US5688464A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Vibrationally enhanced stereolithographic recoating
Assignee: 3D Systems Inc
•
Filing: 1995-03-16
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Granted: 1997-11-18
•
Expires: 2015-03-16
Abstract
Abstract Methods and apparatus for providing a vibrational enhancement to the recoating process in stereolithography are disclosed. The formation of a thin layer of building material over a previous layer of structure of a partially completed three-dimensional object, in preparation for formation of an additional layer of structure, is enhanced by the use of vibrational energy imparted to the building medium. In a first preferred apparatus, vibration is induced into the surface of the material by a plurality of vibrating needles that penetrate below the working surface to a sufficient depth to ensure adequate coupling but not deep enough to come into contact with the surface of the partially completed part. In a second preferred apparatus, vibration is coupled directly to the object support. The vibrational energy is then transmitted through the part to the surface of the building material. In a first preferred method the partially completed object is overcoated with material and vibration is used to reduce the coating thickness. In a second preferred method, the partially completed object is under-coated with material and vibration is used to increase the coating thickness.
Inventors
- 👤 Paul F. Jacobs
- 👤 J. Scot Thompson
- 👤 Hop D. Nguyen
- 👤 Dennis R. Smalley
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 21:21
CPC Classifications
B; B29; B29C; B29C41/00; B29C41/02; B29C41/12; B29C64/00; B29C64/20; B33; B33Y; B33Y10/00; B33Y40/00; B29C2791/00; B29C2791/004; B29C2791/008; B29K; B29K2995/00; B29K2995/0037; B29K2995/0072; B29K2995/0073
Claims Analysis
Total Claims: 43
Claim 1
Independent Claim
77 words
A method for recoating a previous layer of a part having an upper surface comprising the steps of: (1) coating the upper surface of the part with liquid building material to form an upper coat; and (2) inducing vibration in the upper coat, wherein said step (1) is comprised of the substep of: (a) lowering the part having an upper surface in a vat of liquid material by a distance approximately equal to a desired layer thickness.
Claim 2
Independent Claim
77 words
A method for recoating a previous layer of a part having an upper surface comprising the steps of: (1) coating the upper surface of the part with liquid building material to form an upper coat; and (2) inducing vibration in the upper coat, wherein said step (1) is comprised of the substep of: (a) lowering the part having an upper surface in a vat of liquid material by a distance approximately equal to a desired layer thickness.
Claim 3
Independent Claim
85 words
A method for recoating a previous layer of a part having an upper surface comprising the steps of: (1) coating the upper surface of the part with liquid building material to form an upper coat; and (2) inducing vibration in the upper coat, wherein said step (1) is comprised of the substeps of: (a) over-dipping the part; and (b) locating the part in a position in which the upper surface is below a working surface by a distance substantially equal to a desired layer thickness.
Claim 4
Independent Claim
85 words
A method for recoating a previous layer of a part having an upper surface comprising the steps of: (1) coating the upper surface of the part with liquid building material to form an upper coat; and (2) inducing vibration in the upper coat, wherein said step (1) is comprised of the substeps of: (a) over-dipping the part; and (b) locating the part in a position in which the upper surface is below a working surface by a distance substantially equal to a desired layer thickness.
Claim 5
Independent Claim
81 words
A method for recoating a previous layer of a part having an upper surface comprising the steps of: (1) coating the upper surface of the part with liquid building material to form an upper coat; and (2) inducing vibration in the upper coat, wherein said step (2) is comprised of the substeps of: (a) providing a vibration generator; (b) providing a physical coupling between said vibration generator and liquid building material; (c) causing said vibration generator to vibrate liquid building material.
Claim 6
Independent Claim
81 words
A method for recoating a previous layer of a part having an upper surface comprising the steps of: (1) coating the upper surface of the part with liquid building material to form an upper coat; and (2) inducing vibration in the upper coat, wherein said step (2) is comprised of the substeps of: (a) providing a vibration generator; (b) providing a physical coupling between said vibration generator and liquid building material; (c) causing said vibration generator to vibrate liquid building material.
Claim 7
Dependent Claim
23 words
The method of claim 3 further comprising vibrating through a speaker at a frequency between 0.5 Hertz and 300 Hertz in substep (c).
Claim 8
Dependent Claim
16 words
The method of claim 3 further comprising transmitting vibration through the part to the liquid material.
Claim 9
Independent Claim
85 words
A method of recoating a previous layer of a part comprising the steps of: applying excess liquid building material over a substantial portion of the previous layer of said part, wherein the liquid building material has an actual material surface locatable at a desired working surface; locating an upper portion of the previous layer approximately one layer thickness below the working surface; and applying vibration to the excess liquid building material to aid in locating the actual surface of the material at the working surface.
Claim 10
Independent Claim
85 words
A method of recoating a previous layer of a part comprising the steps of: applying excess liquid building material over a substantial portion of the previous layer of said part, wherein the liquid building material has an actual material surface locatable at a desired working surface; locating an upper portion of the previous layer approximately one layer thickness below the working surface; and applying vibration to the excess liquid building material to aid in locating the actual surface of the material at the working surface.
