Stereolithographic apparatus and method for manufacturing three-dimensional object with photohardenable resin

Abstract

In stereolithographic apparatus and method, a mask is formed on a light-transmissible member (glass plate) on the basis of stereolithographic data for one layer of photohardenable resin; photohardenable resin of one layer is successively supplied to form an unhardened resin layer of photohardenable resin; if necessary, a film having light transmission is attached onto the unhardened resin layer so as to cover the unhardened resin layer in close contact with the unhardened resin layer; the light-transmissible member having the mask on or above the film; the unhardened resin layer is plane-exposed to light through the mask to harden the photohardenable resin of the unhardened resin layer; and the light-transmissible member and the film are evacuated from the hardened photohardenable resin layer after the exposure by the exposure means, thereby obtaining a desired three-dimensional object through stereolithography. As the photohardenable resin may be used having a melting temperature ranging from 5 to 90° C. when unhardened. In this case, in at least a part of the photohardened layer forming/laminating process, under a state that an unhardened photohardenable resin layer forming the same surface as a photohardened layer which has been already formed is kept solid at a temperature less than the melting temperature, a layer of photohardenable resin is formed on the surface of the solid photohardenable resin layer, and the photohardenable resin layer is exposed to light controlled on the basis of stereolithographic data to laminate a photohardened layer on the solid photohardenable resin composition layer.