Thermal stereolithograp using slice techniques

Details Thermal stereolithograp using slice techniques Thermal stereolithograp using slice techniques

1994-09-01

1998-07-07

Tentoni, Leo B.

Plastic and nonmetallic article shaping or treating: processes

Stereolithographic shaping from liquid precursor

118407, 118423, 118429, 118500, 118620, 118693, 118694, 118712, 156 64, 1562728, 1562735, 1562755, 1563071, 156378, 1563796, 156538, 222 55, 2221451, 2221462, 250432R, 2504921, 264 401, 264 407, 264255, 264308, 364468, 364476, 395119, 425135, 425145, 425147, 4251744, 427 8, 427557, 427561, B29C 3508, B29C 4102

Patent

active

057764093

DESCRIPTION:

BRIEF SUMMARY
FIELD OF THE INVENTION

This invention relates generally to improvements in methods and apparatus for forming three-dimensional objects. More particularly, this invention relates to improvements in methods and apparatus involving the formation of such objects using materials including those which are normally solid but which are made flowable.


BACKGROUND OF THE INVENTION

Several model 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 previously-transformed material. The process of forming these untransformed layers is known as a recoating step, and is described in detail in U.S. application Ser. No. 515,479.
Upon formation, the untransformed layers are selectively exposed to synergistic stimulation such as UV radiation, or the like, whereupon they form object layers. Moreover, upon transformation into the object layers, the untransformed layers typically adhere to the previously-formed layers through the natural adhesive properties of the photopolymer upon solidification. Additional details about stereolithography are available in the following co-pending patent applications, all of which, including appendices, are hereby fully incorporated by reference herein as though set forth in full:


______________________________________ patent appl. No. Filing Date Status ______________________________________ U.S. 07/182,830 4/18/88 U.S. Pat. No. 5,059,359 U.S. 07/183,016 4/18/88 U.S. Pat. No. 4,996,010 U.S. 07/182,801 4/18/88 U.S. Pat. No. 4,999,143 U.S. 07/183,015 4/18/88 U.S. Pat. No. 5,015,424 U.S. 07/268,429 11/8/88 U.S. Pat. No. 5,076,974 U.S. 07/268,837 11/8/88 U.S. Pat. No. 5,123,734 U.S. 07/268,816 11/8/88 U.S. Pat. No. 5,058,988 U.S. 07/268,907 11/8/88 U.S. Pat. No. 5,059,021 U.S. 07/331,644 3/31/89 U.S. Pat. No. 5,184,307 U.S. 07/339,246 4/7/89 U.S. Pat. No. 5,104,592 U.S. 07/429,435 10/30/89 U.S. Pat. No. 5,130,064 U.S. 07/365,444 6/12/89 U.S. Pat. No. 5,143,663 U.S. 07/427,885 10/27/89 U.S. Pat. No. 5,133,987 ______________________________________
In conventional embodiments of a stereolithographic apparatus, the material used is normally flowable so that it can be disposed onto a working surface in preparation for exposure to the synergistic stimulation. Conventional materials which are typically used are photopolymers which solidify upon exposure to UV radiation from a UV laser or the like.
The use of these conventional materials is sometimes problematic, since they can be toxic when placed in contact with the skin, and are also difficult to dispose of easily. The use of UV radiation from UV lasers is also sometimes problematic because of the potential injury to the human eye. As a result, the use of this radiation must be controlled, and precautions taken, to minimize the risk of eye injury. Moreover, the time required for the photopolymers to solidify upon exposure to the UV radiation can be prohibitively long. Finally, these materials are typically very viscous, so that the time required to form a fresh layer of material over the working surface in anticipation of the formation of the next object cross-section can be prohibitively long.
Another problem with conventional stereolithographic apparatus is the difficulty of rapidly substituting material

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