Method of and apparatus for making a three-dimensional product by stereolithography

An apparatus for stereolithographically forming a portion of a three-dimensional object wherein a subsequent layer of the three-dimensional object is formed over a previously formed layer of the object, comprising:

• a) a vessel for holding a building material having a working surface and the building material selectively physically transformable upon exposure to prescribed synergistic stimulation;
• b) means for forming a uniform coating over the previously formed layer, including:
• a smoothing member;
• means for sweeping the smoothing member in a direction different from a direction of sweeping during a previous sweep of the smoothing member;
• and
• c) means for applying a prescribed pattern of synergistic stimulation to the building material at the working surface to form the subsequent layer.

An apparatus for stereolithographically forming a portion of a three-dimensional object wherein a subsequent layer of the three-dimensional object having a layer thickness is formed over a previously formed layer of the object, comprising:

• a) means for holding a volume of building material having a working surface wherein the building material is capable of selective transformation upon exposure to prescribed synergistic stimulation;
• b) means for forming a uniform coating over the previously formed layer including means for sweeping a smoothing member over the previously formed layer with a value of a clearance between a lower surface of the smoothing member and an upper surface of the previously formed layer which is different from the layer thickness;
• and
• c) means for applying a prescribed pattern of synergistic stimulation to the building material at the desired working surface to transform at least a portion of the building material to form the subsequent layer.

An apparatus for stereolithographically forming at least a portion of a three-dimensional object wherein at least a first subsequent layer and a second subsequent layer of the three-dimensional object are formed over a first and second previously formed layer of the object, respectively, comprising:

• a) means for holding a volume of building material having a working surface wherein the building material is capable of selective transformation upon exposure to prescribed synergistic stimulation;
• b) means for forming a unfirm coating of desired thickness over the previously formed layer in preparation for forming the first subsequent layer of the three-dimensional object including means for sweeping a smoothing member over the first previously formed layer at least once with a first smoothing member velocity;
• c) means for applying a prescribed pattern of synergistic stimulation to the building material at the working surface to transform at least a portion of the building material to form the first subsequent layer;
• d) means for forming a uniform coating of desired thickness over the second previously formed layer in preparation for forming the second subsequent layer of the three-dimensional object including means for sweeping a smoothing member over the second previously formed layer at least once with a second smoothing member velocity;
• e) means for causing the first and second smoothing member velocities to be different;
• and
• means for applying a prescribed pattern of synergistic stimulation to the building material at the working surface to transform at least a portion of the building material to form the first subsequent layer.

An apparatus for stereolithographically forming a portion of a three-dimensional object wherein a subsequent layer of the three-dimensional object is formed over a previously formed layer of the object, comprising:

• a) means for holding a volume of building material having a working surface wherein the building material is capable of selective transformation upon exposure to prescribed synergistic stimulation;
• b) means for forming a unfirm coating of desired thickness over the previously formed layer including:
• means for sweeping a smoothing member over the previously formed layer at least once with a first smoothing member velocity,
• means for sweeping the smoothing member at least once with a second smoothing member velocity,
• means for causing the first and second smoothing member velocities to be different;
• and
• c) means for applying a prescribed pattern of synergistic stimulation to the building material at the working surface to transform at least a portion of the building material to form the subsequent layer.

An apparatus for stereolithographically forming a portion of a three-dimensional object wherein a subsequent layer of the three-dimensional object is formed over a previously formed layer of the object, comprising:

• a) means for holding a volume of building material having a working surface wherein the building material is capable of selective transformation upon exposure to prescribed synergistic stimulation;
• b) means for forming a unfirm coating of desired thickness over the previously formed layer including:
• means for sweeping a smoothing member at least once over the previously formed layer with a first value of a clearance between a lower surface of the smoothing member and an upper surface of the previously formed layer,
• means for sweeping a smoothing member at least once over the previously formed layer with a second value of a clearance between a lower surface of the smoothing member and the upper surface of the previously formed layer,
• means for causing the second value of clearance to be less than the first value of clearance;
• and
• c) means for applying a prescribed pattern of synergistic stimulation to the building material at the desired working surface to transform at least a portion of the building material to form the subsequent layer.

An apparatus for stereolithographically forming a portion of a three-dimensional object wherein a subsequent layer of the three-dimensional object is formed over a previously formed layer of the object, comprising:

• a) a vessel for holding a building material having a working surface and selectively transformable upon exposure to prescribed synergistic stimulation;
• b) means for forming a unfirm coating of desired thickness over the previously formed layer including:
• means for sweeping a smoothing member over the previously formed layer,
• adjustment means attached to the smoothing member for adjusting its vertical position,
• needles attached to the smoothing member for adjusting a gap between a lower surface of the smoothing member and the working surface;
• and
• c) means for applying a prescribed pattern of synergistic stimulation to the building material at the working surface to transform at least a portion of the building material to form the subsequent layer.

