EP0429196A2
Expired / Lapsed
EP
⏱️ 0.0 years remaining
Improved stereolithographic construction techniques
Assignee: 3D Systems Inc
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Filing: 1990-10-30
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Granted: —
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Expires: 2010-10-30
Abstract
Abstract Improved methods for building stereolithographically-formed parts include providing skinned layers in more than the up- and down- facing features of the part, to methods for avoiding over-exposure of down-facing regions at points of intersection of exposing vectors, and to methods for determining skin thickness.
Inventors
- 👤 Paul Frances Jacobs
- 👤 Charles William Hull
- 👤 Dennis Rollette Smalley
- 👤 Joseph W. Allison
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-11-08 21:02
CPC Classifications
G; G03; G03F; G03F7/00; G03F7/70; G03F7/70375; B; B29; B29C; B29C64/00; B29C64/10; B29C64/106; B29C64/124; B29C64/129; B29C64/135; B29C64/40; B29C67/00; B29C67/02; G03F7/0037; G05; G05B; G05B2219/00; G05B2219/30; G05B2219/49; G05B2219/49013
Claims Analysis
Total Claims: 42
Claim 1
Independent Claim
164 words
A stereolithographic method of constructing an object by forming stacked layers of a medium solidified by exposure to synergistic stimulation applied in a pattern, comprising the steps of: identifying any up-facing regions, down-facing regions, and internal regions of a first layer; identifying any internal regions of a second layer; exposing any down-facing region of the first layer to synergistic stimulation to solidify substantially all area elements of the down-facing region; exposing any up-facing region of the first layer to synergistic stimulation to solidify substantially all area elements of the up-facing region; exposing at least a first portion of any internal region of the first layer to synergistic stimulation to solidify substantially all area elements first portion wherein the first portion has a width substantially greater than the width and length of the lines of the hatch pattern; and hatching a second portion of any internal region of a second layer by exposing the second portion to synergistic stimulation in lines of a hatch pattern.
Claim 2
Dependent Claim
164 words
A stereolithographic method of constructing an object by forming stacked layers of a medium solidified by exposure to synergistic stimulation applied in a pattern, comprising the steps of: identifying any up-facing regions, down-facing regions, and internal regions of a first layer; identifying any internal regions of a second layer; exposing any down-facing region of the first layer to synergistic stimulation to solidify substantially all area elements of the down-facing region; exposing any up-facing region of the first layer to synergistic stimulation to solidify substantially all area elements of the up-facing region; exposing at least a first portion of any internal region of the first layer to synergistic stimulation to solidify substantially all area elements first portion wherein the first portion has a width substantially greater than the width and length of the lines of the hatch pattern; and hatching a second portion of any internal region of a second layer by exposing the second portion to synergistic stimulation in lines of a hatch pattern.
Claim 3
Dependent Claim
21 words
The method of claim 1 further comprising the steps of solidifying a skin on internal regions of layers of the object.
Claim 4
Dependent Claim
18 words
The method of claim 1 further comprising the step of hatching the first portion of any internal region.
Claim 5
Dependent Claim
22 words
The method of claim 3 further comprising the step of hatching the first section with lines of an X/60/120 degree hatch pattern.
Claim 6
Dependent Claim
19 words
The method of claim 3 further comprising the step of hatching all regions of each layer of the object.
Claim 7
Dependent Claim
18 words
The method of claim 6 wherein all area elements of down-facing region are provided with a equivalent exposures.
Claim 8
Dependent Claim
92 words
A stereolithographic method of constructing an object by forming stacked layers of a medium solidified by exposure to synergistic stimulation applied in a pattern, comprising the steps of: providing skin fill on at least a portion of a layer by exposing the portion to a first exposure of synergistic stimulation comprising a first set of nonconsecutive parallel skin lines; and exposing the portion to a second exposure of synergistic stimulation comprising a second set of nonconsecutive parallel skin lines substantially interposed between and parallel to the first set of nonconsecutive parallel lines.
Claim 9
Dependent Claim
92 words
A stereolithographic method of constructing an object by forming stacked layers of a medium solidified by exposure to synergistic stimulation applied in a pattern, comprising the steps of: providing skin fill on at least a portion of a layer by exposing the portion to a first exposure of synergistic stimulation comprising a first set of nonconsecutive parallel skin lines; and exposing the portion to a second exposure of synergistic stimulation comprising a second set of nonconsecutive parallel skin lines substantially interposed between and parallel to the first set of nonconsecutive parallel lines.
