Patent US5597520A successfully refreshed from Google Patents.
US5597520A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Simultaneous multiple layer curing in stereolithography
Assignee: 3D Systems Inc
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Filing: 1994-04-25
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Granted: 1997-01-28
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Expires: 2014-04-25
Abstract
Abstract A method and apparatus for making high resolution objects by stereolithography utilizing low resolution materials which are limited by their inability to form unsupported structures of desired thinness and/or their inability to form coatings of desired thinness. Data manipulation techniques, based on layer comparisons, are used to control exposure in order to delay solidification of the material on at least portions of at least some cross-sections until higher layers of material are deposited so as to allow down-facing features of the object to be located at a depth in the building material which is equal to or exceeds a minimum cure depth that can effectively be used for solidifying these features. Similar data manipulations are used to ensure minimum reliable coating thicknesses exist, above previously solidified material, before attempting solidification of a next layer. In addition, horizontal comparison techniques are used to provide enhanced cross-sectional data for use in forming the object.
Inventors
- 👤 Dennis R. Smalley
- 👤 Thomas J. Vorgitch
- 👤 Chris R. Manners
- 👤 Charles W. Hull
- 👤 Stacie L. VanDorin
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 21:27
CPC Classifications
G; G06; G06T; G06T17/00; B; B29; B29C; B29C64/00; B29C64/40; B33; B33Y; B33Y10/00; G05; G05B; G05B2219/00; G05B2219/30; G05B2219/49; G05B2219/49013
Claims Analysis
Total Claims: 43
Claim 1
Independent Claim
110 words
An improved method of stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising the steps of receiving data descriptive of said cross-sectional layers, forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising the steps of: modifying data descriptive of at least a portion of at least one cross-sectional layer by copying said data from a first cross-section to a second cross-section; and using said modified data in forming said three-dimensional object.
Claim 2
Dependent Claim
110 words
An improved method of stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising the steps of receiving data descriptive of said cross-sectional layers, forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising the steps of: modifying data descriptive of at least a portion of at least one cross-sectional layer by copying said data from a first cross-section to a second cross-section; and using said modified data in forming said three-dimensional object.
Claim 3
Dependent Claim
52 words
The method of claim 1 further comprising the step of: further modifying data descriptive of said second cross-section by differencing the copied data from any other data on the second cross-section and on any intermediate cross-sections between said first and second cross-sections; using said further modified data in forming said three-dimensional object.
Claim 4
Dependent Claim
23 words
The method of claim 2 wherein said step of modifying comprises copying data descriptive of at least a portion of a down-facing feature.
Claim 5
Dependent Claim
45 words
The method of claim 3 wherein said step of copying of at least a portion of a down-facing feature comprises exposing said copied portion with an amount of synergistic stimulation necessary to achieve a cure depth of approximately the amount shifted plus one layer thickness.
Claim 6
Dependent Claim
25 words
The method of claim 4 wherein the synergistic stimulation is electromagnetic radiation and the material is a photopolymer which solidifies in response to said radiation.
Claim 7
Dependent Claim
27 words
The method of claim 4 wherein the copying is from one layer thickness away and the exposure applied to the copied portion is approximately two layer thicknesses.
Claim 8
Dependent Claim
31 words
The method of claim 4 wherein the copying is from at least two layer thicknesses away and the exposure applied to the copied portion is at least approximately three layer thicknesses.
Claim 9
Dependent Claim
51 words
The method of claim 2 wherein said step of modifying comprises shifting data descriptive of a non-down-facing feature such that at least a two layer thickness separation occurs between at least a portion of said modified cross-sectional data on said second layer and any modified data located directly below said portion.
Claim 10
Dependent Claim
25 words
The method of claim 8 wherein the synergistic stimulation is electromagnetic radiation and the material a photopolymer which is solidifies in response to said radiation.
Claim 11
Dependent Claim
16 words
The method of claim 8 wherein the shifting of data is at least two layer thicknesses.
Claim 12
Dependent Claim
16 words
The method of claim 10 wherein the shifting of data is at least three layer thicknesses.
Claim 13
Dependent Claim
136 words
An improved method of stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising the steps of receiving data descriptive of said cross-sectional layers, forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising the steps of: modifying data descriptive of at least portions of two cross-sectional layers by shifting said data from a first cross-sectional layer through at least one intermediate cross-sectional layer to a second cross-sectional layer and by differencing the shifted data from data descriptive of said second and said at least one intermediate cross-sectional layers; and using said modified data in forming said three-dimensional object.
