US5637169A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of building three dimensional objects with sheets
Assignee: 3D Systems Inc
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Filing: 1995-06-07
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Granted: 1997-06-10
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Expires: 2015-06-07
Abstract
Abstract The instant invention is directed to related methods of producing a three-dimensional object by dispensing sheets of a material, capable of physical transformation upon exposure to synergistic stimulation, onto a substantially flat working surface of a previous cross-section. In one preferred embodiment, sheets of a photoresist are employed which change solubility upon exposure to electromagnetic radiation. In other preferred embodiments, non-photoreactive sheets are employed, which ablate upon exposure to infrared radiation.
Inventors
- 👤 Charles W. Hull
- 👤 Paul F. Jacobs
- 👤 Kris A. Schmidt
- 👤 Dennis R. Smalley
- 👤 Wayne A. Vinson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 18:45
CPC Classifications
B; B29; B29C; B29C64/00; B29C64/40; B29C64/10; B29C64/106; B29C64/124; B29C64/141; B29C64/147; B29C64/188; B33; B33Y; B33Y10/00; B33Y30/00; B33Y70/00; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1052; Y10T156/1062; Y10T156/1075; Y10T156/108; Y10T156/12; Y10T156/13; Y10T156/17
Claims Analysis
Total Claims: 27
Claim 1
Independent Claim
124 words
A method for producing a three-dimensional object from sheets of material capable of selective solidification upon exposure to electromagnetic radiation, wherein portions of said sheets solidify to form cross-sections of said object, comprising the steps of: dispensing at least one of said sheets onto a working surface adjacent to a previously formed cross-section; forming a successive cross-section of the object by selectively exposing first portions of said sheet to said electromagnetic radiation according to a corresponding representation of said successive cross-sections, whereupon said first portions selectively solidify, and unexposed regions comprise second portions of said sheet; removing at least some material from said second portions of said sheet; and selectively adhering said successive cross-section to said previously formed cross-section to form said three-dimensional object.
Claim 2
Independent Claim
124 words
A method for producing a three-dimensional object from sheets of material capable of selective solidification upon exposure to electromagnetic radiation, wherein portions of said sheets solidify to form cross-sections of said object, comprising the steps of: dispensing at least one of said sheets onto a working surface adjacent to a previously formed cross-section; forming a successive cross-section of the object by selectively exposing first portions of said sheet to said electromagnetic radiation according to a corresponding representation of said successive cross-sections, whereupon said first portions selectively solidify, and unexposed regions comprise second portions of said sheet; removing at least some material from said second portions of said sheet; and selectively adhering said successive cross-section to said previously formed cross-section to form said three-dimensional object.
Claim 3
Dependent Claim
19 words
The method of claim 1 wherein said sheets are metal sheets which ablate upon exposure to said electromagnetic radiation.
Claim 4
Dependent Claim
20 words
The method of claim 1 wherein said sheets are non-photoreactive plastic sheets which ablate upon exposure to said electromagnetic radiation.
Claim 5
Dependent Claim
20 words
The method of claim 1 wherein said sheets are photoreactive sheets which selectively solidify upon exposure to said electromagnetic radiation.
Claim 6
Dependent Claim
21 words
The method of claim 1 wherein said sheets are photoreactive plastic sheets which selectively change solubility upon exposure to electromagnetic radiation.
Claim 7
Dependent Claim
13 words
The method of claim 1 wherein said sheets comprise sheets of a photoresist.
Claim 8
Dependent Claim
14 words
The method of claim 1 wherein said sheets comprise sheets of a thixotropic material.
Claim 9
Dependent Claim
16 words
The method of claim 1 wherein said dispensing step comprises unwinding sheets from a pre-formed roll.
Claim 10
Dependent Claim
15 words
The method of claim 1 wherein said dispensing step comprises dispensing sheets from a cartridge.
Claim 11
Dependent Claim
20 words
The method of claim 1 wherein said dispensing step comprises transporting said sheet to the working surface by a web.
Claim 12
Dependent Claim
17 words
The method of claim 1 wherein said dispensing step comprises rotating a platen to dispense said sheet.
Claim 13
Dependent Claim
14 words
The method of claim 1 wherein said sheets are sheets of a negative photoresist.
Claim 14
Dependent Claim
14 words
The method of claim 1 wherein said sheets are sheets of a positive photoresist.
Claim 15
Dependent Claim
34 words
The method of claim 1 wherein said forming step comprises selectively exposing said first portion to UV-radiation, whereupon said first portion solidifies into said successive cross-section, and also adheres to said previously formed cross-section.