Claim 10
Dependent Claim
31 words
The method of claim 7 wherein adjacent lines of the first set are sufficiently spaced apart to prevent lines of solidified medium of the first set from adhering to each other.
Claim 11
Dependent Claim
92 words
A stereolithographic method of constructing an object by forming stacked layers of a medium solidified by exposure to synergistic stimulation applied in a pattern, comprising the steps of: forming a skin on at least a portion of a layer by exposing the medium to synergistic stimulation comprising a first set of parallel skin lines; further solidifying the portion by exposing it to synergistic stimulation comprising at least one second set of parallel skin lines, said lines in said at least one second set being non-parallel to said lines in said first set.
Claim 12
Dependent Claim
92 words
A stereolithographic method of constructing an object by forming stacked layers of a medium solidified by exposure to synergistic stimulation applied in a pattern, comprising the steps of: forming a skin on at least a portion of a layer by exposing the medium to synergistic stimulation comprising a first set of parallel skin lines; further solidifying the portion by exposing it to synergistic stimulation comprising at least one second set of parallel skin lines, said lines in said at least one second set being non-parallel to said lines in said first set.
Claim 13
Dependent Claim
20 words
The method of claim 9 wherein the lines of the first set and second set are perpendicular to each other.
Claim 14
Dependent Claim
22 words
The method of claim 9 wherein the skin lines of at least one of the first set and second set are non-overlapping.
Claim 15
Dependent Claim
22 words
The method of claim 9 wherein the skin lines of at least one of the first set and second set are overlapping.
Claim 16
Dependent Claim
24 words
The method of claim 9 further comprising the step of hatching the layer prior to exposing the first and second sets of skin lines.
Claim 17
Dependent Claim
78 words
The method of claim 13 wherein the hatching comprises a first set of parallel hatch lines and a second set of parallel hatch lines, with the lines of the second set of hatch line not parallel to the lines of the first set of hatch lines, and the first set of hatch lines runs parallel to the first set of skin lines, and the second set of hatch lines runs parallel to the second set of skin lines.
Claim 18
Dependent Claim
23 words
The method of claim 13 wherein the hatch lines of the first set are perpendicular to the hatch lines of the second set.
Claim 19
Dependent Claim
100 words
A stereolithographic method of constructing an object by forming stacked layers of a medium solidified by exposure to synergistic stimulation applied in a pattern, comprising the steps of: solidifying a first skin on at least a first portion of a first layer by selectively exposing medium to synergistic stimulation comprising a first set of parallel skin lines; solidifying a second skin on at least a second portion of a second layer by selectively exposing medium to synergistic stimulation comprising at least a second set of parallel skin lines which are not parallel to the skin lines of the first set.
Claim 20
Dependent Claim
100 words
A stereolithographic method of constructing an object by forming stacked layers of a medium solidified by exposure to synergistic stimulation applied in a pattern, comprising the steps of: solidifying a first skin on at least a first portion of a first layer by selectively exposing medium to synergistic stimulation comprising a first set of parallel skin lines; solidifying a second skin on at least a second portion of a second layer by selectively exposing medium to synergistic stimulation comprising at least a second set of parallel skin lines which are not parallel to the skin lines of the first set.
Claim 21
Independent Claim
225 words
A method for reducing irregularities in cure depth of a region of a layer of an object made by stereolithography, comprising the steps of: at least partially solidifying a first portion of a region of a layer by exposing the first portion to synergistic stimulation comprising at least a first individual set of lines, which lines of each set are spaced apart from each other so that no direct adhesion occurs between material at least partially solidified in association with each individual set; at least partially solidifying a second portion of the region of the layer, which at least substantially includes all area elements not at least partially solidified in association with the at least first set, by exposing the second portion to synergistic stimulation comprising at least a second set of lines, wherein the lines of the at least second set result in a net exposure in area elements of material not at least partially solidified in association with the at least first set, wherein the combined exposure of the at least first set and the at least second set result in substantially the same exposure in the area elements which were at least partially solidified in association with the at least first set, wherein the lines of the second set are adhered to each other and to the lines of the first set.
