Process and device for producing a three-dimensional object

• US 9,067,361 B2
• Filed: 05/08/2014
• Issued: 06/30/2015
• Est. Priority Date: 07/04/2007
• Status: Active Grant

• Current Assignee: Envisiontec GmbH
• Original Assignee: Envisiontec GmbH
• Inventors: El-Siblani, Ali
• Primary Examiner(s): SMITH, JEREMIAH R
• Application Number:
  US14/272,826
• Publication Number:
  US 20140239554A1
• Time in Patent Office: 418 Days
• Field of Search: 425/149, 425/174.4, 425/135, 425/150, 264/34, 264/401, 264/497
• US Class Current: 1/1
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 70/88 characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
• CPC Class Codes: B29K 2105/24 crosslinked or vulcanised
• 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 50/02 for controlling or regulating additive manufacturing processes

Abstract

A process for producing at least one three-dimensional object by solidifying a solidifyable material, comprising the steps of:

• providing an object carrier capable of carrying the object to be produced;
• providing a material capable of solidifying when subjected to energy supply;
• bringing a solidifyable material carrier/provider in a position to carry/provide solidifyable material at least in a building region where solidifyable material is to be solidified;
• supplying, to the building region, energy capable of solidifying the solidifyable material; and
• sensing, measuring and/or controlling a condition selected from the group consisting of pressure and/or strain. Alternatively or in combination, contact pressure, fluid pressure and/or material flowability can be sensed and/or adjusted.

Claims

1. A device for producing at least one three-dimensional object from a solidifiable material, comprising:

a source of solidification energy, wherein the source of solidification energy selectively provides solidification energy through a transparent plate to a building plane in a pattern corresponding to the three-dimensional object;

an object carrier movable relative to the building plane;

a source of the solidifiable material, wherein the source of solidifiable material provides solidifiable material to the building plane, and the building plane is between the object carrier and the source of solidification energy;

a controller operative to adjust a relative tilt angle between the transparent plate and the building plane, and

a sensor arranged to sense or measure a condition selected from the group consisting of (i) a force between the object carrier and the building plane, and (ii) a pressure between the object carrier and the building plane, wherein the controller is operatively connected to the sensor and is operative to adjust the relative tilt angle between the transparent plate and the building plane based on the sensed or measured condition.

2. The device of claim 1, wherein the sensor is arranged to sense or measure a separation force of the three-dimensional object from the building plane, and during an object separation operation, the controller adjusts the tilt angle such that the transparent plate and the building plane tilt relatively away from one another based on the sensed or measured separation force.

3. The device of claim 1, wherein the sensor is arranged to sense or measure a contact pressure between the object carrier and the building plane, and during an operation of providing solidifiable material to the building plane the controller adjusts the tilt angle such that the transparent plate and the building plane tilt relatively toward one another based on the sensed or measured contact pressure.

4. The device of claim 1, wherein the controller is operatively connected to the transparent plate to tilt the transparent plate.

5. The device of claim 1, wherein the source of the solidifiable material is a container that includes the transparent plate.

6. The device of claim 1, wherein the source of solidification energy comprises a laser diode.

7. The device of claim 6, wherein the laser diode emits solidification energy in lines.

8. The device of claim 1, wherein the source of solidification energy comprises one selected from a spatial light modulator and a digital light projector.

9. The device of claim 1, wherein the source of solidification energy is located beneath the transparent plate and selectively transmits solidification energy upward through the transparent plate to the building plane.

10. A method of producing at least one three-dimensional object from a solidifiable material, comprising:

supplying solidification energy through a transparent plate to solidifiable material in a building plane in a pattern corresponding to the three-dimensional object, thereby forming a portion of the at least one three-dimensional object on an object carrier, wherein the object carrier is movable relative to the building plane;

adjusting a relative tilt angle between the transparent plate and the building plane, and

sensing or measuring a condition selected from the group consisting of (i) a force between the object carrier and the building plane, and (ii) a pressure between the object carrier and the building plane, wherein the step of adjusting a relative tilt angle between the transparent plate and the building plane is executed by a controller configured to adjust the tilt angle based on the sensed or measured condition.

11. The method of claim 10, wherein the sensed or measured condition is a sensed or measured separation force between the object carrier and the building plane, and the step of adjusting a relative tilt angle between the transparent plate and the building plane comprises increasing the relative tilt angle based on the sensed or measured separation force.

12. The method of claim 10, wherein the sensed or measured condition is a sensed or measured contact pressure between the object carrier and the building plane, and the step of adjusting a relative tilt angle between the transparent plate and the building plane comprises decreasing the relative tilt angle based on the sensed or measured contact pressure.

13. The method of claim 10, further comprising:

providing a solidifiable material container comprising the transparent plate.

14. The method of claim 10, wherein the step of adjusting a relative tilt angle between the transparent plate and the building plane comprises tilting the transparent plate in a direction away from the building plane.

15. The method of claim 10, wherein the step of supplying solidification energy comprises supplying solidification energy from a laser diode.

16. The method of claim 15, wherein the step of supplying solidification energy from a laser diode comprises supplying solidification energy from the laser diode in lines.

17. The method of claim 10, wherein the step of supplying solidification energy comprises supplying solidification energy from one selected from a spatial light modulator and a digital light projector.

18. The method of claim 10, wherein the step of supplying solidification energy comprises transmitting solidification energy upward through the transparent plate to the building plane.