Method and device for producing a three-dimensional object, and computer and data carrier useful therefor

A method for producing a three-dimensional object by solidification of a material solidifiable under the action of electromagnetic radiation by means of energy input via an imaging unit comprising a predetermined number of discrete imaging elements (pixels), comprising the steps of:

• a) providing a stack of bitmap data from a three-dimensional volume completely or partially enclosing a three-dimensional model of at least a part of the three-dimensional object to be produced, wherein the stack of bitmap data had been generated by a process including:
• superimposing a grid raster over the three-dimensional volume completely or partially enclosing the three-dimensional model,
• determining whether there is an overlap with the three-dimensional model, and
• setting bitmap data to an energy output status where an overlap has been determined, or setting bitmap data to a status of no energy output where no overlap has been determined;
• and
• b) performing solidification with exposure using a bitmap mask formed from the stack of bitmap data provided in step a),
• wherein the provided stack of bitmap data includes a stack of multiple bitmaps for an XY plane, and raster points of bitmaps representing pixels in the Z direction are set to an energy output status in the region between an entrance point or entrance area and an exit point of a line or area respectively projected from the corresponding grid raster in the Z dimension through the three-dimensional model.

A computer-readable medium having instructions stored for execution by a computer processor to perform a method comprising:

• accessing a three-dimensional model of a three-dimensional object that is to be produced by solidification of a material solidifiable under the action of electromagnetic radiation by means of energy input via an imaging unit comprising a predetermined number of discrete imaging elements (pixels);
• and
• generating a stack of bitmap data from a three-dimensional volume completely or partially enclosing the three-dimensional model or at least a part thereof, the generating further including:
• superimposing a grid raster over the three-dimensional volume completely or partially enclosing the three-dimensional model;
• determining whether there is an overlap with the three-dimensional model, and
• setting bitmap data to an energy output status where an overlap has been determined, or setting bitmap data to a status of no energy output where no overlap has been determined.

An apparatus for producing a three-dimensional object by solidification of a material solidifiable under the action of electromagnetic radiation by means of energy input, the apparatus comprising:

• an imaging unit providing the energy input and comprising a predetermined number of discrete imaging elements (pixels);
• a storage medium containing:
• a stack of bitmap data, which are generated from a three-dimensional volume that includes at least a part of a three-dimensional model of the object to be produced, each bitmap data comprising energy output level information such that pixels corresponding to a location within the three-dimensional model are set to an energy output status, and pixels corresponding to a location outside the three-dimensional model are set to a status of no energy output, and
• instructions for generating a bitmap mask based on bitmap data of the stack for controlling the image unit;
• a basin for a photohardening material;
• and
• a carrier for carrying the object to be produced within the basin at a processing level in a projection region of the bitmap mask of the imaging unit.

A method of producing a three-dimensional object by solidification of a material solidifiable under the action of electromagnetic radiation by means of energy input comprising:

• generating a stack of bitmap data from a three-dimensional volume completely or partially enclosing a three-dimensional model of the object or at least a part thereof, the generating step further including:
• superimposing a grid raster over the three-dimensional volume completely or partially enclosing the three-dimensional model,
• determining whether there is an overlap with the three-dimensional model, and
• setting bitmap data to an energy output status where an overlap has been determined or setting bitmap data to a status of no energy output where no overlap has been determined;
• controlling an imaging unit of a device for producing the three-dimensional object by creating a bitmap mask from bitmap data of the stack;
• and
• projecting the created bitmap mask onto a processing level above a carrier carrying the object provided within a basin filled with the photo hardening material.