Use of a support liquid to manufacture three-dimensional objects

Claim 1

Apparatus for producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said system comprising: a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; platform means for supporting the object being constructed; control means for providing coordinate information to enable definition of a three dimensional object of required configuration; a source of synergistic stimulation for solidifying at least part of a two dimensional layer at the surface of the reactive liquid medium; imaging means responsive to said control means for selectively controlling the size and shape of that part of the two dimensional layer of the reactive liquid medium to be solidified; and replenishment means operable for providing a further two dimensional layer of the reactive liquid medium overlying the two dimensional solidified layer substantially at the surface of the reactive liquid medium; wherein said imaging means includes: optical means intermediate said source of synergistic stimulation and the surface of the reactive liquid medium; and including: means for maintaining the surface of the reactive liquid medium at a focal plane which is a substantially constant distance from said imaging optical means; and wherein said maintaining means includes: means for sensing changes from the desired height of the surface of the reactive liquid medium relative to said imaging optical means; and means responsive to said sensing means for adjusting the height of the reactive liquid medium in said reservoir when the height of the surface of the reactive liquid medium falls below the desired height or rises above the desired height.

Claim 26

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the step of: (h) adjusting the thickness of the further layer of the reactive liquid medium to achieve the further layer of step (g); and wherein the reactive liquid medium is confined within an enclosed area in the reservoir; and wherein step (h) includes the step of: (i) altering the size of the enclosed area of the further layer of the reactive liquid medium so as to maintain a thickness thereof equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified.

Claim 27

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the step of: (h) adjusting the thickness of the further layer of the reactive liquid medium to achieve the further layer of step (g); and wherein the reactive liquid medium is confined within an enclosed area in the reservoir; and wherein step (h) includes the step of: (i) altering the size of the enclosed area of the further layer of the reactive liquid medium so as to maintain a thickness thereof equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified.

Claim 31

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (d) includes the step of: (h) positioning the imaging means intermediate the source of synergistic stimulation and the reactive liquid medium and spaced from the surface of the reactive liquid medium; and further including the step of (i) maintaining the surface of the reactive liquid medium at a focal plane which is a substantially constant distance from the imaging means; and wherein step (i) includes the step of: (j) replenishing the reactive liquid medium in the reservoir when the height of the surface of the reactive liquid medium falls below a desired height and withdrawing excess reactive liquid medium from the reservoir when the height of the surface of the reactive liquid medium tends to increase above the desired height.

Claim 32

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (d) includes the step of: (h) positioning the imaging means intermediate the source of synergistic stimulation and the reactive liquid medium and spaced from the surface of the reactive liquid medium; and further including the step of (i) maintaining the surface of the reactive liquid medium at a focal plane which is a substantially constant distance from the imaging means; and wherein step (i) includes the step of: (j) replenishing the reactive liquid medium in the reservoir when the height of the surface of the reactive liquid medium falls below a desired height and withdrawing excess reactive liquid medium from the reservoir when the height of the surface of the reactive liquid medium tends to increase above the desired height.

Claim 34

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (d) includes the step of: (h) positioning the imaging means intermediate the source of synergistic stimulation and the reactive liquid medium and spaced from the surface of the reactive liquid medium; and wherein the method further includes the step of: (i) maintaining the surface of the reactive liquid medium at a focal plane which is a substantially constant distance from the imaging means; and wherein step (i) includes the step of: (j) adjusting the volume of the non-reactive liquid medium in the reservoir.

Claim 35

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (d) includes the step of: (h) positioning the imaging means intermediate the source of synergistic stimulation and the reactive liquid medium and spaced from the surface of the reactive liquid medium; and wherein the method further includes the step of: (i) maintaining the surface of the reactive liquid medium at a focal plane which is a substantially constant distance from the imaging means; and wherein step (i) includes the step of: (j) adjusting the volume of the non-reactive liquid medium in the reservoir.

Claim 38

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (d) includes the step of: (h) positioning the imaging means intermediate the source of synergistic stimulation and the reactive liquid medium and spaced from the surface of the reactive liquid medium; and wherein the method further includes the steps of: (i) maintaining the surface of the reactive liquid medium at a focal plane which is a substantially constant distance from the imaging means; (j) providing displacement mass means within the reservoir operable for movement between first and second spaced positions in at least one of the reactive liquid medium and the non-reactive liquid medium; and (k) moving the displacement mass means in response to changes in the level of the surface of the reactive liquid medium such that the surface of the reactive liquid medium is maintained at a focal plane which is a substantially constant distance from the imaging optical means.

Claim 39

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (d) includes the step of: (h) positioning the imaging means intermediate the source of synergistic stimulation and the reactive liquid medium and spaced from the surface of the reactive liquid medium; and wherein the method further includes the steps of: (i) maintaining the surface of the reactive liquid medium at a focal plane which is a substantially constant distance from the imaging means; (j) providing displacement mass means within the reservoir operable for movement between first and second spaced positions in at least one of the reactive liquid medium and the non-reactive liquid medium; and (k) moving the displacement mass means in response to changes in the level of the surface of the reactive liquid medium such that the surface of the reactive liquid medium is maintained at a focal plane which is a substantially constant distance from the imaging optical means.