Claim 11
Dependent Claim
14 words
The method of claim 6 wherein said material application step comprises overdipping said part.
Claim 12
Dependent Claim
18 words
The method of claim 6 wherein said material application step comprises adding liquid material to a building chamber.
Claim 13
Dependent Claim
16 words
The method of claim 6 wherein said vibration application step comprises applying vibration to said part.
Claim 14
Independent Claim
80 words
A method of recoating a previous layer of a part, having an upper portion, wherein the previous layer is formed from a liquid building material having an upper surface locatable at a desired working surface, and wherein the upper portion is at the desired working surface comprising the steps of: separating the desired working surface and the upper portion of the previous layer by substantially a desired layer thickness; and vibrating and flowing liquid building material over said upper portion.
Claim 15
Independent Claim
80 words
A method of recoating a previous layer of a part, having an upper portion, wherein the previous layer is formed from a liquid building material having an upper surface locatable at a desired working surface, and wherein the upper portion is at the desired working surface comprising the steps of: separating the desired working surface and the upper portion of the previous layer by substantially a desired layer thickness; and vibrating and flowing liquid building material over said upper portion.
Claim 16
Dependent Claim
11 words
The method of claim 10 wherein said separating step comprises downdipping.
Claim 17
Dependent Claim
18 words
The method of claim 10 wherein said separating step comprises increasing the material level in a building chamber.
Claim 18
Dependent Claim
11 words
The method of claim 10 wherein said flowing comprises gravity leveling.
Claim 19
Dependent Claim
11 words
The method of claim 10 wherein said flowing comprises blade sweeping.
Claim 20
Dependent Claim
14 words
The method of claim 10 wherein said vibrating comprises applying vibration to said part.
Claim 21
Dependent Claim
40 words
The method of claim 15 wherein said vibrating comprises vibrating a platform upon which said part is being fabricated and further comprising the additional step of relocating said platform to the same position after said vibrating as before said vibrating.
Claim 22
Independent Claim
161 words
A method for forming a three-dimensional object comprising the steps of: maintaining a container of liquid building material that has an actual material surface which is an upper surface and which is locatable at a desired working surface; forming a first layer of structure having an upper surface at the actual material surface when the actual material surface is substantially at the desired working surface; separating the upper surface of the first layer of structure from the desired working surface; inducing vibration into the liquid building material to aid formation of a substantially uniform coating of material having an upper surface over said first layer of structure and having a thickness substantially equal to the desired layer thickness; selectively exposing the uniform coating of material to synergistic stimulation to form a second layer of structure integral with said first layer of structure; and repeating the separating and exposing steps to form said object from a plurality of integral layers of structure.
Claim 23
Independent Claim
161 words
A method for forming a three-dimensional object comprising the steps of: maintaining a container of liquid building material that has an actual material surface which is an upper surface and which is locatable at a desired working surface; forming a first layer of structure having an upper surface at the actual material surface when the actual material surface is substantially at the desired working surface; separating the upper surface of the first layer of structure from the desired working surface; inducing vibration into the liquid building material to aid formation of a substantially uniform coating of material having an upper surface over said first layer of structure and having a thickness substantially equal to the desired layer thickness; selectively exposing the uniform coating of material to synergistic stimulation to form a second layer of structure integral with said first layer of structure; and repeating the separating and exposing steps to form said object from a plurality of integral layers of structure.
Claim 24
Dependent Claim
13 words
The method of claim 17, where the building material is a liquid photopolymer.
Claim 25
Dependent Claim
12 words
The method of claim 18, where the synergistic stimulation is ultra-violet radiation.
Claim 26
Dependent Claim
12 words
The method of claim 17, where the synergistic stimulation is infrared radiation.
Claim 27
Dependent Claim
12 words
The method of claim 19, where the synergistic stimulation is a laser.
Claim 28
Dependent Claim
18 words
The method of claim 18, where the desired working surface is at a fixed location in the container.
Claim 29
Independent Claim
134 words
A method for coating a previous layer of structure of a three-dimensional object with liquid building material comprising: forming a coating of said liquid building material over the previous layer of structure; and inducing vibrational energy into the liquid building material to form the coating of liquid building material into a uniform coating of thickness substantially equal to that of a layer thickness, where the coating of said building material over the previous layer of structure is a coating of excess material over a substantial portion of the previous layer of structure and where the excess coating is obtained by overdipping the previous layer of structure into a container of said building material and then positioning an upper surface of the previous layer of structure subtantially one layer thickness below a desired working surface.
Claim 30
Independent Claim
134 words
A method for coating a previous layer of structure of a three-dimensional object with liquid building material comprising: forming a coating of said liquid building material over the previous layer of structure; and inducing vibrational energy into the liquid building material to form the coating of liquid building material into a uniform coating of thickness substantially equal to that of a layer thickness, where the coating of said building material over the previous layer of structure is a coating of excess material over a substantial portion of the previous layer of structure and where the excess coating is obtained by overdipping the previous layer of structure into a container of said building material and then positioning an upper surface of the previous layer of structure subtantially one layer thickness below a desired working surface.
