US5184307A — Method and apparatus for production of high resol…

Claim 1

Independent Claim 141 words

A system for producing a three-dimensional object comprising: means for deriving data descriptive of cross-sections of the object from data descriptive of the object, including at least some skin data descriptive of at least part of at least one cross-section; a container containing at least in part material capable of selective physical transformation upon exposure to the synergistic stimulation; means for successively providing layers of said material; means for selectively exposing said layers of said material to said synergistic stimulation in accordance with said data descriptive of said cross-sections of said object to form successive object cross-sections; and control means for obtaining said cross-sectional descriptive data from said deriving means, and utilizing said data to control said means for successively providing said layers, and said means for selectively exposing said layers, to produce said three-dimensional object comprising said successively formed cross-sections.

Claim 2

Independent Claim 141 words

A system for producing a three-dimensional object comprising: means for deriving data descriptive of cross-sections of the object from data descriptive of the object, including at least some skin data descriptive of at least part of at least one cross-section; a container containing at least in part material capable of selective physical transformation upon exposure to the synergistic stimulation; means for successively providing layers of said material; means for selectively exposing said layers of said material to said synergistic stimulation in accordance with said data descriptive of said cross-sections of said object to form successive object cross-sections; and control means for obtaining said cross-sectional descriptive data from said deriving means, and utilizing said data to control said means for successively providing said layers, and said means for selectively exposing said layers, to produce said three-dimensional object comprising said successively formed cross-sections.

Claim 3

Dependent Claim 26 words

The system of claim 1, wherein said deriving means derives at least some flat skin data descriptive of at least part of at least one cross-section.

Claim 4

Dependent Claim 26 words

The system of claim 1, wherein said deriving means derives at least some near-flat skin data descriptive of at least part of at least one cross-section.

Claim 5

Dependent Claim 26 words

The system of claim 1, wherein said deriving means derives at least some up-facing skin data descriptive of at least part of at least one cross-section.

Claim 6

Dependent Claim 26 words

The system of claim 1, wherein said deriving means derives at least some down-facing skin data descriptive of at least part of at least one cross-section.

Claim 7

Independent Claim 176 words

A system for producing a three-dimensional object comprising: means for producing synergistic stimulation; means for deriving data descriptive of cross-sections of the object from data descriptive of the object, wherein said synergistic stimulation induces a corresponding cure width, and said deriving means derives at least some data descriptive of at least part of at least one cross-section and then offsets at least some of said data to at least partly compensate for said cure width; a container containing at least in part material capable of selective physical transformation upon exposure to the synergistic stimulation; means for successively providing layers of said material; means for selectively exposing said layers of said material to said synergistic stimulation in accordance with said data descriptive of said cross-sections of said object to form successive object cross-sections; and control means for obtaining said cross-sectional descriptive data from said deriving means, and utilizing said data to control said means for successively providing said layers, and said means for selectively exposing said layers, to produce said three-dimensional object comprising said successively formed cross-sections.

Claim 8

Independent Claim 176 words

A system for producing a three-dimensional object comprising: means for producing synergistic stimulation; means for deriving data descriptive of cross-sections of the object from data descriptive of the object, wherein said synergistic stimulation induces a corresponding cure width, and said deriving means derives at least some data descriptive of at least part of at least one cross-section and then offsets at least some of said data to at least partly compensate for said cure width; a container containing at least in part material capable of selective physical transformation upon exposure to the synergistic stimulation; means for successively providing layers of said material; means for selectively exposing said layers of said material to said synergistic stimulation in accordance with said data descriptive of said cross-sections of said object to form successive object cross-sections; and control means for obtaining said cross-sectional descriptive data from said deriving means, and utilizing said data to control said means for successively providing said layers, and said means for selectively exposing said layers, to produce said three-dimensional object comprising said successively formed cross-sections.

Claim 9

Independent Claim 122 words

A method for producing a three-dimensional object comprising the steps of: deriving data descriptive of cross-sections of the object from data descriptive of the object including deriving at least some skin data descriptive of at least part of at least one cross-section; producing synergistic stimulation; containing a material capable of selective physical transformation upon exposure to the synergistic stimulation; successively producing layers of said material; selectively exposing said layers of said material to said synergistic stimulation in accordance with said data descriptive of said cross-sections of said object to successively form object cross-sections; and utilizing the cross-sectional descriptive data to control said successive producing, and selective exposing steps set forth above to produce said three-dimensional object comprising said successively formed object cross-sections.