Claim 14
Dependent Claim
136 words
An improved method of stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising the steps of receiving data descriptive of said cross-sectional layers, forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising the steps of: modifying data descriptive of at least portions of two cross-sectional layers by shifting said data from a first cross-sectional layer through at least one intermediate cross-sectional layer to a second cross-sectional layer and by differencing the shifted data from data descriptive of said second and said at least one intermediate cross-sectional layers; and using said modified data in forming said three-dimensional object.
Claim 15
Dependent Claim
129 words
An improved method of stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising the steps of receiving data descriptive of said cross-sectional layers, forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising the steps of: modifying data descriptive of at least a portion of one cross-sectional layer by copying said data from a first cross-section to a second cross-section and intersecting the copied data with data descriptive of the second cross-sectional layer and utilizing only that portion which is common; and using said modified data in forming said three-dimensional object.
Claim 16
Dependent Claim
129 words
An improved method of stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising the steps of receiving data descriptive of said cross-sectional layers, forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising the steps of: modifying data descriptive of at least a portion of one cross-sectional layer by copying said data from a first cross-section to a second cross-section and intersecting the copied data with data descriptive of the second cross-sectional layer and utilizing only that portion which is common; and using said modified data in forming said three-dimensional object.
Claim 17
Dependent Claim
23 words
The method of claim 13 wherein the first layer is located below the second layer and the shifted data is down-facing skin data.
Claim 18
Dependent Claim
47 words
The method of claim 14 wherein the down-facing skin data on the first layer is final down-facing skin data that was shifted from a layer below the first layer to the first layer prior to copying the down-facing data from the first layer to the second layer.
Claim 19
Dependent Claim
23 words
The method of claim 13 wherein the first layer is located above the second layer and the shifted data is up-facing skin data.
Claim 20
Dependent Claim
29 words
The method of claim 13 wherein a non-flat priority embodiment is used to determine appropriate regions to misplace in regions where the object thickness is less than the MSD.
Claim 21
Dependent Claim
28 words
The method of claim 13 wherein only exterior portions of at least some regional boundaries are used in forming boundary portions of the cross-sectional layers of the object.
Claim 22
Dependent Claim
90 words
An improved method of stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising the steps of receiving data descriptive of said cross-sectional layers, forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising the steps of: delaying forming a portion of a first cross-sectional layer to enhance proper placement of object features.
Claim 23
Dependent Claim
90 words
An improved method of stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising the steps of receiving data descriptive of said cross-sectional layers, forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising the steps of: delaying forming a portion of a first cross-sectional layer to enhance proper placement of object features.
Claim 24
Dependent Claim
30 words
The method of claim 19 wherein said delaying step includes the step of shifting said data descriptive of at least said portion of said first cross-section to a second cross-section.
Claim 25
Dependent Claim
28 words
The method of claim 20 wherein said shifting step includes the step of copying said data descriptive of said portion of said first cross-section to said second cross-section.
Claim 26
Dependent Claim
95 words
An improved method of stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising the steps of receiving data descriptive of said cross-sectional layers and forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising the step of: delaying forming a portion of a first cross-sectional layer to allow for physical transformation of an appropriate depth of material.
Claim 27
Dependent Claim
95 words
An improved method of stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising the steps of receiving data descriptive of said cross-sectional layers and forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising the step of: delaying forming a portion of a first cross-sectional layer to allow for physical transformation of an appropriate depth of material.
Claim 28
Dependent Claim
111 words
An improved method of stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising the steps of receiving data descriptive of said cross-sectional layers and forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising the step of: modifying data descriptive of at least a portion of at least one cross-sectional layer by shifting said data from a first cross-section to a second cross-section; and using said modified data in forming said three-dimensional object.
Claim 29
Dependent Claim
111 words
An improved method of stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising the steps of receiving data descriptive of said cross-sectional layers and forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising the step of: modifying data descriptive of at least a portion of at least one cross-sectional layer by shifting said data from a first cross-section to a second cross-section; and using said modified data in forming said three-dimensional object.
Claim 30
Dependent Claim
91 words
An improved apparatus for stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising means for receiving data descriptive of said cross-sectional layers and means for forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising: means for delaying forming a portion of a first cross-sectional layer to enhance proper placement of object features.
Claim 31
Dependent Claim
91 words
An improved apparatus for stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising means for receiving data descriptive of said cross-sectional layers and means for forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising: means for delaying forming a portion of a first cross-sectional layer to enhance proper placement of object features.
Claim 32
Dependent Claim
31 words
The apparatus of claim 24 wherein said delaying means includes means for shifting said data descriptive of at least said portion of said first cross-sectional layer to a second cross-sectional layer.
Claim 33
Dependent Claim
29 words
The apparatus of claim 25 wherein said shifting means includes means for copying said data descriptive of said portion of said first cross-sectional layer to said second cross-sectional layer.
