Process for the production of a three-dimensional object with an improved separation of hardened material layers from a construction plane

A device for the production of a three-dimensional object by layer-wise solidification of a photo-polymerizable resin in a basin by means of a planar or essentially planar construction/reference plane, at which the photo-polymerizable resin, which is contained in a liquid material, is to be hardened layer-wise by electromagnetic irradiation, wherein the construction/reference plane is formed by an elastic film, characterized in that the film is fixed in a frame, and the height position of the frame with the film in the basin containing the liquid material is adjustable such that the lower side of the film is capable of being in contact with the material permanently during the whole construction process, and that, for planarizing the film in the construction/reference plane, the device comprises the following:

• a press element which is placeable and movable over the upper side of the film portion which lies above a construction zone of the three-dimensional object,
• a plate or mat which is formed of one or more parts and comprises multiple elongated portions, on at least one of which portions rib(s) or protrusion(s) is formed in the longitudinal direction, and that by rolling or sliding said press element over the plate or mat the respective portions thereof, optionally certain portions concurrently, may press successively against the film to thereby establish a planar or essentially planar construction/reference plane.

A device for forming a three-dimensional object by exposing a solidifiable material contained in a basin to electromagnetic radiation, the device comprising:

• a frame having an interior and first and second sides defining a width, wherein the first and second sides are spaced apart by a fixed distance along the frame width;
• a film attached to the first and second sides of the frame and disposed in the interior of the frame, wherein the film has a first surface facing the solidifiable material, a second surface facing away from the solidifiable material, the film is attached to the first side of the frame at a location defining a first height relative to the basin, and the film is attached to the second side of the frame defining a second height relative to the basin, and the first height is the same as the second height;
• and
• a roll engaging the second surface of the film and moveable along the second surface of the film in the direction of the width.

A device for forming a three-dimensional object by exposing a solidifiable material to electromagnetic radiation, the device comprising:

• an object carrier moveable in a vertical direction;
• a working area positioned to receive solidification energy from a source of solidification energy;
• a film having a surface, a first location and a second location defining a width between the first location and the second location, and a first portion disposed in the working area, wherein during an entire object construction process, the first portion of the film remains disposed in the working area;
• a film separation member, wherein the film separation member is movable along the width of the film from a first position to a second position to separate the film from the three- dimensional object, and when the film separation member is in the first position, the film is spaced apart from the vertical position of the object carrier by a first distance, when the film separation member is in the second position, the film is spaced apart from the vertical position of the object carrier by a second distance, and the first distance is the same as the second distance.