Claim 10

Independent Claim 122 words

A method for producing a three-dimensional object comprising the steps of: deriving data descriptive of cross-sections of the object from data descriptive of the object including deriving at least some skin data descriptive of at least part of at least one cross-section; producing synergistic stimulation; containing a material capable of selective physical transformation upon exposure to the synergistic stimulation; successively producing layers of said material; selectively exposing said layers of said material to said synergistic stimulation in accordance with said data descriptive of said cross-sections of said object to successively form object cross-sections; and utilizing the cross-sectional descriptive data to control said successive producing, and selective exposing steps set forth above to produce said three-dimensional object comprising said successively formed object cross-sections.

Claim 11

Dependent Claim 24 words

The method of claim 7, further comprising deriving at least some flat skin data descriptive of at least part of at least one cross-section.

Claim 12

Dependent Claim 20 words

The method of claim 7, further comprising deriving at least some near-flat skin data descriptive of at least one cross-section.

Claim 13

Dependent Claim 20 words

The method of claim 7, further comprising deriving at least some up-facing skin data descriptive of at least one cross-section.

Claim 14

Dependent Claim 20 words

The method of claim 7, further comprising deriving at least some down-facing skin data descriptive of at least one cross-section.

Claim 15

Independent Claim 147 words

A method for producing a three-dimensional object comprising the steps of: producing synergistic stimulation, wherein said synergistic stimulation induces a corresponding cure width; deriving data descriptive of cross-sections of the object from data descriptive of the object, including deriving at least some data descriptive of at least part of at least one cross-section, and offsetting at least some of said data to at least partly compensate for said cure width; containing a material capable of selective physical transformation upon exposure to the synergistic stimulation; successively producing layers of said material; selectively exposing said layers of said material to said synergistic stimulation in accordance with said data descriptive of said cross-sections of said object to successively form object cross-sections; and utilizing the cross-sectional descriptive object to control said successive producing, and selective exposing steps set forth above to produce said three-dimensional object comprising said successively formed object cross-sections.

Claim 16

Independent Claim 147 words

A method for producing a three-dimensional object comprising the steps of: producing synergistic stimulation, wherein said synergistic stimulation induces a corresponding cure width; deriving data descriptive of cross-sections of the object from data descriptive of the object, including deriving at least some data descriptive of at least part of at least one cross-section, and offsetting at least some of said data to at least partly compensate for said cure width; containing a material capable of selective physical transformation upon exposure to the synergistic stimulation; successively producing layers of said material; selectively exposing said layers of said material to said synergistic stimulation in accordance with said data descriptive of said cross-sections of said object to successively form object cross-sections; and utilizing the cross-sectional descriptive object to control said successive producing, and selective exposing steps set forth above to produce said three-dimensional object comprising said successively formed object cross-sections.

Claim 17

Independent Claim 191 words

A system for producing a three-dimensional object comprising: means for deriving data descriptive of cross-sections of the object from data descriptive of the object, said data comprising a plurality of datum, and each datum comprising at least a beginning endpoint and an ending endpoint and representing a path to be taken by a beam of synergistic stimulation between the beginning and ending endpoints; means for producing said beam of said synergistic stimulation; a container containing, at least in part, material capable of selective physical transformation upon exposure to the beam of synergistic stimulation; means for successively producing layers of said material; means for successively exposing said layers of said material to said beam of synergistic stimulation in accordance with said data descriptive of said cross-sections of said object to successively form object cross-sections, the beginning and ending endpoints of each datum of said data being derived before the beam of synergistic stimulation begins tracing the path represented by the datum; and control means for controlling said means for successively producing said layers, and said means for selectively exposing said layers, to produce said three-dimensional object comprising said successively formed object cross-sections.

