Computer graphics processing and selective visual display system – Computer graphics processing – Three-dimension
Reexamination Certificate
1998-12-18
2001-12-25
Vo, Cliff N. (Department: 2671)
Computer graphics processing and selective visual display system
Computer graphics processing
Three-dimension
C345S419000
Reexamination Certificate
active
06333741
ABSTRACT:
APPENDICES
The following two appendices are affixed to this application and are hereby fully incorporated by reference herein as though set forth in full:
Appendix A: A User's Manual for SLICE Version 46
Appendix B: A Software Source Code Listing for SLICE Version 47, comprising the following software modules: S0.C, S1.C, S2.C, S3.C, S4.C, S5.C, S6.C, S.H, SCHIRIS.MAK, and SMAKE.
BACKGROUND OF THE INVENTION
I. Field of the Invention
This invention relates generally to the slicing of a three-dimensional object representation into layer representations for subsequent use in the stepwise layer-by-layer formation of the three-dimensional object through application of the principles of stereolithography, and more specifically, to the slicing of the object representation into the layer representations utilizing boolean comparisons between the borders of successive layers.
II. Background of the Invention
Several building techniques have recently become available for building three-dimensional objects in layers. One such technique is stereolithography, which is described in U.S. Pat. Nos. 4,575,330 and 4,929,402 (hereinafter the '330 and the '402 patents), the disclosures of which are hereby fully incorporated by reference herein as though set forth in full. According to the principles of stereolithography, a three-dimensional object is formed layer-by-layer in a stepwise fashion out of a material capable of physical transformation upon exposure to synergistic stimulation. In one embodiment of stereolithography, layers of untransformed material such as liquid photopolymer or the like are successively formed at the working surface of a volume of the liquid photopolymer contained in a container. The untransformed layers are successively formed over untransformed material and previously-transformed material. The process of forming these untransformed layers is known as a recoating step, and is described in detail in Ser. No. 515,479 now U.S. Pat No. 5,174,931.
These layers are then selectively exposed to the synergistic stimulation to form successive object cross-sections. Moreover, upon transformation into the object cross-sections, the transformed material typically adheres to the previously-formed cross-sections through the natural adhesive properties of the photopolymer upon solidification. Additional details about stereolithography are available in the following co-pending U.S. patent applications, all of which, including appendices, are hereby fully incorporated by reference herein as though set forth in full:
186/175
U.S. 415,168
September 29, 1989
Sekowski et al.
186/168
U.S. 429,911
October 27, 1989
Spence et al.
186/171
U.S. 427,885
October 27, 1989
Spence et al.
188/275
U.S. 428,492
October 27, 1989
Vorgitch et al.
188/254
U.S. 429,435
October 30, 1989
Hull et al.
186/173
U.S.S.N. not
October 30, 1989
Lewis et al.
yet available
187/268
U.S. 495,791
March 19, 1990
Jacobs et al.
190/179
U.S. 516,145
April 27, 1990
Allison et al.
188/189
U.S. 515,479
April 27, 1990
Almquist et al.
187/296
U.S. 545,517
June 28, 1990
Cohen
Additional details of stereolithography are also available in two related applications which are being filed concurrently herewith. The disclosures of these two additional applications are hereby fully incorporated by reference herein as though set forth in full.
The first of these concurrently-filed applications is U.S. patent application Ser. No. 07/606,802, now U.S. Pat. No. 5,192,469, entitled “Simultaneous Multiple Layer Curing for Forming Three-Dimensional Objects,” filed by Smalley et al. This application describes methods of building high resolution objects from traditionally low-resolution combinations of building materials and synergistic stimulation, which combinations result in a minimum effective cure depth which is typically too deep to form the thin layers required for high resolution objects. This objective is accomplished by delaying the exposure of those areas on a particular cross-section that would negatively impact resolution if those areas were immediately cured upon formation of the cross-section. Resolution may be negatively impacted, for example, if, because of the cure depth involved, material below this cross-section is inadvertently cured upon exposure of these areas. Therefore, to preserve resolution, exposure of these areas is delayed, and corresponding areas which are above these areas on higher cross-sections are instead subsequently exposed, after a delay if necessary, which higher cross-sections are chosen such that the cure depth is deep enough to cure the desired areas without inadvertently curing material on lower cross-sections.
The second of these concurrently-filed applications is U.S. patent application Ser. No. 07/605,979, now U.S. Pat. No. 5,209,878, entitled “Improved Surface Resolution in Three-Dimensional Objects by Inclusion of Thin Fill Layers,” filed by Smalley et al. This application describes methods for forming high resolution objects by filling the surface discontinuities inherent in three-dimensional objects formed from stereolithography with thin fill layers. applications is Lyon & Lyon Docket 192/71 entitled “Stereolithographic Curl Balancing,” filed by Vinson et al. This application discloses a method for reducing curl distortion by balancing normal curl with reverse curl. This referenced application discloses use of non-traditional cure depths and layer (or portion thereof) forming order to minimize curl distortion. The teachings of curl balancing can be applied to the instant invention as an example of other regions or block types that might be readily determined by the layer comparison
Other embodiments of stereolithography employ materials besides photopolymers such as powdered materials, thermoplastics, dry film photoresists, non-reactive pre-formed films or sheets, all of which share the common characteristics that they are capable of physical transformation upon exposure to an appropriate form of synergistic stimulation. Moreover, a variety of types of synergistic stimulation are possible, other than UV radiation from a laser, including infrared or CO
2
laser radiation, visible radiation, particle beam radiation, reactive chemical agents dispensed from ink jet type printing heads (e.g., binders and initiators) and the like. In addition, various means for selectively exposing the untransformed layers of material are possible, including rotatable scanning mirrors or the like for directing a beam of the synergistic stimulation to trace out the shape of the object layers on the untransformed layers, means such as a mask for selectively applying flood exposure to the untransformed layers, means such as a light valve, imaging system or the like, and xy tables for translating a dispenser for chemical synergistic stimulation or the like.
Various means of performing the recoating process are possible. The '330 patent describes the use of a platform coupled to a Z-stage elevator to overdip a previously-formed layer beyond the working surface as an expeditious means to perform recoating. U.S. patent application Ser. No. 07/515,479, now U.S. Pat. No. 5,174,931, describes the use of a doctor blade to speed up the recoating process. U.S. patent application Ser. No. 07/495,791 now abandoned describes the use of vibrational forces to speed up the recoating process. Additional approaches, which are possible, include dispensing pre-formed sheets or films over a previously-formed layer from a roll or cartridge dispenser. Also, various means of moving the partially-formed part relative to the working surface, besides a platform coupled to a z-stage elevator, are possible, including means for adding or extracting material from the container, or means for moving the container relative to the partially-formed part. Also, various other means of adhering the layers together besides the natural adhesive properties of the material being used are also possible, including pressure or heat sensitive adhesives or the like.
As can be seen from the above description, a wide variety of embodiments are included w
Allison Joseph W.
Chen Thomas P.
Cohen Adam L.
Smalley Dennis R.
Snead David E.
3-D Systems, Inc.
Bishop Laura
D'Alessandro Ralph
Vo Cliff N.
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