inner frame and a first outer frame, a portion of the first film is disposed between the first inner frame and the first outer frame, the second container comprises a second inner frame and a second outer frame, and a portion of the second film is disposed between the second inner frame and the second outer frame.