Claim 18

Independent Claim 191 words

A system for producing a three-dimensional object comprising: means for deriving data descriptive of cross-sections of the object from data descriptive of the object, said data comprising a plurality of datum, and each datum comprising at least a beginning endpoint and an ending endpoint and representing a path to be taken by a beam of synergistic stimulation between the beginning and ending endpoints; means for producing said beam of said synergistic stimulation; a container containing, at least in part, material capable of selective physical transformation upon exposure to the beam of synergistic stimulation; means for successively producing layers of said material; means for successively exposing said layers of said material to said beam of synergistic stimulation in accordance with said data descriptive of said cross-sections of said object to successively form object cross-sections, the beginning and ending endpoints of each datum of said data being derived before the beam of synergistic stimulation begins tracing the path represented by the datum; and control means for controlling said means for successively producing said layers, and said means for selectively exposing said layers, to produce said three-dimensional object comprising said successively formed object cross-sections.

Claim 19

Dependent Claim 45 words

The system of claim 13, wherein said data descriptive of the object comprises at least some polygons having vertices substantially spanning a surface of the object, and said deriving means rounds at least some of said vertices to slicing planes spaced along a slicing axis.

Claim 20

Dependent Claim 48 words

The system of claim 13, wherein said data descriptive of said object comprises at least some polygons having vertices substantially spanning a surface of the object, and said deriving means rounds at least some of said vertices to planes offset from slicing planes spaced along a slicing axis.

Claim 21

Dependent Claim 26 words

The system of claim 13, wherein said driving means derives at least some of said data which describes at least one cross-section having a variable thickness.

Claim 22

Dependent Claim 51 words

The system of claim 13, wherein at least one cross-section has a border surrounding an interior and said deriving means first derives data descriptive of said border of said at least one cross-section, and then derives data descriptive of said interior of said at least one cross-section utilizing a fill parameter.

Claim 23

Dependent Claim 25 words

The system of claim 13, wherein said deriving means derives at least some skin data descriptive of at least part of at least one cross-section.

Claim 24

Dependent Claim 26 words

The system of claim 13, wherein said deriving means derives at least some flat skin data descriptive of at least part of at least one cross-section.

Claim 25

Dependent Claim 26 words

The system of claim 13, wherein said deriving means derives at least some near-flat skin data descriptive of at least part of at least one cross-section.

Claim 26

Dependent Claim 26 words

The system of claim 13, wherein said deriving means derives at least some up-facing skin data descriptive of at least part of at least one cross-section.

Claim 27

Dependent Claim 26 words

The system of claim 13, wherein said deriving means derives at least some down-facing skin data descriptive of at least part of at least one cross-section.

Claim 28

Dependent Claim 20 words

The system of claim 13, wherein said deriving means scales at least some of said data descriptive of said cross-sections.

Claim 29

Dependent Claim 25 words

The system of claim 13, wherein said deriving means derives at least some cross-hatch data descriptive of at least part of at least one cross-section.

Claim 30

Dependent Claim 54 words

The system of claim 13, wherein said beam of synergistic stimulation induces a corresponding cure width, and said deriving means derives at least some vector data descriptive of at least part of at least one cross-section, and offsets at least some of said vector data to at least partly compensate for said cure width.

Claim 31

Dependent Claim 38 words

The system of claim 13, wherein said deriving means derives at least some vector data descriptive of at least one cross-section, and orders said vector data into blocks of vector data descriptive of said at least one cross-section.

Claim 32

Dependent Claim 25 words

The system of claim 13, wherein said deriving means derives at least some boundary data descriptive of at least part of at least one cross-section.

Claim 33

Dependent Claim 76 words

The system of claim 13 wherein at least one cross-section has a boundary encircling an internal portion, and the deriving means derives the data descriptive of the cross-sections by first generating data descriptive of the boundary of the at least one cross-section from the object descriptive data, and then mathematically generating data descriptive of the internal portion of the at least one cross-section from the data descriptive of the boundary of the at least one cross-section.

Claim 34

Dependent Claim 82 words

The system of claim 13 wherein at least one cross-section has a boundary encircling an internal portion, and the deriving means derives vector data descriptive of the at least one cross-section, by first generating boundary vector data descriptive of the boundary of the at least one cross-section from the object descriptive data, and then generating internal vector data descriptive of the internal portion of the at least one cross-section in a manner which is substantially resistant to misplacement of internal vector data.

Claim 35

Dependent Claim 45 words

The system of claim 13, wherein said data descriptive of the object comprises polygons substantially spanning a surface of the object, the polygons having vertices, and said deriving means rounds at least some of said polygon vertices to slicing planes spaced along a slicing axis.

