Process of fabricating three-dimensional objects from a light curable resin liquid

In a process of forming a three-dimensional object from a light curable liquid resin by radiating a light to a surface of said light curable liquid resin to form successive cross-sectional layers of the cured resin and superimposing said layers on each other, an improvement comprising:

• forming a bottom layer having its entire portion solidified into a substantially fully-cured condition;
• forming successively intermediate layers which include portions respectively solidified into substantially full-cured condition and half-cured or uncured condition, a first one of said successive intermediate layers being superimposed on said bottom layer and the remaining intermediate layers being superimposed on each other as they are formed;
• forming a top layer having its entire portion solidified into a substantially fully-cured condition and superimposing said top layer on the preceding intermediate layer;
• and
• subsequently completing the curing of said portions which are half-cured or uncured into fully-cured portions so as to constitute a part of said three dimensional object by subjecting said superimposed layers to a reactive environment, the substantially fully-cured region constituting an outer perimeter and the region which was formerly half-cured or uncured constituting a core of the three-dimensional object.

A process of forming a three-dimensional object from a light curable liquid resin by radiating a light to a surface of said light curable liquid resin to form successive cross-sectional layers of the cured resin and superimposing said layers on each other, said process utilizing a planar support which is transparent to said light and a lift movable toward and away from one side of said support, said process comprising the steps of:

• a) supplying said light curable liquid resin on said support;
• b) moving said support in order to spread said liquid resin thereover to form a thin film of said light curable liquid resin;
• c) irradiating said light through said support to cure said thin film of said liquid resin into a corresponding cross-sectional layer;
• d) operating said lift to remove said cross-sectional layer from said support and accumulate said layer on said lift;
• and
• repeating the steps a) to d) to obtain on said lift successive cross-sectional layers of cured resin forming said three-dimensional object of a desired outer configuration.

A process of forming a three-dimensional object from a light curable liquid resin by radiating a light to a surface of said light curable liquid resin to form successive cross-sectional layers of the cured resin and superimposing said layers on each other, said process utilizing a planar support which is transparent to said light and a lift movable toward said away from one side of said support;

• said process comprising the steps of:
• a) supplying said light curable liquid resin on said support;
• b) moving said support in order to spread said liquid resin thereover to form a thin film of said light curable liquid resin;
• c) irradiating said light through said support to cure a portion of said thin film of the liquid resin into a first corresponding cross-sectional layer;
• d) operating said lift to remove said cross-sectional layer from said support and accumulate said layer on said lift;
• e) displacing said support to locate in place on said support a remaining uncured further portion of said thin film of the liquid resin for subsequent irradiation of said light;
• f) irradiating said light through said support to cure said further portion of said thin film of the liquid resin into a second corresponding cross-sectional layer;
• g) operating said lift to remove said second cross-sectional layer from said support and accumulate said second layer on said first cross-sectional layer on said lift;
• and
• h) repeating the steps a) to g) to obtain on said lift successive cross-sectional layers of cured resin forming said three-dimensional object of a desired outer configuration.

A process of forming a three-dimensional object from a light curable liquid resin by radiating a light to a surface of said light curable liquid resin to form successive cross-sectional layers of the cured resin and superimposing said layers on each other, said process utilizing a generally cylindrical barrel having a generally horizontal center axis, said process comprising the steps of:

• a) supplying said light curable liquid resin on an inner surface of said cylindrical barrel;
• b) rotating said barrel about said generally horizontal center axis for spreading said light curable liquid resin over the inner surface of said barrel to form thereon a thin film of said light curable liquid resin;
• c) irradiating said light to cure said thin film of said liquid resin into a corresponding cross-sectional layer while rotating said barrel about said axis;
• and
• d) repeating steps a) to c) to obtain on said inner surface of said cylindrical barrel successive cross-sectional layer of cured resin to form said three-dimensional object.