Claim 16
Dependent Claim
34 words
The method of claim 1 further comprising the step of registering and adhering said successive cross-section to said previously formed cross-section by adhering means, wherein adhering means is a heat-sensitive, pressure-sensitive, or moisture-sensitive adhesive.
Claim 17
Dependent Claim
71 words
The method of claim 1 further comprising the step of adhering said first portion of said sheet to said previous cross-section wherein said forming step comprises the substeps of thereafter separating said first portion from said second portion by tracing said first portion with electromagnetic radiation, and ablating any areas in said first portion which deviate from said successive cross-section upon exposure to said electromagnetic radiation to obtain said successive cross-section.
Claim 18
Dependent Claim
19 words
The method of claim 1 wherein said removing step comprises dissolving material of said second portion in a developer.
Claim 19
Dependent Claim
29 words
The method of claim 1 wherein said removing step comprises allowing material from said areas in said second portion to fall away from said successive cross-section due to gravity.
Claim 20
Dependent Claim
24 words
The method of claim 1 wherein said removing step comprises lifting material from said areas in said second portion away from said successive cross-section.
Claim 21
Dependent Claim
25 words
The method of claim 1 further comprising filling said areas in said second portion with a material which is substantially inert to said electromagnetic radiation.
Claim 22
Independent Claim
120 words
A method for producing a three-dimensional object from sheets of insoluable material which becomes soluable upon exposure to electromagnetic radiation, wherein portions of said sheets form cross-sections of said object, comprising the steps of: dispensing at least one sheet onto a working surface adjacent to a previously formed cross-section; forming a successive cross-section of the object by selectively exposing first portions of said sheet to said electromagnetic radiation according to representations of said successive cross-section that is to become soluable, whereupon said first portions becomes soluable, and unexposed regions comprise insoluable second portions of said sheet to form sucessive cross-sections of said object; and substantially dissolving at least some material in said first portions of said sheet in said developer.
Claim 23
Independent Claim
120 words
A method for producing a three-dimensional object from sheets of insoluable material which becomes soluable upon exposure to electromagnetic radiation, wherein portions of said sheets form cross-sections of said object, comprising the steps of: dispensing at least one sheet onto a working surface adjacent to a previously formed cross-section; forming a successive cross-section of the object by selectively exposing first portions of said sheet to said electromagnetic radiation according to representations of said successive cross-section that is to become soluable, whereupon said first portions becomes soluable, and unexposed regions comprise insoluable second portions of said sheet to form sucessive cross-sections of said object; and substantially dissolving at least some material in said first portions of said sheet in said developer.
Claim 24
Dependent Claim
37 words
The method of claim 21 further wherein said sheets are a negative photoresist, wherein said forming step further comprises the substep of adhering said successive cross-section to said previously formed cross-section upon exposure to said electromagnetic radiation.
Claim 25
Dependent Claim
46 words
The method of claim 21 wherein said sheets are a positive photoresist, wherein said forming step further comprises the substeps of registering and adhering said successive cross-section to said previously formed cross-section by adhering means, wherein said adhering means is a pressure-sensitive, heat-sensitive, or moisture-sensitive adhesive.
Claim 26
Independent Claim
142 words
A method for producing a three-dimensional object from sheets of material which is capable of selective cutting upon exposure to electromagnetic radiation, wherein said sheets are cut to form cross-sections of said object comprising the steps of: dispensing at least one sheet of said material having a first and a second portion onto a working surface of a previously formed cross-section prior to forming said successive cross-sections from said sheets; adhering at least part of the first portion of said sheet to said working surface of said previously formed cross-section; tracing at least perimeters of said first portion of said sheet with said electromagnetic radiation according to a corresponding representation of said perimeters of said successive cross-section, whereupon said first portion of said sheet forms said successive cross-section; and removing said at least some material in said second portion of said sheet.
Claim 27
Independent Claim
142 words
A method for producing a three-dimensional object from sheets of material which is capable of selective cutting upon exposure to electromagnetic radiation, wherein said sheets are cut to form cross-sections of said object comprising the steps of: dispensing at least one sheet of said material having a first and a second portion onto a working surface of a previously formed cross-section prior to forming said successive cross-sections from said sheets; adhering at least part of the first portion of said sheet to said working surface of said previously formed cross-section; tracing at least perimeters of said first portion of said sheet with said electromagnetic radiation according to a corresponding representation of said perimeters of said successive cross-section, whereupon said first portion of said sheet forms said successive cross-section; and removing said at least some material in said second portion of said sheet.
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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) | 2000-06-09 | 2000-12-09 | 2001-06-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-06-09 | 2004-12-09 | 2005-06-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-06-09 | 2008-12-09 | 2009-06-10 | $7700.00 | Window Closed / Lapsed |