Claim 36

Dependent Claim 48 words

The system of claim 13, wherein said data descriptive of the object comprises polygons substantially spanning a surface of the object, the polygons having vertices, and said deriving means rounds at least some of said polygon vertices to planes offset from slicing planes spaced along a slicing axis.

Claim 37

Independent Claim 174 words

A system for producing a high-resolution reproduction of an object made up of stacked cross-sections of cured polymer, the system comprising: converting means for converting CAD/CAM data descriptive of the object into data descriptive of cross-sections of the object; laser means for producing a laser beam; directing means for controllably directing the laser beam to draw a cross-section of the object using said cross-sectional data on the surface of a layer of liquid photopolymer, which layer of liquid photopolymer is situated with respect to already-cured stacked cross-sections of cured polymer such that the layer of liquid photopolymer cures to form a cross-section which adheres to the already-cured stacked cross-sections; situating means for controllably situating the already cured stacked cross-sections with respect to the layer of liquid photopolymer; and control means coupled to the converting means, the directing means, and the situating means for a) obtaining the cross-sectional data; b) using said data to control the directing means and the situating means to form the stacked cross-sectional reproduction of the object out of cured photopolymer.

Claim 38

Independent Claim 174 words

A system for producing a high-resolution reproduction of an object made up of stacked cross-sections of cured polymer, the system comprising: converting means for converting CAD/CAM data descriptive of the object into data descriptive of cross-sections of the object; laser means for producing a laser beam; directing means for controllably directing the laser beam to draw a cross-section of the object using said cross-sectional data on the surface of a layer of liquid photopolymer, which layer of liquid photopolymer is situated with respect to already-cured stacked cross-sections of cured polymer such that the layer of liquid photopolymer cures to form a cross-section which adheres to the already-cured stacked cross-sections; situating means for controllably situating the already cured stacked cross-sections with respect to the layer of liquid photopolymer; and control means coupled to the converting means, the directing means, and the situating means for a) obtaining the cross-sectional data; b) using said data to control the directing means and the situating means to form the stacked cross-sectional reproduction of the object out of cured photopolymer.

Claim 39

Dependent Claim 21 words

The system of claim 32 wherein the reproduction is within a tolerance of plus or minus 50 mils of the object.

Claim 40

Dependent Claim 21 words

The system of claim 33 wherein the reproduction is within a tolerance of plus or minus 5 mils of the object.

Claim 41

Dependent Claim 44 words

The system of claim 32 wherein the converting means converts the CAD/CAM data into vector data for at least one cross-section of the object, which vector data is used to control the movement of the laser beam on the surface of the liquid photopolymer.

Claim 42

Dependent Claim 54 words

The system of claim 35 wherein the vector data for at least one cross-section comprises a selected one of border vector data descriptive of the border of the cross-section, skin vector data descriptive of any outward surface portion of the cross-section, and hatch vector data descriptive of any interior solid portion of the cross-section.

Claim 43

Dependent Claim 37 words

The system of claim 36 wherein the skin vector data comprises flat skin vector data descriptive of flat outward surfaces on the cross-section, and near flat skin vector data descriptive of slanted outward surfaces on the cross-section.

Claim 44

Dependent Claim 55 words

The system of claim 35 wherein the vector data for said at least one cross-section is representative of a plurality of vectors, wherein each vector is comprised of a head and a tail endpoint, and a direction which points from the tail to the head endpoint, and the vector data further includes vector orientation information.

Claim 45

Dependent Claim 56 words

The system of claim 38 wherein the vector data is hatch vector data which comprises data representative of a selected one of vectors pointing in the X-direction, vectors pointing in the Y-direction, vectors pointing in both the X- and a Y-directions, and vectors pointing in directions which are 60 degrees and 120 degrees from the X-direction.

Claim 46

Dependent Claim 33 words

The system of claim 35 wherein the vector data is skin vector data which comprises data representative of a selected one of vectors pointing in the X-direction, and vectors pointing in the Y-direction.

Claim 47

Dependent Claim 27 words

The system of claim 35 wherein the vector data is border vector data which is representative of a plurality of border vectors situated to form a loop.

Claim 48

Dependent Claim 41 words

The system of claim 35 wherein the vector data comprises border vector data and a selected one of hatch and skin vector data, wherein the selected one of said hatch and skin vector data is generated from the border vector data.