Claim 31
Dependent Claim
41 words
The method of claim 17 where vibration is induced into the building material by vibrating an object support platform with the vibrational energy being transmitted, at least in part, through the object to the actual material surface of the building material.
Claim 32
Dependent Claim
23 words
The method of claim 17 where vibration is induced into the building material by contact between a vibrating element and the building material.
Claim 33
Independent Claim
77 words
A method for recoating a previous layer of a part having an upper surface comprising the steps of: coating the upper surface of the previous layer with liquid building material to form an upper coat; and inducing vibration in the upper coat; wherein inducing vibration further comprises the steps of: providing a vibration generator; providing a physical coupling between said vibration generator and the liquid building material; and causing said vibration generator to vibrate the upper coat.
Claim 34
Independent Claim
77 words
A method for recoating a previous layer of a part having an upper surface comprising the steps of: coating the upper surface of the previous layer with liquid building material to form an upper coat; and inducing vibration in the upper coat; wherein inducing vibration further comprises the steps of: providing a vibration generator; providing a physical coupling between said vibration generator and the liquid building material; and causing said vibration generator to vibrate the upper coat.
Claim 35
Independent Claim
69 words
A method of recoating a previous layer of a part, formed from a fluid-like material having an upper surface which is locatable at a desired working surface, comprising the steps of: separating the desired working surface and an upper portion of a previous layer by substantially a desired layer thickness; and vibrating and flowing fluid-like material over said upper portion, wherein said vibrating comprises applying vibration to said part.
Claim 36
Independent Claim
69 words
A method of recoating a previous layer of a part, formed from a fluid-like material having an upper surface which is locatable at a desired working surface, comprising the steps of: separating the desired working surface and an upper portion of a previous layer by substantially a desired layer thickness; and vibrating and flowing fluid-like material over said upper portion, wherein said vibrating comprises applying vibration to said part.
Claim 37
Dependent Claim
40 words
The method of claim 27 wherein said vibrating comprises vibrating a platform upon which said part is being fabricated and further comprising the additional step of relocating said platform to the same position after said vibrating as before said vibrating.
Claim 38
Dependent Claim
15 words
The method as claimed in claim 27 wherein the fluid-like material is a sinterable powder.
Claim 39
Dependent Claim
22 words
The method of claim 27 wherein the fluid-like material is a powder that can be solidified by the addition of a binder.
Claim 40
Independent Claim
174 words
A method for forming a three-dimensional object comprising the steps of: maintaining a container of liquid building material that has an actual material surface which is an upper surface and which is locatable at a desired working surface, wherein the desired working surface is substantially fixed in a vertical plane; forming a first layer of structure having an upper surface at the actual material surface when the actual material surface is substantially at the desired working surface; separating the upper surface of the first layer of structure from the desired working surface; inducing vibration into the liquid building material to aid formation of a substantially uniform coating of material having an upper surface over said first layer of structure and having a thickness substantially equal to the desired layer thickness; selectively exposing the substantially uniform coating of material to synergistic stimulation to form a second layer of structure integral with said first layer of structure; and repeating the separating and exposing steps to form said object from a plurality of integral layers of structure.
Claim 41
Independent Claim
174 words
A method for forming a three-dimensional object comprising the steps of: maintaining a container of liquid building material that has an actual material surface which is an upper surface and which is locatable at a desired working surface, wherein the desired working surface is substantially fixed in a vertical plane; forming a first layer of structure having an upper surface at the actual material surface when the actual material surface is substantially at the desired working surface; separating the upper surface of the first layer of structure from the desired working surface; inducing vibration into the liquid building material to aid formation of a substantially uniform coating of material having an upper surface over said first layer of structure and having a thickness substantially equal to the desired layer thickness; selectively exposing the substantially uniform coating of material to synergistic stimulation to form a second layer of structure integral with said first layer of structure; and repeating the separating and exposing steps to form said object from a plurality of integral layers of structure.
Claim 42
Independent Claim
68 words
A method for forming, layer by layer, a three-dimensional object comprising the steps of: forming a layer of a liquid building material, wherein forming the layer includes inducing vibration into the building material to aid formation of a substantially uniform layer of material; selectively solidifying the layer of building material; and repeating the steps of forming the layer and solidifying the layer until the three-dimensional object is formed.
Claim 43
Independent Claim
68 words
A method for forming, layer by layer, a three-dimensional object comprising the steps of: forming a layer of a liquid building material, wherein forming the layer includes inducing vibration into the building material to aid formation of a substantially uniform layer of material; selectively solidifying the layer of building material; and repeating the steps of forming the layer and solidifying the layer until the three-dimensional object is formed.
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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) | 2000-11-17 | 2001-05-19 | 2001-11-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-11-17 | 2005-05-19 | 2005-11-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-11-17 | 2009-05-19 | 2009-11-18 | $7700.00 | Window Closed / Lapsed |