Rapid recoating of three-dimensional objects formed on a cross-sectional basis
Assignee3D Systems, Inc.
InventorsThomas A. Almquist, Charles W. Hull, Jeffrey S. Thayer, Richard N. Leyden, Paul F. Jacobs, Dennis R. Smalley
Life of this patent
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Abstract
Methods and apparatus for use in building three-dimensional objects on substantially a cross-sectional basis including methods and apparatus for forming successive layers using counter-rotating rollers, ink jet recoaters, spinning members which sling material, applicator bars that dispense material via a meniscus and/or independently dispensed streams, and also including methods and apparatus to determine a preferred region over which to form a layer and to check for building errors.
Claims82
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a liquid material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- means for supplying data descriptive of the object;
- means for forming layers of material adjacent to any previously formed object cross-sections including a counter-rotating roller which sweeps at or near at least a portion of a desired upper surface of at least some of the layers to render the layers of desired thickness;
- and
- a source of synergistic stimulation for exposing the layers according to the descriptive data.
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a liquid material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- supplying data descriptive of the object;
- forming a layer of material adjacent to a previously formed object cross-session including sweeping a counter-rotating roller at or near at least a portion of a desired upper surface of the layer;
- exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form a successive object cross-section adjacent to the previously formed object cross-section;
- and
- repeating said forming and exposing a plurality of times to form the at least portion of the object.
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- means for supplying data descriptive of the object;
- means for forming layers of material over areas and adjacent to any previously formed object cross-sections, said areas being larger than regions of said layers to be transformed, comprising an ink-jet dispenser for depositing material over at least a portion of at least some of any previously formed object cross-sections;
- a source of synergistic stimulation;
- and
- means for exposing the layers to said synergistic stimulation according to the data descriptive of the object to form and adhere successive object cross-sections.
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- supplying data descriptive of the object;
- exposing a first region of a first layer of material to synergistic stimulation according to the descriptive data to form a first object cross-section;
- forming a second layer of material over an area larger than a second region to be transformed and adjacent to said first object cross-section including dispensing material from an ink-jet dispenser over selected locations of said area;
- exposing the second region of the second layer to synergistic stimulation according to the data descriptive of the object to form a second object cross-section adjacent to and adhered to the first formed object cross-section;
- and
- repeating said forming a second layer and said exposing the second region to form subsequent layers and cross-sections over previously formed layers and cross-sections to form the at least portion of the object from a plurality of adhered layers.
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- means for supplying data descriptive of the object;
- an applicator for dispensing material over at least a portion of any previously formed object cross-sections to form layers of material, the applicator including a housing, a spinning member mounted within the housing, and a source of material for delivering material to the spinning member wherein the spinning member ejects the delivered material toward a surface of the previously formed object cross-sections;
- and
- a source of synergistic stimulation for exposing the layers according to the data descriptive of the object to form successive object cross-sections.
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- supplying data descriptive of the object;
- forming a layer over at least a portion of a previously formed object cross-section including dispensing material from an applicator comprising a housing, a spinning member mounted within the housing, and a source of material for delivering material to the spinning member wherein the spinning member ejects the delivered material toward a surface of the previously formed object cross-section;
- exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form a successive object cross-section;
- and
- repeating said forming and exposing to form subsequent layers and cross-sections to form the at least portion of the object.
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- means for supplying data descriptive of the object;
- a container for containing a volume of material having a working surface;
- an applicator for forming layers of material over at least portions of previously formed object cross-sections, the applicator having a bottom opening located in proximity to the working surface;
- a device coupled to the applicator for drawing up material from the working surface through the bottom opening and into the applicator;
- means for sweeping the applicator across at least a portion of at least some of the previously formed object cross-sections;
- and
- a source of synergistic stimulation for exposing the layers according to the descriptive data to form the at least portion of the object from a plurality of object cross-sections.
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- supplying data descriptive of the object;
- containing a volume of material having a working surface;
- locating an applicator having a bottom opening in proximity to the working surface;
- forming a meniscus of material between the applicator and working surface;
- drawing up material from the working surface into the applicator through the bottom opening thereby at least partially filling the applicator;
- forming a layer over at least a portion of a previously formed object cross-section including dispensing material from the applicator by sweeping the applicator across at least a portion of the previously formed object cross-section;
- exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form an object cross-section adhered to the previously formed object cross-section;
- and
- repeating said forming and exposing to form subsequent layers and cross-sections to form the at least portion of the object.