Claim 49

Dependent Claim 75 words

The system of claim 42 wherein the border vector data includes border vector orientation information, and wherein the selected one of said hatch and skin vector data is generated by overlapping the border vector data with a plurality of spaced paths, and starting and stopping the generation of the selected one of said hatch and skin vector data at the intersection of a path with the border vector data, utilizing the border vector orientation information.

Claim 50

Dependent Claim 19 words

The system of claim 32 wherein the CAD/CAM data comprises a plurality of polygons which substantially surface the object.

Claim 51

Dependent Claim 55 words

The system of claim 44 wherein the CAD/CAM data is overlayed with a plurality of spaced slicing planes, wherein each slicing plane comprises a gird of spaced points, and wherein at least one polygon vertex is rounded to at least one of said points on any of said planes such that rounding error is minimized.

Claim 52

Dependent Claim 14 words

The system of claim 45 wherein the spacing between the slicing planes is variable.

Claim 53

Dependent Claim 14 words

The system of claim 44 wherein the CAD/CAM data also includes polygon orientation information.

Claim 54

Dependent Claim 44 words

The system of claim 45 wherein the rounding of the vertices of at least one polygon causes the flipping of at least one polygon and the system detects and corrects for the flipping of the at least one polygon utilizing the polygon orientation information.

Claim 55

Dependent Claim 48 words

The system of claim 44 wherein the CAD/CAM data is overlayed with a plurality of slicing planes spaced along a slicing axis, and the system derives border vector data for at least one cross-section from the intersection of at least one slicing plane with at least one polygon.

Claim 56

Dependent Claim 59 words

The system of claim 44 wherein the CAD/CAM data is overlayed with a plurality of planes offset from slicing planes spaced along a slicing axis, and the system drives border vector data for at least one cross-section from the intersection of at least one plane, which is offset from at least one slicing plane, with at least one polygon.

Claim 57

Dependent Claim 28 words

The system of claim 35 wherein the vector data is used to produce an oversized reproduction of an object, which reproduction is sanded down in a post-processing step.

Claim 58

Dependent Claim 32 words

The system of claim 35 wherein the vector data is used to produce an undersized reproduction of an object, which reproduction is coated with liquid photopolymer and cured in a post-processing step.

Claim 59

Dependent Claim 43 words

The system of claim 35 wherein the vector data is an average of the vector data of claims 51 and 52, which vector data is used to produce a reproduction of an object which is not sanded or filled in a post-processing step.

Claim 60

Dependent Claim 21 words

The system of claim 38 wherein the vector data is border vector data which is selectively offset for beam width compensation.

Claim 61

Dependent Claim 51 words

The system of claim 54 wherein the border vector data represents a loop of border vectors, and wherein the endpoints of the border vectors in the loop are successively offset to compensate for cure width by approximately one-half the cure width in a direction determined by utilizing the vector orientation information.

Claim 62

Dependent Claim 24 words

The system of claim 55 wherein the cure width is determined automatically by the system, and used for beam width compensation without manual intervention.

Claim 63

Dependent Claim 62 words

The system of claim 55 wherein the endpoints of the border vectors in a loop are successively offset by about one-half of the cure width, wherein the border vectors are then recomputed and pairwise checked for crossover with the other border vectors in the loop, and wherein the offsetting of the endpoints is backed up to eliminate crossover if it is detected.

Claim 64

Dependent Claim 130 words

A process for high resolution reproduction of an object, made up of stacked cross-sections of cured photopolymer, comprising the steps of: converting CAD/CAM data descriptive of the object, and comprising a plurality of triangles which substantially surface the object, wherein substantially all of said plurality of triangles have vertices which join other triangles only at their vertices, into vector data descriptive of cross-sections of the object; directing a laser beam to successively draw cross-sections on the surface of layers of liquid photopolymer using said descriptive cross-sectional data, which layers are situated with respect to already-cured stacked cross-sections which adhere to the already cured cross-sections; and successively situating the already-cured stacked cross-sections with respect to said layers of liquid photopolymer; wherein said reproduction is formed from said successively formed object cross-sections.

