3d Systems, Inc.

Other

Thomas J Vorgitch

Dennis R Smalley

Thomas P Chen

Adam L Cohen

Joseph W Allison

David E Snead

Charles W Hull

Chris Robert Manners

Jocelyn M Earl

Stacie L VanDorin

Mark Anthony Lewis

Harry L Tarnoff

Borzo Modrek

Bryan J L Bedal

Wayne A Vinson

Richard A Harlow

Frank F Little

Paul H Marygold

Robert T Pitlak

Yehoram Uziel

Wolfgang Schwarzinger

Grady O Floyd

Raymond A Bradford

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

A method of and apparatus for slicing a three-dimensional object representation into a plurality of layer representations is described, wherein the layer representations are subsequently used to form the object layer-by-layer according to the principles of stereolithography. If not already provided in the object representation, a plurality of layer boundary representations are first formed, and then the boolean difference of successive layer boundary representations are computed to derive boundaries of up and down-facing regions, enabling different cure parameters to be specified for these different regions.

Boolean layer comparison slice

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.

A method and apparatus for making an object by stereolithography from layers of a medium solidifiable upon exposure to synergistic stimulation by selecting an area element of a first layer of medium. The depth of the medium within the object underlying the area element is determined and compared to the depth to the minimum solidification depth of the medium. The area element is exposed to solidifying synergistic stimulation only if the depth of the medium equals or exceeds the minimum solidification depth. A next layer is created over the first layer without exposing the first layer to solidifying synergistic stimulation, if the depth is less than the minimum solidification depth. The layers may have a thickness selected such that the minimum solidification depth is a integer multiple of the layer thickness.

A stereolithography system employing a more powerful laser and faster dynamic mirrors to speed up part building without sacrificing accuracy is described, especially large or complex parts. A controllable shutter is placed in the beam path of the laser to selectably block the passage of the beam and prevent unwanted solidification. A suitable servo controlled feedback loop is provided to accurately position the mirrors at the higher velocity. Also described is a means to reduce data flow by distributing tasks in a multiple processor environment, and to improve user interaction by the use of a spreadsheet model. These also improve the speed of part building, especially for large or complex parts.

Rapid and accurate production of stereolighographic parts

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Simi Valley, CA, United States of America

Thomas J Vorgitch