Method and apparatus for layerwise production of a 3D object

• US 8,905,739 B2
• Filed: 12/18/2009
• Issued: 12/09/2014
• Est. Priority Date: 12/22/2008
• Status: Active Grant

• Current Assignee: Nederlandse Organisatie Voor Toegepast-Natuurwetenschappelijk Onderzoek Tno
• Original Assignee: Nederlandse Organisatie Voor Toegepast-Natuurwetenschappelijk Onderzoek Tno
• Inventors: Vermeer, Adrianus Johannes Petrus Maria, Maalderink, Herman Hendrikus, Jamar, Jacobus Hubertus Theodoor, Rijfers, Andries, Vaes, Mark Herman Else
• Primary Examiner(s): Kennedy, Timothy
• Assistant Examiner(s): Brown, II, David N
• Application Number:
  US13/141,360
• Publication Number:
  US 20120168989A1
• Time in Patent Office: 1,817 Days
• Field of Search: 425/115, 425/174.4, 425/375, 264/446, 264/494
• US Class Current: 425/115
• CPC Class Codes: B29C 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask

Abstract

A system and method of layerwise production of a tangible object (5), they system comprising a construction shape (6) to form a liquid layer to be brought in contact with the tangible object; solidifying means (9) for solidifying a predetermined area of a layer (10) of the liquid (3), so as to obtain a solid layer (14) of the tangible object (5), the solid layer thus having a predetermined shape, separating means (18; 19′; 19″) for separating said solid layer from said construction shape; moving means (18) for moving, relative to one another, the construction shape (6) to a predetermined position relative to the tangible object (5), for carrying out a successive such method cycle for solidifying a predetermined area of a successive such liquid layer; the system is arranged to provide a limited volume of liquid adhered to the construction shape to form a liquid layer of limited height that does not contact the tangible object; wherein said moving of said construction shape and said solidifying of said predetermined area are carried out to take place simultaneously.

Claims

1. A system for layerwise production of a tangible object, the system comprising:

a construction shape arranged to provide a liquid layer of limited height that does not contact the tangible object, to be brought in contact with the tangible object;

solidifying means for solidifying a predetermined area of a layer of the liquid, so as to obtain a solid layer of the tangible object, the solid layer thus having a predetermined shape;

removing means for removing uncured material from the layer outside the intersection pattern;

moving means for moving, relative to one another, the construction shape to a predetermined position relative to the tangible object, such that the moving means moves the liquid layer on the construction shape into contact with the tangible object, for solidifying a predetermined area of a successive such liquid layer;

characterized in that

the system is arranged to move said construction shape and to operate said solidifying means simultaneously, such that the moving means moves the construction shape to bring the liquid layer into contact with the tangible object while the solidifying means solidifies a predetermined area of such liquid layer.

2. A system according to claim 1, wherein the system is further arranged to carry out said layer provision and said solidifying such that solidifying of certain parts of the layer takes place simultaneously with provision of the liquid layer on the construction shape.

3. A system according to claim 1, wherein the construction shape comprises a flexible foil that is bent such that time-dependently varying contacting parts of the liquid contacting side of the flexible foil are in contact with the tangible object for solidifying said certain parts of the layer.

4. A system according to claim 1, wherein the construction shape comprises guiding means and wherein the guiding means are brought in pressing contact with the side of the flexible foil opposite to the liquid contacting side for defining the time-dependently varying contacting parts of the liquid contacting side of the flexible foil.

5. The system according to claim 4, wherein the guiding means comprises a foil guiding stage comprising at least two foil guiding elements arranged thereon defining a contact height H and at least one position distanced from the contact height, for guiding the foil to or from the contact height to contact the tangible object by movement along the tangible object while having opposite ends fixed relative to the tangible object at least during contacting.

6. The system according to claim 5, wherein the foil guiding stage further comprises an applicator system for flattening and adjusting the layer volume.

7. The system according to claim 1, further comprising:

a stage arranged for holding the tangible object, the stage being a movable z-stage for moving the tangible object in a z-direction before providing the layer of curable material.

8. The system according to claim 5, said solidifying means further comprising:

a first energy source arranged for at least partially curing at least part of an intersection pattern in the layer of curable material, wherein the energy source is positioned on the movable foil guiding stage, between the protruding foil guiding elements so as to expose the layer of uncured material through the foil.

9. The system according to claim 8, said solidifying means further comprising:

separating means for separating said solid layer from said construction shape, and

a second energy source for post-curing the layer, wherein the second energy source comprises a wide-range energy source that is positioned on the movable foil guiding stage for post-curing the layer.

10. The system according to claim 8, wherein the first energy source comprises a plurality of individually operable LED'"'"'s.