3D Systems, Inc.

Hongqing V Wang

Charles W Hull

Thomas Alan Kerekes

Rajeev B Kulkarni

Richard Ora Gregory, Ii

Soon-Chun Kuek

Medhi Mojdeh

John Corbin West

Khalil M Moussa

John S Stockwell

Mehdi Mojdeh

Pavan Kumar

Rajeev Kulkami

Richard Ora Ii Gregory

There is provided methods and apparatus for compensation of intensity profiles of imagers used in three-dimensional modelers. The intensity profile of the actinic radiation projected from the imager is determined by a variety of techniques, including but not limited to manually operated sensors, exposed and scanned actinic radiation-sensitive paper, and intensity profilers. Once the intensity profile of the imager is determined, each layer of the solidifiable liquid material is cured by projecting a plurality of patterns (as opposed to a single pattern) defining the two-dimensional cross-section of the part being cured. The patterns vary in duration, number, and/or shape to correlate to the intensity profile so that a single layer of selectively cured solidifiable liquid material is cured with a substantially equivalent (or otherwise controlled) amount of actinic radiation per unit of surface area to provide generally controlled and consistent part quality.

Compensation of actinic radiation intensity profiles for three-dimensional modelers

There are provided method and apparatus for the forming of three-dimensional objects in a layered fashion, wherein improvements are made to the support structure to improve the quality of the resulting three-dimensional objects. The support structure may include encapsulation along the interface boundary of the support-object interface to prevent or reduce the likelihood of separation of the build material, that forms the three-dimensional object, from the support material, that forms the support structure, or vice versa. The support structure may also or alternatively include both a porous support structure and a solid support structure to prevent or reduce the likelihood of separation of the support structure from the build platform and to improve the quality of the down-facing surfaces of the three-dimensional object. Methods are also provided for selectively depositing the support material and build material and for encapsulating the interface boundary with support material.

Selective deposition modeling methods for improved support-object interface

Methods for generating supports () for parts () produced by solid freeform fabrication ('SFF') are disclosed. The method includes defining a plurality of layers (L) that make up the part, and for each layer, determining those regions (R) that require support. The method also includes merging the regions for the different layers (L) into one or more common regions that require support, and providing at least one support for each of the one or more common regions. The result is that fewer supports are used as compared to conventional SFF fabrication methods.

Region-based supports for parts produced by solid freeform fabrication

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Ft. Mill, SC, United States of America

Hongqing V Wang