Method of and apparatus for making partially solidified three-dimensional objects on a layer-by-layer basis from a solidifiable medium

A method of forming a three-dimensional object on a layer-by-layer basis from a solidifiable medium, comprising the steps of:

• forming an internal portion of the object on at least a portion of a first layer comprising solidified and unsolidified medium according to a first pattern comprising unsolidified medium and a plurality of first elements of solidified medium in a first plane, each first element having an elongated dimension in the first plane;
• forming an internal portion of the object on at least a portion of a second layer comprising solidified and unsolidified medium according to a second pattern which is different than the first pattern, the second pattern comprising unsolidified medium and a plurality of second elements of solidified medium, the second pattern being in a second plane separated from the first lane and each second element having an elongated dimension in the second plane;
• forming an internal portion of the object on at least a portion of at least one layer comprising solidified and unsolidified medium intermediate to the first and second layers according to a third pattern comprising unsolidified medium and at least one third element having an elongated dimension in a third plane intermediate to the first and second planes, the elongated dimension of each third element having an elongated portion which is aligned with and connected to at least a portion of the elongated dimension of at least one of the first elements and having a further elongated portion which is aligned with and connected to at least a portion of the elongated dimension of at least one of the second elements;
• and
• forming the external portion of the object.

A method of forming an internal portion of a three-dimensional object defining x, y and z dimensions in successive levels which are stacked in the z dimension, from a solidifiable medium, the method comprising:

• forming a first level of an internal portion of the object comprising solidified and unsolidified medium having a first pattern comprising a plurality of first elements of solidified medium adjacent unsolidified medium, each first element having an elongated dimension in a first x-y plane and thickness in the z dimension;
• forming a second level of an internal portion of the object comprising solidified and unsolidified medium having a second pattern different from the first pattern, the second pattern comprising a plurality of second elements of solidified medium adjacent unsolidified medium, each second element having an elongated dimension in a second x-y plane spaced from the first x-y plane and a thickness in the z dimension;
• forming a third level of an internal portion of the object comprising solidified and unsolidified medium intermediate to the first and second levels and having a third pattern of solidified medium, the third pattern comprising at least one third element of solidified medium adjacent unsolidified medium, each third element having an elongated dimension in a third x-y plane intermediate the first and second x-y planes, the elongated dimension of each third element having an elongated portion which is aligned with and connected to at least a portion of the elongated dimension of at least one of the first elements and having a further elongated portion which is aligned with and connected to at least a portion of the elongated dimension of at least one of the second elements.

A method of forming an internal portion of a three-dimensional object on a layer-by-layer basis from a solidifiable medium, comprising the steps of:

• forming an internal portion of the object comprising solidified and unsolidified medium on at least a portion of a first layer according to a first pattern comprising a plurality of first elements of solidified medium adjacent unsolidified medium in a first plane, each first element having an elongated dimension in the first plane;
• forming an internal portion of the object comprising solidified and unsolidified medium on at least a portion of a second layer according to a second pattern which is different than the first pattern, the second pattern comprising a plurality of second elements of solidified medium adjacent unsolidified medium, the second pattern being in a second plane separated from the first plane and each second element having an elongated dimension in the second plane;
• and
• forming an internal portion of the object comprising solidified and unsolidified medium on at least a portion of at least one layer intermediate to the first and second layers according to a third pattern comprising at least one third element of solidified medium adjacent unsolidified medium, each third element having an elongated dimension in a third plane intermediate to the first and second planes, the elongated dimension of each third element crossing a location on the elongated dimension of at least one of said first elements and further crossing a location on the elongated dimension of at least one of said second elements, each third element being connected to the first and second elements at the crossing locations and having a portion extending beyond the crossing locations;
• wherein each third element crosses no more than two first elements.