Claim 34
Dependent Claim
95 words
An improved apparatus for stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising means for receiving data descriptive of said cross-sectional layers and means for forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising: means for delaying forming a portion of a first cross-sectional layer to allow for physical transformation of an appropriate depth of material.
Claim 35
Dependent Claim
95 words
An improved apparatus for stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising means for receiving data descriptive of said cross-sectional layers and means for forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising: means for delaying forming a portion of a first cross-sectional layer to allow for physical transformation of an appropriate depth of material.
Claim 36
Dependent Claim
120 words
An improved apparatus for stereolithographically forming a three-dimensional object from layers of a material capable of physical transformation upon exposure to synergistic stimulation comprising means for receiving data descriptive of cross-sections of the three-dimensional object, each cross-section representing one layer of the object to be formed, means for forming layers of said material, and means for exposing said layers to synergistic stimulation according to said data descriptive of said cross-sections to build up the three-dimensional object layer-by-layer, the improvement comprising: means for modifying data descriptive of at least two cross-sections by shifting said data from a first cross-section to a second cross-section and by differencing the shifted data from any other data on the second cross-section and on intermediate cross-section.
Claim 37
Dependent Claim
120 words
An improved apparatus for stereolithographically forming a three-dimensional object from layers of a material capable of physical transformation upon exposure to synergistic stimulation comprising means for receiving data descriptive of cross-sections of the three-dimensional object, each cross-section representing one layer of the object to be formed, means for forming layers of said material, and means for exposing said layers to synergistic stimulation according to said data descriptive of said cross-sections to build up the three-dimensional object layer-by-layer, the improvement comprising: means for modifying data descriptive of at least two cross-sections by shifting said data from a first cross-section to a second cross-section and by differencing the shifted data from any other data on the second cross-section and on intermediate cross-section.
Claim 38
Dependent Claim
113 words
An improved apparatus for stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising means for receiving data descriptive of said cross-sectional layers and means for forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising: means for modifying data descriptive of at least a portion of at least one cross-sectional layer by shifting said data from a first cross-section to a second cross-section; and means for using said modified data in forming said three-dimensional object.
Claim 39
Dependent Claim
113 words
An improved apparatus for stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising means for receiving data descriptive of said cross-sectional layers and means for forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising: means for modifying data descriptive of at least a portion of at least one cross-sectional layer by shifting said data from a first cross-section to a second cross-section; and means for using said modified data in forming said three-dimensional object.
Claim 40
Dependent Claim
139 words
An improved apparatus for stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising means for receiving data descriptive of said cross-sectional layers and means for forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising: means for modifying data descriptive of at least portions of two cross-sectional layers by shifting said data from a first cross-sectional layer through at least one intermediate cross-sectional layer to a second cross-sectional layer and by differencing the shifted data from data descriptive of said second and said at least one intermediate cross-sectional layers; and means for using said modified data in forming said three-dimensional object.
Claim 41
Dependent Claim
139 words
An improved apparatus for stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising means for receiving data descriptive of said cross-sectional layers and means for forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising: means for modifying data descriptive of at least portions of two cross-sectional layers by shifting said data from a first cross-sectional layer through at least one intermediate cross-sectional layer to a second cross-sectional layer and by differencing the shifted data from data descriptive of said second and said at least one intermediate cross-sectional layers; and means for using said modified data in forming said three-dimensional object.
Claim 42
Dependent Claim
131 words
An improved apparatus for stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising means for receiving data descriptive of said cross-sectional layers and means for forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising: means for modifying data descriptive of at least portions of two cross-sectional layers by copying said data from a first cross-section to a second cross-section and intersecting the copied data with data descriptive of the second cross-sectional layer and keeping only that portion which is common; and means for using said modified data in forming said three-dimensional object.
Claim 43
Dependent Claim
131 words
An improved apparatus for stereolithographically forming a three-dimensional object by forming cross-sectional layers of said object from a material capable of physical transformation upon exposure to synergistic stimulation comprising means for receiving data descriptive of said cross-sectional layers and means for forming said cross-sectional layers by selectively exposing said material to said synergistic stimulation according to said data descriptive of said cross-sectional layers to build up the three-dimensional object layer-by-layer, the improvement comprising: means for modifying data descriptive of at least portions of two cross-sectional layers by copying said data from a first cross-section to a second cross-section and intersecting the copied data with data descriptive of the second cross-sectional layer and keeping only that portion which is common; and means for using said modified data in forming said three-dimensional object.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2000-01-28 | 2000-07-29 | 2001-01-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-01-28 | 2004-07-29 | 2005-01-28 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-01-28 | 2008-07-29 | 2009-01-28 | $7700.00 | Window Closed / Lapsed |