Claim 65

Dependent Claim 130 words

A process for high resolution reproduction of an object, made up of stacked cross-sections of cured photopolymer, comprising the steps of: converting CAD/CAM data descriptive of the object, and comprising a plurality of triangles which substantially surface the object, wherein substantially all of said plurality of triangles have vertices which join other triangles only at their vertices, into vector data descriptive of cross-sections of the object; directing a laser beam to successively draw cross-sections on the surface of layers of liquid photopolymer using said descriptive cross-sectional data, which layers are situated with respect to already-cured stacked cross-sections which adhere to the already cured cross-sections; and successively situating the already-cured stacked cross-sections with respect to said layers of liquid photopolymer; wherein said reproduction is formed from said successively formed object cross-sections.

Claim 66

Dependent Claim 169 words

A process for high resolution reproduction of an object, made up of stacked cross-sections of cured photopolymer, comprising the steps of: converting CAD/CAM data descriptive of the object, and comprising a plurality of polygons which substantially surface the object, into data descriptive of cross-sections of the object, which data includes at least some vector data, said converting step including generating a selected one of border vector data descriptive of the border of at least one cross-section, hatch vector data descriptive of an interior solid of at least one cross-section, and skin vector data descriptive of an exterior surface of at least one cross-section; directing a laser beam to successively draw cross-sections on the surface of layers of liquid photopolymer using said descriptive cross-sectional data, which layers are situated with respect to already-cured stacked, cross-sections so that the layers cure to successively form cross-sections; and successively situating the already-cured stacked cross-sections with respect to said layers of liquid photopolymer; wherein said reproduction is formed from said successively formed object cross-sections.

Claim 67

Dependent Claim 169 words

A process for high resolution reproduction of an object, made up of stacked cross-sections of cured photopolymer, comprising the steps of: converting CAD/CAM data descriptive of the object, and comprising a plurality of polygons which substantially surface the object, into data descriptive of cross-sections of the object, which data includes at least some vector data, said converting step including generating a selected one of border vector data descriptive of the border of at least one cross-section, hatch vector data descriptive of an interior solid of at least one cross-section, and skin vector data descriptive of an exterior surface of at least one cross-section; directing a laser beam to successively draw cross-sections on the surface of layers of liquid photopolymer using said descriptive cross-sectional data, which layers are situated with respect to already-cured stacked, cross-sections so that the layers cure to successively form cross-sections; and successively situating the already-cured stacked cross-sections with respect to said layers of liquid photopolymer; wherein said reproduction is formed from said successively formed object cross-sections.

Claim 68

Dependent Claim 94 words

The process of claim 59 wherein the converting step comprises the substeps of: overlaying the CAD/CAM data with a plurality of spaced slicing planes, wherein at least one slicing plane comprises a grid of spaced points, wherein at least one polygon has vertices, and wherein at least one polygonal vertex is rounded to at least one of said points on any of said planes such that rounding error is minimized; and generating vector data descriptive of at least one cross-section utilizing the intersection of at least one slicing plane with at least one polygon.

Claim 69

Dependent Claim 14 words

The process of claim 60 wherein the spacing of the slicing planes is variable.

Claim 70

Dependent Claim 38 words

The process of claim 60 wherein the rounding of the at least one polygonal vertex causes the flipping of at least one polygon, and the generating substep includes correcting for the flipping of the at least one polygon.

Claim 71

Dependent Claim 28 words

The process of claim 59 wherein the vector data is border vector data derived from the intersection of at least one slicing plane with at least one polygon.

Claim 72

Dependent Claim 39 words

The process of claim 59 wherein the vector data is border vector data derived from the intersection of at least one plane offset from at least one slicing plane spaced along a slicing axis, with at least one polygon.

Claim 73

Dependent Claim 36 words

The process of claim 59 further including a post-processing step wherein the CAD/CAM data is converted into vector data for producing an oversized reproduction of an object, which reproduction is sanded down in said post-processing step.

Claim 74

Dependent Claim 40 words

The process of claim 59 further including a post-processing step wherein the CAD/CAM data is converted into vector data for producing an undersized reproduction of an object, which reproduction is coated with liquid photopolymer and cured in said post-processing step.

Claim 75

Dependent Claim 33 words

The process of claim 59 wherein the vector data is the average of the vector data of claims 65 and 66, and the reproduction is not filled or sanded in a post-processing step.

Claim 76

Dependent Claim 36 words

The process of claim 59 wherein the vector data is descriptive of vectors, each having a head and a tail endpoint, a direction pointing from the tail to the head endpoint, and includes vector orientation information.