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- means for supplying data descriptive of the object;
- an applicator for forming layers of material over at least portions of any previously formed object cross-sections, the applicator including a plurality of apertures for dispensing streams of material, the apertures having an effective spacing therebetween which is large enough so that the streams remain substantially independent before contacting the previously formed object cross-sections and which is small enough so that the streams merge substantially immediately after contacting the previously formed object cross-sections;
- means for sweeping the applicator across at least a portion of the previously formed object cross-sections;
- and
- a source of synergistic stimulation for exposing the layers according to the descriptive data.
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- supplying data descriptive of the object;
- forming a layer over at least a portion of a previously formed object cross-section by dispensing material from an applicator having a plurality of apertures for dispensing streams of material, the apertures having an effective spacing therebetween which is large enough so that the streams remain substantially independent before contacting the previously formed object cross-section and which is small enough so that the streams merge substantially immediately after contacting the previously formed object cross-section;
- sweeping the applicator across at least a portion of the previously formed object cross-section;
- exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form a successive object cross-section;
- and
- repeating said layer-forming and layer-exposing to form the at least portion of the object.
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- supplying data descriptive of the object;
- containing a volume of material having a working surface;
- determining a minimum region of the working surface including performing a Boolean union operation on data descriptive of the last formed cross-sectional region of the object and data descriptive of at least one other cross-sectional region of the object preceding the last formed cross-sectional region of the object;
- forming a layer over at least the minimum region of the working surface including moving a coating device over at least the minimum region of the working surface;
- exposing the layer to a source of synergistic stimulation according to the descriptive data to form a successive object cross-section;
- and
- repeating said forming and exposing a plurality of times to form the at least portion of the object;
- wherein the coating device is not moved over the entire working surface during the process of forming at least some layers;
- wherein an extent of movement of the recoating device is different for at least some of the layers formed;
- wherein the recoating device has a direction of movement over the last formed cross-section;
- and
- wherein, for at least some layers, the layer is formed over a last formed cross-section which has an extent which is less than an extent of the at least one cross-section formed prior to the last formed cross-section in the direction of movement.
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- means for supplying data descriptive of the object;
- a container for containing a volume of material having a working surface;
- means for determining a minimum region of the working surface including means for performing a Boolean union operation on data descriptive of the last formed cross-sectional region of the object and at least one other cross-sectional region preceding the last formed cross-section of the object;
- a coating device for forming layers over at least the minimum region of the working surface;
- and
- a source of synergistic stimulation for exposing the layers according to the descriptive data;
- wherein the coating device does not move over the entire working surface during the formation of at least some layers;
- wherein a region coated by the coating device is different for at least some of the layers formed;
- wherein the coating device is moved with a direction of movement over the last formed cross-section;
- and
- wherein, for at least some layers, the layer is formed over a last formed cross-section which has an extent which is less than an extent of the at least one cross-section formed prior to the last formed cross-section in the direction of movement.
