Method and apparatus for production of a three-dimensional object

• US 5,460,758 A
• Filed: 03/13/1995
• Issued: 10/24/1995
• Est. Priority Date: 12/21/1990
• Status: Expired due to Fees

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: EOS GmbH Electro Optical Systems
• Inventors: Cabrera, Miguel, Langer, Hans
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US08/402,739
• Time in Patent Office: 225 Days
• Field of Search: 264/22, 264/40.1, 264/40.2, 264/236, 264/308, 425/135, 425/174.4, 156/64, 156/272.8, 156/273.3, 156/273.5, 156/275.5, 156/307.1, 156/378, 156/379.6, 427/8, 427/508, 427/510, 427/512, 427/553, 427/554, 427/555, 118/429, 118/620, 118/712, 250/432 R, 250/492.1, 356/4, 356/4.5, 356/374, 356/376, 364/468, 364/476
• US Class Current: 264/401
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• 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
• CPC Class Codes: G03F 7/0037 Production of three-dimensional images

Abstract

A three-dimensional object is modelled by solidifying superposed layers in such a manner that on an already solidified layer a following layer of initially liquid or powdery material is solidified by light action or the like in correspondence with the form of the object.

Claims

1. A method for the production of a three-dimensional object,

comprising the steps of

solidifying superposed layers of the object by forming a layer of initially liquid or powdery material which is solidifiable by action of electromagnetic radiation, solidifying said layer by irradiation corresponding to the shape of the object, measuring the surface or the contour of said layer or object, comparing the measurement result with predetermined data of the object and determining correction data on the basis of said comparison, wherein said surface is measured by projecting a modulation pattern onto said surface to generate a reflected line pattern, viewing said reflected line pattern at an angle with respect to the direction of projection and evaluate said reflected line pattern to determine coordinates of said surface based on said reflected line pattern, and forming the three-dimensional object.

2. The method of claim 1, comprising postcuring said object before measuring.

3. The method of claim 1,

comprising measuring the surface of said liquid or powdery layer before solidification thereof for determining unevenness of said surface, and enabling said irradiation based on said unevenness measured.

4. The method claim 1,

comprising combining said correction data with said predetermined data for determining corrected object data for the production of the object.

23. The method of claim 1 in which the electromagnetic radiation is light.

5. A method for the production of a three-dimensional object, comprising the steps of

solidifying superposed layers of the object by forming a layer of an initially liquid or powdery material which is solidifiable by action of electromagnetic radiation, solidifying said layer by irradiation corresponding to the shape of the object, measuring the surface or the contour of said layer or object, comparing the measurement result with predetermined data of the object and determining correction data of the basis of said comparison, providing a bath of at least partially fluorescent or phosphorescent material and measuring said layer or object within said bath after the solidification of said layer and forming the three-dimensional object.

6. The method of claim 5, wherein said surface is measured by projecting a first modulation pattern onto said surface, viewing said surface at an angle with respect to the direction of projection through a second modulation pattern, thereby producing an interference pattern, and determining coordinates of said surface based on said interference pattern.

7. The method of claim 6, wherein the projection of the modulation pattern is made using light having a wave length stimulating the fluorescence or phosphorescence and the observation is made within a wave length region of the florescent or phosphorescent radiation of said material.

8. The method of claim 5,

comprising measuring said surface after solidifying one of said layers and using said determined correction data for the solidification of the layers.

9. The method of claim 5,

comprising combining said correction data with said predetermined data for determining corrected object data for the production of the objects.

24. The method of claim 5 in which the electromagnetic radiation is light.

10. Apparatus for producing a three-dimensional object, comprising means for generating superposed layers of a liquid or powdery material which is solidifiable by action of electromagnetic radiation, means for controlled solidification of each said layers in correspondence with the shape of said object, measuring means for measuring said layers or object and for generating measurement data,

means for comparing said measurement data with predetermined data of said layers or said object, coupling means for connecting said measuring means and said comparing means with said solidifying means for control thereof in response to the measurement data, means provided in said measuring means for illuminating said object and, image recording means for viewing said object and at angle with respect to the direction of illumination, a first grating disposed in the course of said illumination, optionally a second grating in the course of the viewing beam, and evaluation means coupled to said image recording means.

11. The apparatus of claim 10, comprising a computer coupled to said measuring means and to said solidifying means, said computer generating data sets of said object, comparing said data sets with said measurement data and determining corrected object data on the basis of said comparison, the computer further controlling said solidifying means in response to said corrected object data.

12. The apparatus of claim 10, comprising a light source provided in said solidifying means for generating a focussed light beam, control means for controllably moving the position of said light beam across the surface of said layer, and means for adjusting the intensity of said light beam.

13. The apparatus of claim 10,

said illuminating means comprising means for illuminating said object using a radiation which stimulates fluorescence or phosphorescence of said material, said recording means being tuned to said fluorescent or phosphorescent radiation emitted by said material.

14. The apparatus of claim 13,

said recording means comprising a wave length selective receiver for determining a shift or variation of the width of said fluorescent of phosphorescent radiation band.

