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

• US 9,533,450 B2
• Filed: 07/09/2014
• Issued: 01/03/2017
• 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:
  US14/326,557
• Publication Number:
  US 20140319735A1
• Time in Patent Office: 909 Days
• US Class Current: 1/1
• 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;

at least one linear solidification device movable only along a first axis, wherein during an object solidification operation, the at least one linear solidification device scans solidification energy along a second axis while moving along the first axis;

a second solidifiable material source; and

a build platform movable in a first build platform operation along a third axis, wherein during a second build platform operation, at least one of the build platform and first solidifiable material source moves relative to the other of the build platform and the first solidifiable material source in a plane perpendicular to the third axis;

wherein the first solidifiable material source is spaced apart from the second solidifiable material source along the first axis or the second axis; and

wherein the first solidifiable material source is spaced apart from the second solidifiable material source along the second axis, and the build platform is translatable along the second axis as well as the third axis.

2. The apparatus of claim 1, wherein the at least one linear solidification device comprises a solidification energy source in optical communication with a rotating energy reflector rotating in a plane perpendicular to the first axis.

3. The apparatus of claim 1, wherein the first solidifiable material source is spaced apart from the second solidifiable material source along the first axis, and the build platform is rotatable about the third axis.

4. The apparatus of claim 1, wherein the at least one linear solidification device comprises two linear solidification devices.

5. The apparatus of claim 1, wherein the first solidifiable material source comprises a first solidifiable material container having a transparent bottom, the object solidification operation is a first object solidification operation, and during the first object solidification operation, the at least one linear solidification device projects solidification energy through the transparent bottom of the first solidifiable material container to solidify a first solidifiable material in the first solidifiable material container.

6. The apparatus of claim 5, wherein the second solidifiable material source comprises a second solidifiable material container having a transparent bottom, and during a second object solidification operation, the at least one linear solidification device projects solidification energy through the transparent bottom of the second solidifiable material container and along the second axis while moving along the first axis to solidify a second solidifiable material in the second solidifiable material container.

7. The apparatus of claim 5, wherein during the first object solidification operation, the transparent bottom tilts as the at least one linear solidification device moves along the first axis.

8. The apparatus of claim 5, wherein the transparent bottom comprises a rigid or semi-rigid transparent solidification substrate.

9. The apparatus of claim 5, wherein the transparent bottom is resilient.

10. The apparatus of claim 1, further comprising a cleaning station, wherein during the second build platform operation, the build platform moves in the plane from a first position in alignment with the first solidifiable material container to a second position in alignment with the cleaning station.

11. The apparatus of claim 10, wherein the cleaning station is a vacuum cleaning station.

12. The apparatus of claim 10, wherein during a third operation, the build platform is movable from the second position in alignment with the cleaning station to a third position in alignment with the second solidifiable material container.

13. A method of making a three-dimensional object from multiple solidifiable materials, the method comprising:

aligning a build platform with a first solidifiable material source;

first moving a linear solidification device along a first axis while scanning solidification energy in a plurality of linear scans having lengths along a second axis;

moving the build platform away from the first solidifiable material source along a third axis;

moving at least one of the build platform and the second solidifiable material source relative to the other of the build platform and the second solidifiable material source to align the build platform and the second solidifiable material source;

second moving a linear solidification device along the first axis while scanning solidification energy in a plurality of linear scans having lengths along the second axis;

wherein the step of moving at least one of the build platform and the second solidifiable material source relative to the other of the build platform and the second solidifiable material source comprises translating the build platform along the second axis.

14. The method of claim 13, wherein the step of moving a linear solidification device along a first axis while projecting solidification energy in a plurality of linear scans along a second axis comprises moving the linear solidification device along the first axis while projecting solidification energy to a rotating energy deflector rotating in a plane perpendicular to the first axis.

15. The method of claim 13, wherein the step of moving at least one of the build platform and the second solidifiable material source relative to the other of the build platform and the second solidifiable material source comprises rotating the build platform about the third axis.

16. The method of claim 13, wherein the step of first moving a linear solidification device along a first axis while projecting solidification energy in a plurality of linear scans having lengths along a second axis comprises moving a first linear solidification device along the first axis while projecting solidification energy in a plurality of linear scans having lengths along the second axis, and the step of second moving a linear solidification device along the first axis while projecting solidification energy in a plurality of linear scans along the second axis comprises moving a second linear solidification device along the first axis while projecting solidification energy in a plurality of linear scans having lengths along the second axis.

17. The method of claim 13, wherein the first source of solidifiable material comprises a container with a transparent bottom, and the step of first moving a linear solidification device along a first axis while projecting solidification energy in a plurality of linear scans having lengths along a second axis further comprises projecting the solidification energy through the transparent bottom.