3d Systems, Inc.

Other

Chris Robert Manners

Hop D Nguyen

Dennis R Smalley

Charles W Hull

Rajeev B Kulkarni

Jouni P Partanen

Jocelyn M Earl

Charles R Sperry

Khalil M Moussa

Suzanne M Scott

Dennis F McNamara

Thomas Alan Kerekes

Jeffrey S Thayer

Thomas J Vorgitch

Patrick Dunne

Michelle D Guertin

Paul H Marygold

Stacie L VanDorin

Richard Noel Leyden

Paul F Jacobs

Thomas H Pang

Martin Alan Johnson

Bryan J L Bedal

Nansheng Tang

Jan Richter

Leigh Herran

Theodore R Kruger

Michael A Everett

John J Gigl

Kerry J Allen

Hop D Hguyen

Terry Wilkes

Cathy Yenly Vu Phan

Kabir Bhatia

Jenny Reilly

Nickalaus K Podgursky

Dennis Mcnamara

Dennis F Mcnamara

An apparatus is provided for fracturing a shell of a three-dimensional object. The apparatus may be caused to receive a shell of a three-dimensional object composed of a plurality of facets including first facets and distinct second facets, and form layer data defining a plurality of layers of the shell for use in forming the three-dimensional object on a layer-by-layer basis. At least some of the plurality of layers may include respective first fragments, and at least some of the plurality of layers may include respective second fragments. The first fragments may be produced by first facets and exclusive of second facets, and the second fragments may be produced by second facets and exclusive of first facets. And at least one layer of the plurality of layers may include both a first fragment of the respective first fragments, and a second fragment of the respective second fragments.

Fracturing a shell of a three-dimensional object

A solid imaging apparatus and method employing sub-pixel shifting in multiple exposures of the digitally light projected image of a cross-section of a three-dimensional object on a solidifiable liquid medium. The multiple exposures provide increased resolution, preserving image features in a three-dimensional object and smoothing out rough or uneven edges that would otherwise be occur using digital light projectors that are limited by the number of pixels in an image projected over the size of the image. Algorithms are used to select pixels to be illuminated within the boundary of each image projected in the cross-section being exposed.

Edge smoothness with low resolution projected images for use in solid imaging

A solid freeform fabrication method and apparatus for making objects in a layer by layer manner in which the objects have special geometrical features requiring specialized control parameters. The method and apparatus automatically determines and selects the build parameters for the build process based on automatic part feature recognition. A general build style is first determined having a plurality of default parameters for building the object. Data representing the object is imported and oriented with a Z-axis. The data is then processed by slicing software that automatically identifies special build types for specific ranges of Z-values and selects the alternative parameters needed to successfully build these features. Preferably a look-up table contains special sets of values for the parameters for each special build type possible in which the slicing algorithm can select from. During slicing, operator intervention is not needed to prepare all the parameters necessary for a successful build.

Automatic determination and selection of build parameters for solid freeform fabrication techniques based on automatic part feature recognition

An improved stereolithographic process for forming three-dimensional objects using an improved support structure and the improved support structure is described. The support structure is formed by using differential curing of the liquid media material to form solid supports with weak points at selected locations to facilitate support removal from a three-dimensional object and minimize post-processing.

Stereolithographic supports

A method of forming a three-dimensional object in layerwise fashion by selectively solidifying a build material. The method solidifies the main part area, delays or pauses for a desired period of time to permit shrinkage to occur, and then, in multiple drawings of the main part borders, solidifies the borders from the portion closest to the main part outwardly to the portion farthest from the main part.

Method for forming three-dimensional objects

An improved slicing technique is disclosed that employs micro-slicing or intermediate slices by identifying intermediate triangle vertices in the STL data and passing slice layers through each intermediate vertex to create a final build object or part that has smoother contouring, greater accuracy and an improved surface appearance than parts obtained using prior slicing methods.

Micro-slicing contour smoothing technique

A method of forming a three-dimensional object in layerwise fashion by selectively solidifying a build material in a reinforced cyclical fashion. The method solidifies a first fully cured layer of build material and then partially solidifies at least one partially cured intermediate layer of build material having areas of liquid build material and areas of solidifying build material. The method repeats the cycle by solidifying a next overlying fully cured layer of build material and also the underlying liquid areas of build material in the at least one partially cured intermediate layer of build material.

Method to reduce differential shrinkage in three-dimensional stereolithographic objects

An improved stereolithographic process for forming three-dimensional objects using an improved support structure. The support structure is formed by using differential curing of the liquid media material to form solid supports with weak points at selected locations to facilitate support removal from a three-dimensional object and minimize post-processing.

