Method for manufacturing physical objects using precision stereolithography

In a system for fabricating a three-dimensional structure by means of stereolithography, said system including:

• a controllable source of light for generating a focused light beam at a selectable and variable location;
• a vat containing liquid photocurable material, said liquid having an upper surface on which said beam is brought to a focus;
• a horizontal platform immersed in said liquid photocurable material, said platform further being attached to a support member and the elevation of said platform being controllably movable in the vertical direction by means of said support member;
• platform control means attached to said support member, for controlling and varying the elevation of said platform;
• and
• a computer connected to said platform control means and said controllable source of light, said computer having a memory containing control software and data files for controlling said platform control means and said controllable source of light, said computer further containing design software for designing said three-dimensional structure;
• an improved method for fabricating a three-dimensional structure by means of stereolithography, comprising the steps of:
• providing a source of light as said light source that is substantially smaller and lower in power, and that generates a smaller focused spot, than light sources conventionally used in stereolithographic fabrication processes;
• modifying the parameters and variables in said data files to fabricate a structure in said system with said light source that is substantially smaller and lower in power and generates a smaller focused spot, with substantially higher precision than 10 mils;
• and
• carrying out the stereolithographic fabrication process utilizing said light source that is substantially smaller and lower in power and generates a smaller focused spot, and said modified parameters and variables to fabricate said three-dimensional structure.