15. Apparatus of producing a three-dimensional object, comprising means for generating superposed layers of a liquid or powdery material which is solidifiable by action of electromagnetic radiation, means for controlled solidification of each of said layers in correspondence with the shape of said object, measuring means for measuring said layers or object and for generating measurement data, means for comparing said measurement data with predetermined data of said layers or said object, coupling means for connecting said measuring means and said comparing means with said solidifying means for control thereof in response to the measurement data, means provided in said measuring means for illuminating said object, image recording means for viewing said object at an angle with respect to the direction of illumination, means for producing a modulation pattern disposed in the course of said illumination, evaluation means coupled to said image recording means, said illuminating means comprising means for illuminating said object using a radiation band which stimulates fluorescence or phosphorescence of said material, said recording means being tuned to said fluorescent of phosphorescent radiation emitted by said material.

16. The apparatus of claim 15,

said recording means comprising a wave length selective receiver for determining a shift or variation of the width of said fluorescent of phosphorescent radiation band.

17. The apparatus of claim 15,

a computer coupled to said measuring means and to said solidifying means, said computer generating data sets of said object, comparing said data sets with said measurement data and determining corrected object data on the basis of said comparison, the computer further controlling said solidifying means in response to said corrected object data.

18. The apparatus of claim 15, comprising,

a light source provided in said solidifying means for generating

a focussed light beam control means for controllably moving the position of said light beam across the surface of said layer and means for adjusting the intensity of said light beam.

19. Apparatus for producing a three-dimensional object, comprising means for generating superposed layers of a liquid or powdery material which is solidifiable by action of electromagnetic radiation, means for controlled solidification of each of said layers in correspondence with the shape of said object, measuring means for measuring said layers or object and for generating measurement data,

means for comparing said measurement data with predetermined data of said layers or said object, coupling means for connecting said measuring means and said comparing means with said solidifying means for control thereof in response to the measurement data, means provided in said measuring means for illuminating said object,

image recording means for viewing said object at an angle with respect to the direction of illumination, means for producing a modulation pattern disposed in the course of said illumination, and evaluation means coupled to said image recording means, said recording means comprising a wave length selective receiver for determining a shift or variation of the width of said fluorescent or phosphorescent radiation band.

20. The apparatus of claim 19,

said illuminating means comprising means for illuminating said object using a radiation which stimulates fluorescence or phosphorescence of said material, said recording means being tuned to said fluorescent of phosphorescent radiation emitted by said material.

21. The apparatus of claim 19, comprising a computer coupled to said measuring means and to said solidifying means, said computer generating data sets of said object, comparing said data sets with said measurement data and determining corrected object data on the basis of said comparison, the computer further controlling said solidifying means in response to said corrected object data.

22. The apparatus of claim 19, comprising

a light source provided in said solidifying means for generating a focussed light beam,

control means for controllably moving the position of said light beam across the surface of said layer, and means for adjusting the intensity of said light beam.

25. A method for the production of a three-dimensional object,

comprising the steps of

solidifying superposed layers of the object by forming a layer of initially liquid or powdery material which is solidifiable by action of electromagnetic radiation, solidifying said layer by irradiation corresponding to the shape of the object, measuring the surface and the contour of said layer or object, comparing the measurement result with predetermined data of the object and determining correction data on the basis of said comparison, wherein said surface is measured by projecting a modulation pattern onto said surface to generate a reflected line pattern, viewing said reflected line pattern at angle with respect to the direction of projection and evaluate said reflected line pattern to determine coordinates of said surface based on said reflected line pattern, and forming the three-dimensional object.

26. The method of claim 25, comprising postcuring said object before measuring.

27. The method of claim 25,

comprising measuring the surface of said liquid or powdery layer before solidification thereof for determining unevenness of said surface, and enabling said irradiation based on said unevenness measured.

28. The method claim 25,

comprising combining said correction data with said predetermined data for determining corrected object data for the production of following objects.

29. The method of claims 25, 26, 27 or 28 in which the electromagnetic radiation is light.

30. A method for the production of a three-dimensional object, comprising the steps of

solidifying superposed layers of the object by forming a layer of an initially liquid or powdery material which is solidifiable by action of electromagnetic radiation, solidifying said layer by irradiation corresponding to the shape of the object, measuring the surface and the contour of said layer or object,

comparing the measurement result with predetermined data of the object and determining correction data of the basis of said comparison, providing a bath of at least partially fluorescent or phosphorescent material and measuring said layer or object within said bath after the solidification of said layer and forming the three-dimensional object.

31. The method of claim 30, wherein said surface is measured by projecting a first modulation pattern onto said surface, viewing said surface at an angle with respect to the direction of projection through a second modulation pattern, thereby producing an interference pattern, and determining coordinates of said surface based on said interference pattern.

32. The method of claims 31, wherein the projection of the modulation pattern is made using light having a wave length stimulating the fluorescence or phosphorescence and the observation is made within a wave length region of the florescent or phosphorescent radiation of said material.

33. The method of claim 30,

comprising measuring said surface after solidifying one of said layers and using said determined correction data for the solidification of the following layers.

34. The method of claim 30, comprising combining said correction data with said predetermined data for determining corrected object data for the production of following objects.

35. The method of claims 31, 32, 33 or 34 in which the electromagnetic radiation is light.