A method of forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- supplying data descriptive of the object;
- containing a volume of material having a working surface;
- deriving a tailored coating region of the working surface for a layer including deriving combined extents of:
- (1) a region exposed when forming a last formed object cross-section, and (2) a region exposed when forming at least one object cross-section formed prior to forming the last formed object cross-section;
- forming a layer of material in preparation for forming a successive object cross-section, including moving a recoating device to aid in the formation of a coating over the tailored coating region;
- exposing the layer to synergistic stimulation according to the data descriptive of the object to form the successive object cross-section;
- and
- repeating said layer forming and exposing a plurality of times to form the at least portion of the three-dimensional object;
- wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers;
- wherein an extent of movement of the recoating device is different for at least some of the layers formed;
- and
- wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
A method of forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- forming a layer of building material in preparation for forming a successive object cross-section, including moving a recoating device over (1) a region exposed when forming a last-formed object cross-section, and (2) a region exposed when forming at least one cross-section formed prior to the last formed cross-section;
- and
- exposing the layer to synergistic stimulation to form the successive object cross-section;
- and
- repeating said forming and exposing a plurality of times to form the at least portion of the three-dimensional object;
- wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers;
- wherein an extent of movement of the recoating device is different for at least some of the layers formed;
- and
- wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
A method of forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- forming a layer of building material in preparation for forming a subsequent object cross-section, including:
- (1) moving a recoating device over a region exposed when forming a last-formed object cross-section, (2) locating the recoating device beyond a region to be exposed in forming a next cross-section of the object, and (3) locating the recoating device beyond the combined extents of (1) and (2) by a predetermined amount;
- exposing the layer to synergistic stimulation to form the successive object cross-section;
- and
- repeating said forming and exposing a plurality of times to form the at least portion of the three-dimensional object;
- wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers;
- wherein an extent of movement of the recoating device is different for at least some of the layers formed;
- and
- wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- a memory device for receiving data descriptive of the object;
- a container for holding a volume of material having a working surface;
- a computer configured to derive a tailored coating region of the working surface for a layer including deriving combined extents of:
- (1) a region exposed when forming a last formed object cross-section, and (2) a region exposed when forming at least one object cross-section formed prior to forming the last formed object cross-section;
- a recoating device for forming a layer of material in preparation for forming a successive object cross-section,
- a recoating device control system for moving the recoating device to aid in the formation of a coating over the tailored coating region;
- an exposure system for exposing the layer to synergistic stimulation according to the data descriptive of the object to form the successive object cross-section;
- and
- a control system for repeatedly operating the recoating device and exposure system a plurality of times to form the at least portion of the three-dimensional object;
- wherein the recoating device is controlled to move over less than the entire working surface during the process of forming at least some layers;
- wherein an extent of movement of the recoating device is different for at least some of the layers formed;
- and
- wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- a recoating device for forming a layer of building material in preparation for forming a successive object cross-section;
- a recoating device control system for moving the recoating device over:
- (1) a region exposed when forming a last-formed object cross-section, and (2) a region exposed when forming at least one cross-section formed prior to the last formed cross-section;
- and
- an exposure system for exposing the layer to synergistic stimulation to form the successive object cross-section;
- and
- a control system for repeatedly operating the recoating device and the exposure system a plurality of times to form the at least portion of the three-dimensional object;
- wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers;
- wherein an extent of movement of the recoating device is different for at least some of the layers formed;
- and
- wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- a recoating device for forming a layer of building material in preparation for forming a subsequent object cross-section;
- a recoating device control system for:
- (1) moving a recoating device over a region exposed when forming a last-formed object cross-section, (2) locating the recoating device beyond a region to be exposed in forming a next cross-section of the object, and (3) locating the recoating device beyond the combined extents of (1) and (2) by a predetermined amount;
- an exposure system for exposing the layer to synergistic stimulation to form the successive object cross-section;
- and
- a control system for repeatedly operating the recoating device and exposure system a plurality of times to form the at least portion of the three-dimensional object;
- wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers;
- wherein an extent of movement of the recoating device is different for at least some of the layers formed;
- and
- wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising:
- means for supplying data descriptive of the object;
- a container for containing a volume of material having a working surface;
- an applicator for forming layers of material over at least portions of previously formed object cross-sections, the applicator having a bottom opening located in proximity to the working surface;
- a vacuum pump coupled to the applicator for drawing up material from the working surface through the bottom opening and into the applicator;
- means for sweeping the applicator across at least a portion of at least some of the previously formed object cross-sections;
- and
- a source of synergistic stimulation for exposing the layers according to the descriptive data to form the at least portion of the object from a plurality of object cross-sections.
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising
- supplying data descriptive of the object;
- containing a volume of material having a working surface;
- locating an applicator having a bottom opening in proximity to the working surface;
- forming a meniscus of material between the applicator and working surface;
- using a vacuum pump to draw up material from the working surface into the applicator through the bottom opening thereby at least partially filling the applicator;
- forming a layer over at least a portion of a previously formed object cross-section including dispensing material from the applicator by sweeping the applicator across at least a portion of the previously formed object cross-section;
- exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form an object cross-section adhered to the previously formed object cross-section;
- and
- repeating said forming and exposing to form subsequent layers and cross-sections to form the at least portion of the object.
Dependencies are inferred from the claim text.