Claim 22
Independent Claim
225 words
A method for reducing irregularities in cure depth of a region of a layer of an object made by stereolithography, comprising the steps of: at least partially solidifying a first portion of a region of a layer by exposing the first portion to synergistic stimulation comprising at least a first individual set of lines, which lines of each set are spaced apart from each other so that no direct adhesion occurs between material at least partially solidified in association with each individual set; at least partially solidifying a second portion of the region of the layer, which at least substantially includes all area elements not at least partially solidified in association with the at least first set, by exposing the second portion to synergistic stimulation comprising at least a second set of lines, wherein the lines of the at least second set result in a net exposure in area elements of material not at least partially solidified in association with the at least first set, wherein the combined exposure of the at least first set and the at least second set result in substantially the same exposure in the area elements which were at least partially solidified in association with the at least first set, wherein the lines of the second set are adhered to each other and to the lines of the first set.
Claim 23
Dependent Claim
24 words
The method of claim 17 wherein the lines in each individual set of the at least first individual set are parallel to each other.
Claim 24
Dependent Claim
43 words
The method of claim 18 wherein corresponding to each individual set of the at least first set is an individual set of the at least second set which has lines running parallel to the corresponding individual set of the at least first set.
Claim 25
Dependent Claim
25 words
The method of claim 19 wherein corresponding individual sets of the at least first set and at least second set do not overlap each other.
Claim 26
Independent Claim
157 words
A method for reducing irregularities in cure depth of a region of a layer of an object made by stereolithography, comprising the steps of: at least partially solidifying a first portion of a region of a layer by exposing the first portion to synergistic stimulation comprising a first set of lines spaced apart from each other so that no direct adhesion occurs between the lines; at least partially solidifying a second portion of the region of the layer, which at least substantially includes all area elements not at least partially solidified in association with the first set, by exposing the second portion to synergistic stimulation comprising a second set of lines, wherein the exposure of the second set when combined with the exposure of the first set result in substantially all area elements being given similar exposures, wherein the lines of the second set are adhered to each other and to the lines of the first set.
Claim 27
Independent Claim
157 words
A method for reducing irregularities in cure depth of a region of a layer of an object made by stereolithography, comprising the steps of: at least partially solidifying a first portion of a region of a layer by exposing the first portion to synergistic stimulation comprising a first set of lines spaced apart from each other so that no direct adhesion occurs between the lines; at least partially solidifying a second portion of the region of the layer, which at least substantially includes all area elements not at least partially solidified in association with the first set, by exposing the second portion to synergistic stimulation comprising a second set of lines, wherein the exposure of the second set when combined with the exposure of the first set result in substantially all area elements being given similar exposures, wherein the lines of the second set are adhered to each other and to the lines of the first set.
Claim 28
Independent Claim
234 words
A method for reducing irregularities in cure depth of a region of a layer of an object made by stereolithography, comprising the steps of: at least partially solidifying a first portion of a region of a layer by exposing the first portion to synergistic stimulation comprising a first set of lines spaced apart from each other so that no direct adhesion occurs between the lines, at least partially solidifying a second portion of the region of the layer by exposing the second portion to synergistic stimulation comprising a second set of lines spaced apart from each other so that no direct adhesion occurs between the lines of the second set, and wherein at least some individual area elements, exposed by the lines of the first set and the lines of the second set, receive a maximum exposure where they overlap; at least partially solidifying a third portion of the region of the layer, which at least substantially includes all area elements not receiving the maximum exposure resulting from the combined exposures of the first and second sets, by exposing the third portion to synergistic stimulation comprising a third set of lines, wherein the combined exposure of the first, second, and third sets results in substantially all area elements being given similar exposures, wherein the lines of the third set are adhered to each other and to the lines of the first and second sets.
Claim 29
Independent Claim
234 words
A method for reducing irregularities in cure depth of a region of a layer of an object made by stereolithography, comprising the steps of: at least partially solidifying a first portion of a region of a layer by exposing the first portion to synergistic stimulation comprising a first set of lines spaced apart from each other so that no direct adhesion occurs between the lines, at least partially solidifying a second portion of the region of the layer by exposing the second portion to synergistic stimulation comprising a second set of lines spaced apart from each other so that no direct adhesion occurs between the lines of the second set, and wherein at least some individual area elements, exposed by the lines of the first set and the lines of the second set, receive a maximum exposure where they overlap; at least partially solidifying a third portion of the region of the layer, which at least substantially includes all area elements not receiving the maximum exposure resulting from the combined exposures of the first and second sets, by exposing the third portion to synergistic stimulation comprising a third set of lines, wherein the combined exposure of the first, second, and third sets results in substantially all area elements being given similar exposures, wherein the lines of the third set are adhered to each other and to the lines of the first and second sets.