A method for stereolithographically forming at least a portion of a three-dimensional object wherein a subsequent layer of the three-dimensional object is formed over a previously formed layer of the object, comprising the steps of:

• a) holding a volume of building material having a working surface wherein the building material is capable of selective transformation upon exposure to prescribed synergistic stimulation;
• b) forming a unfirm coating over the previously formed layer including sweeping a smoothing member in a direction different from a direction of sweeping during a previous sweep of the smoothing member;
• and
• c) applying a prescribed pattern of synergistic stimulation to the building material at the working surface to transform at least a portion of the building material to form the first subsequent layer.

A method for stereolithographically forming at least a portion of a three-dimensional object wherein a subsequent layer of the three-dimensional object having a layer thickness is formed over a previously formed layer of the object, comprising the steps of:

• a) holding a volume of building material having a working surface wherein the building material is capable of selective transformation upon exposure to prescribed synergistic stimulation;
• b) forming a unfirm coating of desired thickness over the previously formed layer including sweeping a smoothing member over the previously formed layer with a value of a clearance between a lower surface of the smoothing member and an upper surface of the previously formed layer which is different from the layer thickness;
• and
• c) applying a prescribed pattern of synergistic stimulation to the building material at the working surface to transform at least a portion of the building material to form the subsequent layer.

A method for stereolithographically forming at least a portion of a three-dimensional object wherein at least a first subsequent layer and a second subsequent layer of the three-dimensional object are formed over a first and second previously formed layer of the object, respectively, comprising the steps of:

• a) holding a volume of building material having a working surface wherein the building material is capable of selective transformation upon exposure to prescribed synergistic stimulation;
• b) forming a unfirm coating of desired thickness over the previously formed layer in preparation for forming the first subsequent layer of the three-dimensional object, including sweeping a smoothing member over the first previously formed layer at least once with a first smoothing member velocity;
• c) applying a prescribed pattern of synergistic stimulation to the building material at the working surface to transform at least a portion of the building material to form the first subsequent layer;
• d) forming a unfirm coating of desired thickness over the second previously formed layer in preparation for forming the second subsequent layer of the three-dimensional object including sweeping a smoothing member over the second previously formed layer at least once with a second smoothing member velocity different from the first smoothing member velocity;
• and
• c) applying a prescribed pattern of synergistic stimulation to the building material at the working surface to transform at least a portion of the building material to form the second subsequent layer.

A method for stereolithographically forming at least a portion of a three-dimensional object wherein a subsequent layer of the three-dimensional object is formed over a previously formed layer of the object, comprising the steps of:

• a) holding a volume of building material having a working surface wherein the building material is capable of selective transformation upon exposure to prescribed synergistic stimulation;
• b) forming a unfirm coating of desired thickness over the previously formed layer including:
• sweeping a smoothing member at least once over the previously formed layer at a first velocity;
• sweeping the smoothing member at least once over the previously formed layer at a second velocity;
• wherein the first and second velocities are different;
• and
• c) applying a prescribed pattern of synergistic stimulation to the building material at the working surface to transform at least a portion of the building material to form the subsequent layer.

A method for stereolithographically forming at least a portion of a three-dimensional object wherein a subsequent layer of the three-dimensional object is formed over a previously formed layer of the object, comprising the steps of:

• a) holding a volume of building material having a working surface wherein the building material is capable of selective transformation upon exposure to prescribed synergistic stimulation;
• b) forming a unfirm coating of desired thickness over the previously formed layer including:
• sweeping a smoothing member a first time over the previously formed layer with a first value of a clearance between a lower surface of the smoothing member and an upper surface of the formed layer,
• sweeping the smoothing member a second time over the previously formed layer with a second value of a clearance between the lower surface of the smoothing member and the upper surface of the previously formed layer, wherein the second value of the clearance is less than the first value of the clearance;
• and
• c) applying a prescribed pattern of synergistic stimulation to the building material at the working surface to transform at least a portion of the building material to form the subsequent layer.

A stereolithography system for forming at least a portion of a three-dimensional object, comprising:

• a tank for holding a bath of pulverizable fluid, the bath having an upper surface;
• an object support;
• means to apply a coating of pulverizable fluid over a surface of a last-formed object layer supported by the object support;
• means for displacing the coating over the surface of the last-formed object layer above the upper surface of the bath of pulverizable fluid;
• means to strike off excess pulverizable fluid from the applied coating to provide a smoothed layer of pulverizable fluid of desired thickness over the surface of the last-formed object layer;
• and
• means to apply a curing media in a predetermined pattern to the smoothed layer of pulverizable fluid to form a next object layer;
• whereupon said portion of said three-dimensional object is provided comprising said next object layer situated over the surface of the last-formed object layer.