Claim 41

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the steps of: (h) providing an extrusion die having an elongated slot extending across the surface of the reactive liquid medium at a uniform distance; (i) causing flow of the reactive liquid medium from a source thereof through the elongated slot; and (j) translating the extrusion die across the surface of the reactive liquid medium; and wherein the method includes the step of: (k) withdrawing excess reactive liquid medium from the reservoir when the height of the surface of the reactive liquid medium tends to increase above a desired height.

Claim 42

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the steps of: (h) providing an extrusion die having an elongated slot extending across the surface of the reactive liquid medium at a uniform distance; (i) causing flow of the reactive liquid medium from a source thereof through the elongated slot; and (j) translating the extrusion die across the surface of the reactive liquid medium; and wherein the method includes the step of: (k) withdrawing excess reactive liquid medium from the reservoir when the height of the surface of the reactive liquid medium tends to increase above a desired height.

Claim 43

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the steps of: (h) providing an extrusion die having an elongated slot extending across the surface of the reactive liquid medium at a uniform distance; (i) causing flow of the reactive liquid medium from a source thereof through the elongated slot; and (j) translating the extrusion die across the surface of the reactive liquid medium; and wherein the method includes the step of: (k) withdrawing excess reactive liquid medium from the reservoir when the thickness of the reactive liquid medium tends to increase beyond a desired thickness.

Claim 44

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the steps of: (h) providing an extrusion die having an elongated slot extending across the surface of the reactive liquid medium at a uniform distance; (i) causing flow of the reactive liquid medium from a source thereof through the elongated slot; and (j) translating the extrusion die across the surface of the reactive liquid medium; and wherein the method includes the step of: (k) withdrawing excess reactive liquid medium from the reservoir when the thickness of the reactive liquid medium tends to increase beyond a desired thickness.

Claim 48

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the steps of: (h) providing an extrusion die having an elongated slot extending across the surface of the reactive liquid medium at a uniform distance; (i) causing flow of the reactive liquid medium from a source thereof through the elongated slot; and (j) translating the extrusion die across the surface of the reactive liquid medium; and wherein the method includes the steps of: (k) sensing changes in the height of the surface of the reactive liquid medium from a desired height thereof; (l) providing displacement mass means within the reservoir movable between first and second spaced positions in at least one of the reactive liquid medium and the non-reactive liquid medium; and (m) moving the displacement mass means from the first position to the second position in response to changes in the level of the surface of the reactive liquid medium detected in step (k) such that the surface of the reactive liquid medium is maintained at a focal plane which is a substantially constant distance from the imaging optical means.

Claim 49

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the steps of: (h) providing an extrusion die having an elongated slot extending across the surface of the reactive liquid medium at a uniform distance; (i) causing flow of the reactive liquid medium from a source thereof through the elongated slot; and (j) translating the extrusion die across the surface of the reactive liquid medium; and wherein the method includes the steps of: (k) sensing changes in the height of the surface of the reactive liquid medium from a desired height thereof; (l) providing displacement mass means within the reservoir movable between first and second spaced positions in at least one of the reactive liquid medium and the non-reactive liquid medium; and (m) moving the displacement mass means from the first position to the second position in response to changes in the level of the surface of the reactive liquid medium detected in step (k) such that the surface of the reactive liquid medium is maintained at a focal plane which is a substantially constant distance from the imaging optical means.

Claim 52

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the steps of: (h) providing an extrusion die having an elongated slot extending across the surface of the reactive liquid medium at a uniform distance; (i) causing flow of the reactive liquid medium from a source thereof through the elongated slot; and (j) translating the extrusion die across the surface of the reactive liquid medium; and wherein the method includes the step of: (k) heating at least one of the reactive liquid medium and the non-reactive liquid medium to control the viscosity thereof.

Claim 53

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the steps of: (h) providing an extrusion die having an elongated slot extending across the surface of the reactive liquid medium at a uniform distance; (i) causing flow of the reactive liquid medium from a source thereof through the elongated slot; and (j) translating the extrusion die across the surface of the reactive liquid medium; and wherein the method includes the step of: (k) heating at least one of the reactive liquid medium and the non-reactive liquid medium to control the viscosity thereof.

Claim 54

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein steps (d), (f) and (g) include the steps of: (h) positioning the dispenser means in a plane intermediate the imaging means and the surface of the reactive liquid medium; and (i) from an imaging means including a programmable array, projecting an image onto that part of the new two dimensional layer of the reactive liquid medium overlying the object to be solidified; and (j) moving the imaging means across the new two dimensional layer in unison with the dispenser means.