Claim 30
Independent Claim
288 words
A method for reducing irregularities in cure depth of a region of a layer of an object made by stereolithography, comprising the steps of: at least partially solidifying a first portion of a region of a layer by exposing the first portion to synergistic stimulation comprising a first set of lines spaced apart from each other so that no direct adhesion occurs between the lines; at least partially solidifying a second portion of the region of the layer by exposing the second portion to synergistic stimulation comprising a second set of lines spaced apart from each other so that no direct adhesion occurs between the lines of the second set; at least partially solidifying a third portion of the region of the layer by exposing the third portion to synergistic stimulation comprising a third set of lines spaced apart from each other so that no direct adhesion occurs between the lines of the third set, and wherein at least some individual area elements, exposed by the lines of the first set, the lines of the second set, and the lines of the third set, receive a maximum exposure where they overlap; at least partially solidifying a fourth portion of the region of the layer, which at least substantially includes all area elements not receiving the maximum exposure resulting from the combined exposures of the first, second, and third sets, by exposing the fourth portion to synergistic stimulation comprising a fourth set of lines, wherein the combined exposure of the first, second, third, and fourth sets results in substantially all area elements being given similar exposures, wherein the lines of the fourth set are adhered to each other and to the lines of the first, second, and third sets.
Claim 31
Independent Claim
288 words
A method for reducing irregularities in cure depth of a region of a layer of an object made by stereolithography, comprising the steps of: at least partially solidifying a first portion of a region of a layer by exposing the first portion to synergistic stimulation comprising a first set of lines spaced apart from each other so that no direct adhesion occurs between the lines; at least partially solidifying a second portion of the region of the layer by exposing the second portion to synergistic stimulation comprising a second set of lines spaced apart from each other so that no direct adhesion occurs between the lines of the second set; at least partially solidifying a third portion of the region of the layer by exposing the third portion to synergistic stimulation comprising a third set of lines spaced apart from each other so that no direct adhesion occurs between the lines of the third set, and wherein at least some individual area elements, exposed by the lines of the first set, the lines of the second set, and the lines of the third set, receive a maximum exposure where they overlap; at least partially solidifying a fourth portion of the region of the layer, which at least substantially includes all area elements not receiving the maximum exposure resulting from the combined exposures of the first, second, and third sets, by exposing the fourth portion to synergistic stimulation comprising a fourth set of lines, wherein the combined exposure of the first, second, third, and fourth sets results in substantially all area elements being given similar exposures, wherein the lines of the fourth set are adhered to each other and to the lines of the first, second, and third sets.
Claim 32
Independent Claim
269 words
A method for reducing irregularities in cure depth of a region of a layer of an object made by stereolithography, comprising the steps of: at least partially solidifying a first portion of a region of a layer by exposing the first portion to synergistic stimulation comprising a first set of lines spaced apart from each other so that no direct adhesion occurs between the lines, at least partially solidifying a second portion of the region of the layer by exposing the second portion to synergistic stimulation comprising a second set of lines spaced apart from each other so that no direct adhesion occurs between the lines of the second set, and wherein at least a portion of the lines of the first set and a portion of the lines of the second set adhere to each other, and wherein the lines of the first set do not overlap the lines of the second set, wherein at least some individual area elements exposed by the lines of at least one of the sets receive a maximum exposure; at least partially solidifying a third portion of the region of the layer, which at least substantially includes all area elements not receiving the maximum exposure resulting from the exposures of the first and second sets, by exposing the third portion to synergistic stimulation comprising a third set of lines, wherein the combined exposure of the first, second, and third sets results in substantially all area elements being given similar exposures, wherein the lines of the third set are adhered to each other and to the lines of the first and second sets.