Claim 77

Dependent Claim 38 words

The process of claim 68 wherein the converting step includes the substeps of generating vector data which is border vector data, and ordering the data so that the vectors represented by the data are placed in a loop.

Claim 78

Dependent Claim 94 words

The process of claim 68 wherein the converting step includes the substeps of: overlaying the border vector data with spaced paths; at each point where a path intersects at least one border vector; performing a selected one of initiating the generation of a selected one of a hatch vector and a skin vector, stopping the generation of a selected one of a hatch vector and a skin vector, and continuing the generation as is, as determined at least partly by the vector orientation information of the at least one border vector which is intersected.

Claim 79

Dependent Claim 46 words

The process of claim 59 wherein the vector data is hatch vector data which is descriptive of hatch vectors pointing in a selected one of the X-direction, the Y-direction, both the X- and Y-directions, and directions which are 60 degrees and 120 degrees to the X-direction.

Claim 80

Dependent Claim 30 words

The process of claim 59 wherein the vector data is skin vector data which is descriptive of skin vectors pointing in a selected one of the X-direction, and the Y-direction.

Claim 81

Dependent Claim 22 words

The process of claim 59 wherein the converting step includes the substep of compensating for a cure width induced by the laser.

Claim 82

Dependent Claim 33 words

The process of claim 68 wherein the vector data comprises at least some vector data, and the compensation substep comprises selectively offsetting the endpoints of the border vectors to compensate for cure width.

Claim 83

Dependent Claim 109 words

The process of claim 74 wherein the compensating substep further includes the substeps of ordering the border vector data so that the vectors represented by the data form a loop; and successively offsetting each endpoint of the border vectors in the loop to displace the vectors by approximately one-half the cure width in a direction of determined by the vector orientation information of the border vectors; recalculating the border vectors after each offsetting substep, and performing a pairwise comparison of the border vectors in the loop to detect a crossover; and if a crossover is detected, selectively backing off the offsetting of the endpoints until the crossover is eliminated.

Claim 84

Dependent Claim 27 words

The process of claim 73 wherein the compensating substep further includes automatically measuring the beam profile and deriving the cure width for use in beam width compensation.

Claim 85

Independent Claim 169 words

A system for producing a three-dimensional object comprising: means for deriving data descriptive of cross-sections of the object from data descriptive of the object, at least one of the cross-sections having a boundary encircling an internal portion, by first generating data descriptive of the boundary of the at least one cross-section, which includes boundary orientation information, from the object descriptive data, and then generating data descriptive of the internal portion of the at least one cross-section from the boundary descriptive data and the boundary orientation information; a container for containing a material capable of selective physical transformation upon exposure to synergistic stimulation; means for forming successive layers of the material; means for producing the synergistic stimulation; means for selectively exposing the layers of the material to the synergistic stimulation in accordance with the data descriptive of the cross-sections to successively form object cross-sections; and control means for controlling the deriving means, the forming means, and the selective exposing means to produce said object from said successively formed object cross-sections.

Claim 86

Independent Claim 169 words

A system for producing a three-dimensional object comprising: means for deriving data descriptive of cross-sections of the object from data descriptive of the object, at least one of the cross-sections having a boundary encircling an internal portion, by first generating data descriptive of the boundary of the at least one cross-section, which includes boundary orientation information, from the object descriptive data, and then generating data descriptive of the internal portion of the at least one cross-section from the boundary descriptive data and the boundary orientation information; a container for containing a material capable of selective physical transformation upon exposure to synergistic stimulation; means for forming successive layers of the material; means for producing the synergistic stimulation; means for selectively exposing the layers of the material to the synergistic stimulation in accordance with the data descriptive of the cross-sections to successively form object cross-sections; and control means for controlling the deriving means, the forming means, and the selective exposing means to produce said object from said successively formed object cross-sections.