Claim 55

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein steps (d), (f) and (g) include the steps of: (h) positioning the dispenser means in a plane intermediate the imaging means and the surface of the reactive liquid medium; and (i) from an imaging means including a programmable array, projecting an image onto that part of the new two dimensional layer of the reactive liquid medium overlying the object to be solidified; and (j) moving the imaging means across the new two dimensional layer in unison with the dispenser means.

Claim 56

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the steps of: (h) removing from the reservoir all unreacted reactive liquid medium after step (f); and (i) adding a new layer of reactive liquid medium overlying the surface of the non-reactive liquid medium.

Claim 57

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the steps of: (h) removing from the reservoir all unreacted reactive liquid medium after step (f); and (i) adding a new layer of reactive liquid medium overlying the surface of the non-reactive liquid medium.

Claim 60

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the step of: (h) controlling the molecular alignment within the reactive liquid medium during exposure to synergistic stimulation.

Claim 61

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein step (g) includes the step of: (h) controlling the molecular alignment within the reactive liquid medium during exposure to synergistic stimulation.

Claim 63

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to he solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein the object being formed has a bottom and at least one upstanding wall defining an interior region; and including the step of: (h) forming the upstanding wall with a displacement hole therethrough adjacent the bottom to enable flow of the non-reactive liquid medium into the interior region.

Claim 64

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to he solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying at least part of the new two dimensional layer of the reactive liquid medium; (g) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (g) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed; wherein the object being formed has a bottom and at least one upstanding wall defining an interior region; and including the step of: (h) forming the upstanding wall with a displacement hole therethrough adjacent the bottom to enable flow of the non-reactive liquid medium into the interior region.

Claim 65

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying a first part of the new two dimensional layer of the reactive liquid medium; (g) after step (f), removing from the reservoir all unreacted reactive liquid medium; (h) replacing the reactive liquid medium removed in step (g) with a new layer of the reactive liquid medium having a substantially uniform thickness and generally coplanar with and equivalent to the thickness of the first part solidified in step (f); (i) solidifying a second part of the new two dimensional layer of the reactive liquid medium corresponding to the replacement liquid medium of step (h); (j) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (j) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed.

Claim 66

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a new two dimensional layer of the reactive liquid medium to be solidified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying a first part of the new two dimensional layer of the reactive liquid medium; (g) after step (f), removing from the reservoir all unreacted reactive liquid medium; (h) replacing the reactive liquid medium removed in step (g) with a new layer of the reactive liquid medium having a substantially uniform thickness and generally coplanar with and equivalent to the thickness of the first part solidified in step (f); (i) solidifying a second part of the new two dimensional layer of the reactive liquid medium corresponding to the replacement liquid medium of step (h); (j) providing a further layer of the reactive liquid medium having a substantially uniform thickness overlying the new solidified layer on the object and equivalent to the thickness of that part of the next succeeding two dimensional layer to be solidified; and repeating steps (c) through (j) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed.

Claim 71

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a further two dimensional layer of the reactive liquid medium to be soldified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying the further two dimensional layer of the reactive liquid medium; (g) after step (f), removing from the reservoir all unreacted reactive liquid medium; (h) replacing the reactive liquid medium removed in step (g) with a new layer of the reactive liquid medium having a substantially uniform thickness and overlying the preceding solidified layer of the reactive liquid medium; (i) solidifying the new two dimensional layer of the reactive liquid medium corresponding to the replacement liquid medium of step (h); and repeating steps (c) through (i) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed.

Claim 72

A method of producing from a reactive liquid medium capable of being solidified a three dimensional object constructed from a plurality of successive layers of the solidified reactive liquid medium when subjected to appropriate synergistic stimulation, said method comprising the steps of: (a) providing a reservoir containing a reactive liquid medium capable of being solidified and an underlying non-reactive liquid medium substantially immiscible with the reactive liquid medium for supporting the reactive liquid medium; (b) providing a platform within the reservoir having an upper surface and being initially positioned at a depth which is substantially equal to a uniform thickness of that part of a first layer to be solidified to begin forming the object and continuing to support the object being constructed on the platform within the reservoir; (c) directing a source of synergistic stimulation toward the reactive liquid medium to be solidified; (d) operating imaging means for selectively controlling the size and shape of that part of a further two dimensional layer of the reactive liquid medium to be soldified; (e) controlling operation of the imaging means utilizing coordinate information defining a three dimensional object of required configuration; (f) solidifying the further two dimensional layer of the reactive liquid medium; (g) after step (f), removing from the reservoir all unreacted reactive liquid medium; (h) replacing the reactive liquid medium removed in step (g) with a new layer of the reactive liquid medium having a substantially uniform thickness and overlying the preceding solidified layer of the reactive liquid medium; (i) solidifying the new two dimensional layer of the reactive liquid medium corresponding to the replacement liquid medium of step (h); and repeating steps (c) through (i) until all of the layers of the solidified reactive liquid medium define the three dimensional object being constructed.