Stereolithographic process of making a three-dimensional object

A method of manipulating data in a method for forming a three-dimensional object layer by layer from an ink jettable, solidifiable material by providing data corresponding to a plurality of polygons defining the outer surfaces of a plurality of three-demiensional objects and providing sets of x, y, and z coordinates corresponding to each layer and identifying x and y coordinates with each z coordinate such that directional values and counter values are determined for each y coordinate in a first set of coordinates generated. A second set of y coordinates are generated according to a formula that permits the determined layers to be processed to form a three-dimensional object.

Method and apparatus for data manipulation and system control in a selective deposition modeling system

A rapid prototyping and manufacturing (e.g. stereolithography) method and apparatus for making three-dimensional objects on a layer by layer basis by selectively exposing layers of material to prescribed stimulation, using a beam having a first smaller diameter and a beam having a second larger diameter, to form laminae of the object. The power of the smaller beam is typically lower than the power of the larger beam. Object formation is controlled by data representing portions of the layers to be exposed with the larger beam (large spot portions) and those portions to be exposed with the smaller beam (small spot portions). In a preferred embodiment, portions exposed with the larger beam are formed first, for a given layer. Portions are exposed with the small beam next. Thereafter the entire perimeter of the laminae is traced using the small beam. Data manipulation techniques are used to identify which portions may be formed with the large beam to decrease exposure time and which should be formed with the small beam to maintain accuracy of the lamina being formed. More than two beam diameters may be used.

Stereolithographic method and apparatus for production of three dimensional objects using multiple beams of different diameters

A method and apparatus for making high resolution objects by stereolithography utilizing low resolution materials which are limited by their inability to form unsupported structures of desired thinness and/or their inability to form coatings of desired thinness. Data manipulation techniques, based on layer comparisons, are used to control exposure in order to delay solidification of the material on at least portions of at least some cross-sections until higher layers of material are deposited so as to allow down-facing features of the object to be located at a depth in the building material which is equal to or exceeds a minimum cure depth that can effectively be used for solidifying these features. Similar data manipulations are used to ensure minimum reliable coating thicknesses exist, above previously solidified material, before attempting solidification of a next layer. In addition, horizontal comparison techniques are used to provide enhanced cross-sectional data for use in forming the object. Further, several techniques for automatically performing Z-error correction through the manipulation of a three-dimensional object representation are described.

Simultaneous multiple layer curing in stereolithography

An improved method for stereolithographically making an object by alternating the order in which similar sets of vectors are exposed over two or more layers. In another method, a pattern of tightly packed hexagonal tiles are drawn. Each tile is isolated from its neighboring tiles by specifying breaks of unexposed material between the tiles. Using an interrupted scan method, vectors are drawn with periodic breaks along their lengths. In another method, modulator and scanning techniques are used to reduce exposure problems associated with the acceleration and deceleration of the scanning system when jumping between vectors or changing scanning directions. In another method, a capability for automatically inserting vents an drains into a three-dimensional object representation is provided.

Method of making a three-dimensional object by stereolithography

A rapid prototyping and manufacturing (e.g. stereolithography) method and apparatus for making high resolution objects utilizing low resolution materials which are limited by their inability to reliably form coatings of a desired thickness. The formation of coatings of such materials is limited to a Minimum Recoating Depth (MRD), when formed over entirely solidified laminae, which is thicker than the desired layer thickness or object resolution. Data manipulation techniques result in layers of material (and laminae) of the object being categorized as non-consecutive primary layers (laminae) and secondary layers (laminae) positioned intermediate to the primary layers (laminae). Substantially, all portions of primary laminae are exposed in association with primary layers and portions of the secondary laminae are formed in association with their respective secondary layers while other portions of the secondary laminae are formed in association with primary layers so as to form the object with a higher resolution than that dictated by the spacing between the primary layers. Recoating techniques are described which can be used when the thickness between consecutive layers is less than a leading edge bulge phenomena that results from the use of a particular recoating device such that direction of sweeping and/or order of sweeping of the recoating device is varied between consecutive primary layers.

Simplified stereolithographic object formation methods of overcoming minimum recoating depth limitations

A rapid prototyping and manufacturing (e.g. stereolithography) method and apparatus for making three-dimensional objects with simplified correlation of building parameters with object data. Object data is preferably correlated to (1) object build parameters that are used in solidifying object portions of layers of the material, (2) recoating parameters that are used in forming layers of material that include object data, (3) support build parameters that are used in solidifying support portions of layers of the material, (4) recoating parameters that are used in forming layers of material that include support data but no object data, and (5) parameters for use in generating a support structure that will be used to support the object during its formation. A style file is identified with each set of parameters. An algorithm (i.e. style wizard) is used to select among a plurality of styles of each type. The algorithm derives successively narrowing groups of compatible styles, for a particular build, based on answers to a series of questions until a final singular group of compatible styles is identified. This final group of styles is used in the formation of the object. This process results in fewer errors in deriving groups of styles and increases the probability of successful build processes.

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Moorpark, CA, United States of America

Chris Robert Manners