A method of forming at least a portion of a three-dimensional object, comprising the steps of:

• holding a bath of pulverizable fluid in a tank, the bath having an upper surface;
• applying a layer of said polymerizable fluid over a surface of a last-formed object layer supported by a support;
• moving the support to displace said layer of said polymerizable fluid applied over said surface of said last-formed object layer above the upper surface of said bath;
• smoothing the layer of polymerizable fluid on said surface of said last-formed object layer to a desired thickness by striking off any excess polymerizable fluid from the applied layer;
• and
• applying a curing media in a preselected pattern onto the smoothed layer of polymerizable fluid to sufficiently cure the layer so that it forms a next layer of the object;
• whereupon said portion of said three-dimensional object is provided comprising said next layer of said object situated over the surface of the last-formed layer of said object.

A stereolithographically system for forming at least a portion of a three-dimensional object comprising a next layer of the three-dimensional object situated over a previously formed layer, said next layer having a desired thickness and said previously formed layer having an upper surface, comprising:

• a) means for holding a volume of building material;
• b) means to apply a coating of building material, said coating including excess material over at least a portion of the upper surface of the previously formed layer of the object;
• c) means for displacing the previously formed layer relative to a desired working surface so that the upper surface of the previously formed layer is positioned above a level which is below the desired working surface by the desired thickness of the next layer;
• d) means to displace material of said coating of building material to provide a smooth coating of building material of the desired thickness over the previously formed layer, while the upper surface of the previously formed layer is positioned above the level which is below the desired working surface by the desired thickness of the next layer;
• e) means for relatively positioning the upper surface of the previously formed layer to be substantially at the level which is below the desired working surface by the desired thickness of the next layer;
• and
• f) means for applying a prescribed pattern of synergistic stimulation to the building material at the desired working surface in order to transform at least a portion of the building material, whereby the next layer is formed over the previously formed layer.

A method for stereolithographically forming at least a portion of a three-dimensional object comprising a next layer of the three-dimensional object situated over a previously formed layer of said object, comprising the steps of:

• a) holding a volume of building material capable of selective physical transformation upon exposure to prescribed synergistic stimulation;
• b) forming a uniform coating of desired thickness over the previously formed layer including sweeping a smoothing member at least twice above the previously formed layer;
• and
• c) applying a prescribed pattern of synergistic stimulation to the building material at the desired working surface in order to transform at least a portion of the building material, whereby said portion of said three-dimensional object is formed comprising the next object layer formed over the previously formed layer.

A method for stereolithographically forming at least a portion of a three-dimensional object comprising a next layer of the three-dimensional object situated over a previously formed layer of said object, comprising the steps of:

• a) holding a volume of building material capable of selective physical transformation upon exposure to prescribed synergistic stimulation;
• b) forming a uniform coating of desired thickness over the previously formed layer including sweeping a smoothing member at least once above the previously formed layer;
• and
• c) applying a prescribed pattern of synergistic stimulation to the building material at a desired working surface in order to transform at least a portion of the building material, whereby the next object layer is formed over the previously formed layer after waiting at least for the smoothing member to complete sweeping across the previously formed layer;
• whereby said portion of said three-dimensional object is formed comprising said next layer situated over the previously formed layer.

A stereolithographically system for forming at least a portion of a three-dimensional object comprising a next layer of the three-dimensional object situated over a surface of a previously formed layer of the object, comprising:

• a) means for holding a quantity of building material capable of selective physical transformation upon exposure to synergistic stimulation;
• b) means for forming a uniform coating of material over the previously formed layer including a sweepable member having a lower edge which sweeps out a plane above a plane of a desired working surface;
• and
• c) means for selectively applying a prescribed pattern of synergistic stimulation to the building material at the desired working surface in order to transform at least a portion of the building material, whereby said portion of said three-dimensional object is formed comprising said next object layer formed over said previously formed layer.

A stereolithography system for forming at least a portion of a three-dimensional object, comprising:

• a container for holding a volume of material capable of physical transformation upon exposure to synergistic stimulation;
• an object support;
• means to apply a coating of said material over a surface of a last-formed object layer supported by the object support;
• means for relatively displacing the last-formed object layer so that said coating when applied is displaced above a desired working surface;
• means to displace material in the applied coating, when said coating is displaced above said desired working surface, to provide a smoothed layer of material of desired thickness over the surface of the last-formed object layer;
• and
• means to apply said synergistic stimulation in a predetermined pattern to the smoothed layer of material while the upper surface of the smoothed layer is located at the desired working surface to form a next object layer;
• whereupon said portion of said object is provided comprising said next object layer situated over the surface of the last-formed object layer.

A method of forming at least a portion of a three-dimensional object, comprising the steps of:

• holding a volume of material capable of selective physical transformation upon exposure to synergistic stimulation;
• applying a layer of said material over a surface of a last-formed object layer supported by a support;
• relatively displacing said last-formed object layer so that said layer when applied is displaced above a desired working surface;
• smoothing said displaced layer of material to a desired thickness by displacing material from the layer to provide a smoothed layer;
• and
• applying said synergistic stimulation in a prescribed pattern onto the smoothed layer of material to sufficiently transform the layer so that it forms a next layer of the object;
• whereupon said portion of said three-dimensional object is provided comprising said next object layer situated over said surface of said last-formed object layer.