Resin solidification substrate and assembly

• US 9,486,944 B2
• Filed: 01/14/2013
• Issued: 11/08/2016
• Est. Priority Date: 10/19/2009
• 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): Hindenlang, Alison L
• Assistant Examiner(s): Stewart, Kimberly A
• Application Number:
  US13/740,397
• Publication Number:
  US 20130140741A1
• Time in Patent Office: 1,394 Days
• Field of Search: 264/401, 425/174, 425/169
• US Class Current: 1/1
• CPC Class Codes: B29C 33/44 with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
• 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 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/255 Enclosures for the building material, e.g. powder containers
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2827/12 containing fluorine
• CPC Class Codes: B29K 2883/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as mould material
• 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 70/00 Materials specially adapted for additive manufacturing

Abstract

A solidification substrate assembly for making a three-dimensional object from a solidifiable material includes a solidification substrate assembly. In certain examples, the solidifiable material solidifies in contact with the solidification substrate, and the tilting of the substrate and/or or the use of a peeling member facilitates separation of the substrate from the solidified material. In other examples, the solidification substrate assembly includes a film that is adjacent to a rigid or semi-rigid layer. The solidifiable material solidifies in contact with the film, and a peeling member peels the film away from the solidified material. Intelligent solidification substrate assemblies are also described in which a force sensor determines when to expose the solidifiable material to solidification energy and/or whether to use a peeling member to separate the solidification substrate from a solidified objection section.

Claims

1. A method of producing a three-dimensional object on a build platform from a solidifiable material, wherein the build platform moves along a build axis, the method comprising:

providing a source of solidifiable material having a total exposable area perpendicular to the build axis to which solidification energy may be supplied;

supplying solidification energy exclusively to a first sub-area of the total exposable area where the first sub area is at a first location along a horizontal axis with respect to the total exposable area; and

then

supplying solidification energy exclusively to a second sub area that is the same size as the first sub area of the total exposable area where the second sub area is at a second location along the horizontal axis with respect to the total exposable area.

2. The method of claim 1, wherein the step of supplying solidification energy exclusively to a sub-area of the total exposure area while the first sub area is at the first location along the horizontal axis causes the solidifiable material at the first location to solidify in contact with a film, and wherein a step of transitioning along the horizontal axis from the first location to the second location with respect to the total exposable area further comprises peeling solidified material from the film at the first location.

3. The method of claim 2, wherein the step of peeling solidified material from the film at the first location comprises providing at least one film peeling member disposed between the film and the solidified material and moving the at least one film peeling member along the horizontal axis.

4. The method of claim 1, wherein the build platform is moveable in the source of solidifiable material, and during the step of supplying solidification energy exclusively to the first sub area of the total exposable area while the sub-area is at the first location along the horizontal axis, the build platform continuously moves in the source of solidifiable material.

5. The method of claim 1, wherein the step of supplying solidification energy exclusively to the first sub area of the total exposable area while the sub-area is at a first location along the horizontal axis with respect to the total exposable area comprises supplying solidification energy from a pattern generator.

6. The method of claim 5, wherein the pattern generator is a digital light projector.

7. The method of claim 5, wherein the pattern generator is stationary.

8. The method of claim 5, wherein the pattern generator comprises a moving light source.

9. The method of claim 5, wherein the pattern generator supplies solidification energy in selected patterns of pixels having gray scale values and corresponding to the three-dimensional object.

10. The method of claim 1, further comprising:

providing a pair of movable covers spaced apart by a movable opening, wherein the step of supplying solidification energy exclusively to the first sub area of the total exposable area while the sub-area is at a first location along the horizontal axis with respect to the total exposable area opening comprises supplying solidification energy through the movable opening while the opening is at the first location along the horizontal axis with respect to the total exposable area.

11. The method of claim 10, further comprising:

providing a rigid or semi-rigid solidification substrate that is transparent and/or translucent, wherein at least a portion of the rigid or semi-rigid solidification substrate is located in the opening, and wherein a step of transitioning along the horizontal axis from the first location to the second location with respect to the total exposable area further comprises moving the rigid or semi-rigid solidification substrate along the horizontal first axis to the second location with respect to the total exposable area.

12. The method of claim 1, further comprising providing a film, wherein as a result of the step of supplying solidification energy exclusively to the first sub area of the total exposable area while the first sub area is at the first location along the horizontal axis with respect to the total exposable area, a portion of the solidifiable material located within the first sub area solidifies in contact with the film, and the method also comprises peeling the film from the solidified material.

13. The method of claim 12, wherein the step of peeling the film from the solidified material comprises traversing at least one peeling member along the horizontal axis.

14. The method of claim 1, further comprising providing image data representative of a cross-section of the object, wherein the step of supplying solidification energy exclusively to the first sub area of the total exposable area while the first sub area is at a first location along the horizontal axis with respect to the total exposable area comprises first supplying solidification energy in a pattern corresponding to the image data, and the step of supplying solidification energy exclusively to the sub-area of the total exposable area while the second sub area is at the second location along the horizontal axis with respect to the total exposable area comprises second supplying solidification energy in the pattern corresponding to the image data.

24. The method of claim 10, further comprising:

providing a pair of fixed covers comprising first and second fixed covers spaced apart from one another along the horizontal axis, wherein a first movable cover of the pair of movable covers is movable along the horizontal axis over and relative to a first fixed cover of the pair of fixed covers, and a second movable cover of the pair of movable covers is movable along the horizontal axis over and relative to a second fixed cover of the pair of fixed covers.

15. An apparatus for making a three-dimensional object on a build platform from a solidifiable material, wherein the build platform is movable along a vertical build axis, the method comprising:

a source of the solidifiable material having a total exposable area perpendicular to the build axis;

a cover assembly having an opening defining a sub-area of the total exposable area, the cover assembly being movable along a horizontal axis;

a pattern generator operable to supply solidification energy exclusively to the sub-area through the opening.

16. The apparatus of claim 15, wherein the pattern generator is stationary relative to the cover assembly.

17. The apparatus of claim 15, wherein the pattern generator is a digital light projector.

18. The apparatus of claim 15, wherein the pattern generator is a moving light source.

19. The apparatus of claim 15, wherein the pattern generator is configured to supply solidification energy in patterns of pixels based on gray scale values.

20. The apparatus of claim 15, further comprising a rigid or semi-rigid substrate that is transparent and/or translucent, wherein at least a portion of the rigid or semi-rigid solidification substrate is located in the opening and is movable along the horizontal axis with the cover assembly.

21. The apparatus of claim 15, further comprising a film, wherein at least a portion of the film is located in the opening between an exposed surface of the solidifiable material and the pattern generator along the build axis.

22. The apparatus of claim 21, further comprising at least one peeling member that is movable along the horizontal axis with the cover assembly.

23. The apparatus of claim 15, wherein the cover assembly is located between the source of the solidifiable material and the pattern generator along the build axis.