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

• US 9,987,804 B2
• Filed: 12/21/2016
• Issued: 06/05/2018
• 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:
  US15/387,179
• Publication Number:
  US 20170100899A1
• Time in Patent Office: 531 Days
• 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 container comprising a transparent bottom;

a second solidifiable material container comprising a transparent bottom;

at least one pattern generator spaced apart from the transparent bottom of the first container and the transparent bottom of the second container along a first axis and operable to project solidification energy upward along the first axis;

a build platform, wherein during a first build platform operation the build platform moves along the first axis, and during a second build platform operation, at least one of the build platform and the first solidifiable material container translates or rotates relative to the other of the build platform and the first solidifiable material container in a plane perpendicular to the first axis, thereby aligning the build platform and the second solidifiable material container;

wherein during the second build platform operation, the build platform and the at least one pattern generator maintain fixed registration with one another along a second axis perpendicular to the first axis.

2. The apparatus of claim 1, wherein the transparent bottom of at least one of the first solidifiable material container and the second solidifiable material container further comprises a rigid or semi-rigid transparent solidification substrate.

3. The apparatus of claim 2, wherein the transparent bottom of the first solidifiable material container comprises a solidification substrate assembly that includes the rigid or semi-rigid transparent solidification substrate, the solidification substrate assembly further comprises a film, and the rigid or semi-rigid transparent solidification substrate is located between the film and the at least one pattern generator along the first axis.

4. The apparatus of claim 3, wherein the film is resilient.

5. The apparatus of claim 3, wherein the film is coated on a surface of the rigid or semi-rigid transparent solidification substrate, and the coated surface of the rigid or semi-rigid solidification substrate faces away from the at least one pattern generator.

6. The apparatus of claim 5, wherein the first solidifiable material container comprises non-resilient sidewalls, the rigid or semi-rigid transparent solidification substrate extends between the non-resilient side walls, and the coated film extends along only an inner portion of the rigid or semi-rigid transparent solidification substrate such that the film is spaced apart from the non-resilient sidewalls.

7. The apparatus of claim 3, wherein the film is stretched tautly against the rigid or semi-rigid transparent solidification substrate.

8. The apparatus of claim 3, wherein the first solidifiable material container further comprises an inner frame and an outer frame defining first and second sides of the first solidifiable material container, and the film extends from the first side to the second side of the first solidifiable material container.

9. The apparatus of claim 1, wherein the transparent bottom of the first solidifiable material container comprises a film.

10. The apparatus of claim 8, wherein the transparent bottom of the second solidifiable material container comprises a film.

11. The apparatus of claim 1, wherein at least one of the first solidifiable material container and the second solidifiable material container comprises a basin having polymeric side walls, and at least a portion of the transparent bottom of the at least one of the first solidifiable material container and the second solidifiable material container is resilient.

12. The apparatus of claim 1, wherein each of the first solidifiable material container and the second solidifiable material container comprises a basin having polymeric side walls, and at least a portion of the transparent bottom of each of the first solidifiable material container and the second solidifiable material container is resilient.

13. The apparatus of claim 1, wherein the at least one pattern generator is a digital light projector.

14. The apparatus of claim 1, wherein the at least one pattern generator is a linear solidification device, and during an object solidification operation, the linear solidification device moves only along a second axis and projects solidification energy in a plurality of linear scans having lengths along a third axis.

15. The apparatus of claim 1, wherein during the second build platform operation, the first solidifiable material container rotates or translates in the plane perpendicular to the first axis.

16. The apparatus of claim 1, wherein the first solidifiable material container is spaced apart from the second solidifiable material container along the second axis.

17. The apparatus of claim 1, further comprising a cleaning station between the first solidifiable material container and the second solidifiable material container.

18. The apparatus of claim 17, wherein the cleaning station is a vacuum cleaning station.

19. The apparatus of claim 1, wherein at least one of the first solidifiable material container and the second solidifiable material container is tiltable relative to the plane.

20. The apparatus of claim 1, wherein the first solidifiable material container contains the first solidifiable material, and the first solidifiable material has an exposed surface that is spaced apart from the transparent bottom of the first solidifiable material container by a distance ranging from about 0.5 mm to about 4 mm.

21. The apparatus of claim 20, wherein the second solidifiable material container contains the second solidifiable material, and the second solidifiable material has an exposed surface that is spaced apart from the transparent bottom of the second solidifiable material container by a distance ranging from about 0.5 mm to about 4 mm.