Method for producing a three-dimensional object and stereolithography machine employing said method

• US 9,446,557 B2
• Filed: 01/18/2012
• Issued: 09/20/2016
• Est. Priority Date: 01/18/2011
• Status: Active Grant

• Current Assignee: Dws S.R.L.
• Original Assignee: Dws S.R.L.
• Inventors: Zenere, Sergio, Fortunato, Roberto
• Primary Examiner(s): Hauth, Galen
• Application Number:
  US13/992,487
• Publication Number:
  US 20130249146A1
• Time in Patent Office: 1,707 Days
• 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 64/386 Data acquisition or data processing for additive manufacturing
• 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

Abstract

Method for producing a three-dimensional object in layers by way of a stereolithography machine (1) including a container (2) suited to contain a liquid substance (3), structure (5) suited to emit predefined radiation (4) suited to selectively solidify a layer (6) of the liquid substance (3) adjacent to the bottom (2a) of the container (2), and an actuator (8) suited to move the solidified layer (6a) with respect to the bottom (2a). The method includes selectively solidifying the liquid layer (6); separating the solidified layer (6a) from the bottom (2a) through a movement (11) suited to move them away from each other, including a plurality of shifts (12, 12a, 12b, 12c) for corresponding predefined lengths, spaced by corresponding intermediate stops (14, 14a, 14b) for corresponding predefined time intervals (15, 15a, 15b). The intermediate stops are carried out before the solidified layer has become completely detached from the bottom.

Claims

1. A method for producing a three-dimensional object in layers by means of a stereolithography machine of the type comprising:

a container for containing a liquid substance suited to be solidified through exposure to predefined radiation;

means for emitting said predefined radiation, suited to selectively irradiate a layer of said liquid substance having a predefined thickness and arranged adjacent to the bottom of said container in order to solidify it;

actuator means suited to move said solidified layer with respect to said bottom at least according to a direction perpendicular to said bottom;

said method comprising the following operations;

selectively irradiating said layer of liquid substance in such a way as to obtain said solidified layer;

separating said solidified layer from said bottom through a mutual separation movement having a predefined extent, wherein said separation movement comprises a plurality of separation shifts for corresponding predefined lengths, spaced by corresponding intermediate stops for corresponding predefined time intervals, said intermediate stops being carried out before said solidified layer has become completely detached from said bottom.

2. The method according to claim 1, wherein each one of said intermediate stops takes place when said solidified layer is at least partially immersed in said liquid substance.

3. The method according to claim 1, wherein said lengths of said separation shifts, the number of said intermediate stops and the duration of said time intervals are defined so that the predefined extent of said separation movement necessary to obtain said complete separation of said solidified layer from said bottom does not exceed the thickness of the successive layer of said object.

4. The method according to claim 1, wherein the determination of the value of at least one parameter selected among the lengths of said separation shifts, the number of intermediate stops and the corresponding time intervals takes place before starting said separation movement.

5. The method according to claim 4, wherein the values of said selected parameters are calculated as follows:

for each of said selected parameters, defining a corresponding reference curve as a function of the surface area of the layer to be solidified such that the values of the functions evaluated for any given surface area correspond to the values for the selected parameters and that allow minimization of the extent of the separation movement for that surface area, attributing to said selected parameters the values of the respective reference curves evaluated at the actual surface area of the layer to be solidified.

6. The method according to claim 5, wherein the calculation of the values of said selected parameters comprise:

defining a shape function;

calculating the ratio between the surface area and the layer to be solidified and the perimeter of said layer to be solidified; and

multiplying the values of at least one of said selected parameters by the value of said shape function evaluated at said ratio.

7. The method according to claim 5, wherein the calculation of the values of said shape parameters comprises the following operations:

defining a shape function;

dividing the surface area of the layer to be solidified into a plurality of cells;

assigning each cell a weight proportional to the number of cells adjacent to said cell;

summing up said weights in order to obtain a shape parameter; and

multiplying the values of at least one of said selected parameters by the value of the shape function evaluated at said shape parameter.

8. The method according to claim 1, wherein said lengths of said separation shifts are equal to each other.

9. The method according to claim 1, wherein said actuator means comprise a modelling plate provided with a supporting surface for said solidified layer facing the bottom of said container.

11. The method according to claim 1 wherein:

said separation movement comprises between 1 and 20 of said intermediate stops;

said predefined lengths of each of said separation shifts are included between 5 and 200 microns; and

the duration of said time intervals is included between 0.01 seconds and 1 second.

10. A stereolithography machine comprising:

a container for containing a liquid substance suited to be solidified through exposure to predefined radiation;

means for emitting said predefined radiation, suited to selectively irradiate a layer of said liquid substance having a predefined thickness and arranged adjacent to the bottom of said container in order to solidify it;

actuator means suited for moving said solidified layer with respect to said bottom according to a direction perpendicular to said bottom; and

a logic control unit operatively connected to said emitting means and to said actuator means, the logic control unit activates the actuator means intermittently, so that, for each solidified layer, the solidified layer is moved by plurality of separation shifts for corresponding predefined lengths, spaced by corresponding intermediate stops for corresponding predefined time intervals.