Claim 87

Independent Claim 207 words

A method for producing a three-dimensional object comprising the steps of: driving data descriptive of cross-sections of the object from data descriptive of the object, including deriving first data descriptive of a down-facing region and second data descriptive of a non-down-facing region within at least one cross-section; containing a material capable of selective physical transformation upon exposure to synergistic stimulation; associating the data descriptive of the cross-sections with building parameters, including associating the first data with first building parameters, and the second data with second building parameters, wherein the first building parameters may differ from the second building parameters; successively forming layers of the material; producing synergistic stimulation; selectively exposing the layers of the material to the synergistic stimulation in accordance with the data descriptive of the cross-sections, and in accordance with the associated building parameters, to generate successive object cross-sections; and producing said object from said successively formed object cross-sections; whereby said at least one object cross-section is formed in said object with a down-facing region and a non-down-facing region, the down-facing region being formed with first characteristics determined by sai first building parameters, the non-down facing region being formed with second characteristics determined by said second building parameters which may differ from said first characteristics.

Claim 88

Independent Claim 207 words

A method for producing a three-dimensional object comprising the steps of: driving data descriptive of cross-sections of the object from data descriptive of the object, including deriving first data descriptive of a down-facing region and second data descriptive of a non-down-facing region within at least one cross-section; containing a material capable of selective physical transformation upon exposure to synergistic stimulation; associating the data descriptive of the cross-sections with building parameters, including associating the first data with first building parameters, and the second data with second building parameters, wherein the first building parameters may differ from the second building parameters; successively forming layers of the material; producing synergistic stimulation; selectively exposing the layers of the material to the synergistic stimulation in accordance with the data descriptive of the cross-sections, and in accordance with the associated building parameters, to generate successive object cross-sections; and producing said object from said successively formed object cross-sections; whereby said at least one object cross-section is formed in said object with a down-facing region and a non-down-facing region, the down-facing region being formed with first characteristics determined by sai first building parameters, the non-down facing region being formed with second characteristics determined by said second building parameters which may differ from said first characteristics.

Claim 89

Independent Claim 182 words

A method for producing a three-dimensional object comprising: deriving data descriptive of cross-sections of the object from data descriptive of the object, said data including a plurality of datum, and each datum comprising at least a beginning endpoint and an ending endpoint and representing a path to be taken by a beam of synergistic stimulation between the beginning and ending endpoints; producing said beam of said synergistic stimulation; containing, at least in part, material capable of selective physical transformation upon exposure to the beam of synergistic stimulation; successively producing layers of said material; selectively exposing said layers of said material to said beam of synergistic stimulation in accordance with said data descriptive of said cross-sections of said object, to successively form object cross-sections, the beginning and ending endpoints of each datum included in said plurality being derived before the beam of synergistic stimulation begins tracing the path represented by that datum; and utilizing said data descriptive of said cross-sections to control said successive producing and selective exposing steps set forth above to produce said three-dimensional object comprising said successively formed object cross-sections.

Claim 90

Independent Claim 182 words

A method for producing a three-dimensional object comprising: deriving data descriptive of cross-sections of the object from data descriptive of the object, said data including a plurality of datum, and each datum comprising at least a beginning endpoint and an ending endpoint and representing a path to be taken by a beam of synergistic stimulation between the beginning and ending endpoints; producing said beam of said synergistic stimulation; containing, at least in part, material capable of selective physical transformation upon exposure to the beam of synergistic stimulation; successively producing layers of said material; selectively exposing said layers of said material to said beam of synergistic stimulation in accordance with said data descriptive of said cross-sections of said object, to successively form object cross-sections, the beginning and ending endpoints of each datum included in said plurality being derived before the beam of synergistic stimulation begins tracing the path represented by that datum; and utilizing said data descriptive of said cross-sections to control said successive producing and selective exposing steps set forth above to produce said three-dimensional object comprising said successively formed object cross-sections.

Claim 91

Dependent Claim 49 words

The method of claim 79, wherein said data descriptive of said object comprises at least some polygons having vertices substantially spanning a surface of the object, and said deriving step includes the substep of rounding at least some of said vertices to slicing planes spaced along a slicing axis.

Claim 92

Dependent Claim 52 words

The method of claim 79, wherein said data descriptive of said object comprises at least some polygons having vertices substantially spanning a surface of the object, and said deriving step includes the substep of rounding at least some of said vertices to planes offset from slicing planes spaced along a slicing axis.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1996-02-02	1996-08-03	1997-02-02	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2000-02-02	2000-08-03	2001-02-02	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2004-02-02	2004-08-03	2005-02-02	$7700.00	Window Closed / Lapsed

Method and apparatus for production of high resolution three-dimensional objects by stereolithography

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