Claim 33
Independent Claim
269 words
A method for reducing irregularities in cure depth of a region of a layer of an object made by stereolithography, comprising the steps of: at least partially solidifying a first portion of a region of a layer by exposing the first portion to synergistic stimulation comprising a first set of lines spaced apart from each other so that no direct adhesion occurs between the lines, at least partially solidifying a second portion of the region of the layer by exposing the second portion to synergistic stimulation comprising a second set of lines spaced apart from each other so that no direct adhesion occurs between the lines of the second set, and wherein at least a portion of the lines of the first set and a portion of the lines of the second set adhere to each other, and wherein the lines of the first set do not overlap the lines of the second set, wherein at least some individual area elements exposed by the lines of at least one of the sets receive a maximum exposure; at least partially solidifying a third portion of the region of the layer, which at least substantially includes all area elements not receiving the maximum exposure resulting from the exposures of the first and second sets, by exposing the third portion to synergistic stimulation comprising a third set of lines, wherein the combined exposure of the first, second, and third sets results in substantially all area elements being given similar exposures, wherein the lines of the third set are adhered to each other and to the lines of the first and second sets.
Claim 34
Independent Claim
114 words
A method for determining a solidification depth of at least a portion of a skin of a three-dimensional object being formed by stereolithography from a medium solidified by exposure of a set of spaced skin lines to a beam of synergistic stimulation having a scanning velocity, comprising the steps of: a) determining the power of the beam of synergistic stimulation; b) determining the spacing between the skin lines; c) determining the scanning velocity of the beam; d) calculating the exposure which the beam provides; e) specifying medium parameters of the medium relating solidification depth to exposure; and f) determining the solidification depth from the calculated exposure and the relationship between solidification depth and exposure.
Claim 35
Independent Claim
114 words
A method for determining a solidification depth of at least a portion of a skin of a three-dimensional object being formed by stereolithography from a medium solidified by exposure of a set of spaced skin lines to a beam of synergistic stimulation having a scanning velocity, comprising the steps of: a) determining the power of the beam of synergistic stimulation; b) determining the spacing between the skin lines; c) determining the scanning velocity of the beam; d) calculating the exposure which the beam provides; e) specifying medium parameters of the medium relating solidification depth to exposure; and f) determining the solidification depth from the calculated exposure and the relationship between solidification depth and exposure.
Claim 36
Dependent Claim
22 words
The method of claim 25 wherein the medium parameters are contained in a graph of exposure versus solidification depth for the medium.
Claim 37
Independent Claim
129 words
A method for selecting exposure parameters to provide a desired depth of a skin formed from a set of spaced skin lines on a layer of an object made stereolithographically by forming stacked layers of a fluid medium solidified by exposure to a beam of synergistic stimulation having a scanning velocity comprising the steps of: a) selecting the desired skin depth; b) specifying the medium parameters of the medium relating solidification depth to exposure; c) determining the exposure required to obtain the desired skin depth, using the material parameters of the medium which relate skin depth to exposure; d) specifying two of beam power, skin line spacing and scanning velocity; e) calculating the remaining unspecified parameter of step d) using the exposure and two parameters specified in step d).
Claim 38
Independent Claim
129 words
A method for selecting exposure parameters to provide a desired depth of a skin formed from a set of spaced skin lines on a layer of an object made stereolithographically by forming stacked layers of a fluid medium solidified by exposure to a beam of synergistic stimulation having a scanning velocity comprising the steps of: a) selecting the desired skin depth; b) specifying the medium parameters of the medium relating solidification depth to exposure; c) determining the exposure required to obtain the desired skin depth, using the material parameters of the medium which relate skin depth to exposure; d) specifying two of beam power, skin line spacing and scanning velocity; e) calculating the remaining unspecified parameter of step d) using the exposure and two parameters specified in step d).
Claim 39
Independent Claim
12 words
The method of any preceding claim, wherein the medium comprises a photopolymer.
Claim 40
Independent Claim
13 words
The method of any preceding claim, wherein the synergistic stimulation comprises UV light.
Claim 41
Independent Claim
32 words
The method of any preceding claim, further comprising the step of reducing any curl by using a technique selected from the group consisting of smalleys, rivets, webs, multipass and the combination thereof.
Claim 42
Independent Claim
12 words
The method of any preceding claim, wherein the medium comprises a powder.
References Cited (Backward Citations)
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