Apparatus and method for forming three-dimensional objects using linear solidification

A method of making a three-dimensional object from a solidifiable material comprising a photohardenable material, comprising:

• traversing an ultraviolet laser diode, a collimating lens, a cylindrical lens, two F-Theta lenses and a rotating polygonal mirror in a first direction across a source of the solidifiable material, wherein the ultraviolet laser diode and rotating polygonal mirror are spaced apart by a first fixed distance, the ultraviolet laser diode and the collimating lens are spaced apart by a second fixed distance, the ultraviolet laser diode and the cylindrical lens are spaced apart by a third fixed distance, the two F-theta lenses are located between the rotating polygonal mirror and the solidifiable material, the cylindrical lens is located between the ultraviolet laser diode and the rotating polygonal mirror, the collimating lens is located between the ultraviolet laser diode and the cylindrical lens, the collimating lens is coated with an anti-reflective coating, the rotating polygonal mirror comprises a plurality of facets, and each facet has rotational positions that correspond to a location on the solidifiable material along a second direction;
• selectively activating the ultraviolet laser diode while one of the facets is in optical communication with the ultraviolet laser diode and is at one of the rotational positions that correspond to a location on the solidifiable material along the second direction, thereby transmitting solidification energy from the ultraviolet laser diode through the collimating lens and the cylindrical lens to the facet;
• and
• deflecting received solidification energy from the facet, through at least one lens, and to the source of solidifiable material.