US5902537A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Rapid recoating of three-dimensional objects formed on a cross-sectional basis
Assignee: 3D Systems Inc
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Filing: 1997-01-28
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Granted: 1999-05-11
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Expires: 2017-01-28
Abstract
Abstract Methods and apparatus for use in building three-dimensional objects on substantially a cross-sectional basis including methods and apparatus for forming successive layers using counter-rotating rollers, ink jet recoaters, spinning members which sling material, applicator bars that dispense material via a meniscus and/or independently dispensed streams, and also including methods and apparatus to determine a preferred region over which to form a layer and to check for building errors.
Inventors
- 👤 Thomas A. Almquist
- 👤 Charles W. Hull
- 👤 Jeffrey S. Thayer
- 👤 Richard N. Leyden
- 👤 Paul F. Jacobs
- 👤 Dennis R. Smalley
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 20:56
CPC Classifications
B; B29; B29C; B29C41/00; B29C41/02; B29C41/12; B29C41/34; B29C41/36; B29C64/00; B29C64/10; B29C64/106; B29C64/124; B29C64/129; B29C64/135; B29C64/20; B29C64/205; B29C64/209; B29C64/218; B29C64/40; B33; B33Y; B33Y10/00; B33Y30/00
Claims Analysis
Total Claims: 102
Claim 1
Independent Claim
99 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a liquid material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; means for forming layers of material adjacent to any previously formed object cross-sections including a counter-rotating roller which sweeps at or near at least a portion of a desired upper surface of at least some of the layers to render the layers of desired thickness; and a source of synergistic stimulation for exposing the layers according to the descriptive data.
Claim 2
Independent Claim
99 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a liquid material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; means for forming layers of material adjacent to any previously formed object cross-sections including a counter-rotating roller which sweeps at or near at least a portion of a desired upper surface of at least some of the layers to render the layers of desired thickness; and a source of synergistic stimulation for exposing the layers according to the descriptive data.
Claim 3
Dependent Claim
28 words
The apparatus of claim 1, further comprising: means to deep-dip and raise the previously formed object cross-section before the counter-rotating roller sweeps across the surface of the layer.
Claim 4
Dependent Claim
38 words
The apparatus of claim 1, further comprising: a dam positioned in proximity to the counter-rotating roller for limiting the amount of material that passes from a front portion of the roller to a rear portion of the roller.
Claim 5
Dependent Claim
19 words
The apparatus of claim 3, wherein the dam is positioned between 1/2 to 4 mils from the counter-rotating roller.
Claim 6
Dependent Claim
22 words
The apparatus of claim 1, further comprising: a material dispenser for depositing a quantity of material in front of the counter-rotating roller.
Claim 7
Dependent Claim
26 words
The apparatus of claim 1, further comprising: a material transporter located adjacent to the counter-rotating roller for removing material accumulated in front of the counter-rotating roller.
Claim 8
Independent Claim
115 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a liquid material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; forming a layer of material adjacent to a previously formed object cross-session including sweeping a counter-rotating roller at or near at least a portion of a desired upper surface of the layer; exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form a successive object cross-section adjacent to the previously formed object cross-section; and repeating said forming and exposing a plurality of times to form the at least portion of the object.
Claim 9
Independent Claim
115 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a liquid material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; forming a layer of material adjacent to a previously formed object cross-session including sweeping a counter-rotating roller at or near at least a portion of a desired upper surface of the layer; exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form a successive object cross-section adjacent to the previously formed object cross-section; and repeating said forming and exposing a plurality of times to form the at least portion of the object.
Claim 10
Dependent Claim
26 words
The method of claim 7, further comprising deep-dipping and raising the previously formed object cross-section before sweeping the counter-rotating roller over the surface of the layer.
Claim 11
Dependent Claim
28 words
The method of claim 7, further comprising limiting the amount of material that passes from a front portion of the roller to a rear portion of the roller.
Claim 12
Dependent Claim
20 words
The method of claim 9, further comprising providing a dam positioned between 1/2 to 4 mils from the counter-rotating roller.
Claim 13
Dependent Claim
18 words
The method of claim 7, further comprising dispensing a quantity of material in front of the counter-rotating roller.
Claim 14
Dependent Claim
17 words
The method of claim 7, further comprising transporting away material accumulated in front of the counter-rotating roller.
Claim 15
Independent Claim
118 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; means for forming layers of material over areas and adjacent to any previously formed object cross-sections, said areas being larger than regions of said layers to be transformed, comprising an ink-jet dispenser for depositing material over at least a portion of at least some of any previously formed object cross-sections; a source of synergistic stimulation; and means for exposing the layers to said synergistic stimulation according to the data descriptive of the object to form and adhere successive object cross-sections.
Claim 16
Independent Claim
118 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; means for forming layers of material over areas and adjacent to any previously formed object cross-sections, said areas being larger than regions of said layers to be transformed, comprising an ink-jet dispenser for depositing material over at least a portion of at least some of any previously formed object cross-sections; a source of synergistic stimulation; and means for exposing the layers to said synergistic stimulation according to the data descriptive of the object to form and adhere successive object cross-sections.
Claim 17
Independent Claim
172 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; exposing a first region of a first layer of material to synergistic stimulation according to the descriptive data to form a first object cross-section; forming a second layer of material over an area larger than a second region to be transformed and adjacent to said first object cross-section including dispensing material from an ink-jet dispenser over selected locations of said area; exposing the second region of the second layer to synergistic stimulation according to the data descriptive of the object to form a second object cross-section adjacent to and adhered to the first formed object cross-section; and repeating said forming a second layer and said exposing the second region to form subsequent layers and cross-sections over previously formed layers and cross-sections to form the at least portion of the object from a plurality of adhered layers.
Claim 18
Independent Claim
172 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; exposing a first region of a first layer of material to synergistic stimulation according to the descriptive data to form a first object cross-section; forming a second layer of material over an area larger than a second region to be transformed and adjacent to said first object cross-section including dispensing material from an ink-jet dispenser over selected locations of said area; exposing the second region of the second layer to synergistic stimulation according to the data descriptive of the object to form a second object cross-section adjacent to and adhered to the first formed object cross-section; and repeating said forming a second layer and said exposing the second region to form subsequent layers and cross-sections over previously formed layers and cross-sections to form the at least portion of the object from a plurality of adhered layers.
Claim 19
Independent Claim
123 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; an applicator for dispensing material over at least a portion of any previously formed object cross-sections to form layers of material, the applicator including a housing, a spinning member mounted within the housing, and a source of material for delivering material to the spinning member wherein the spinning member ejects the delivered material toward a surface of the previously formed object cross-sections; and a source of synergistic stimulation for exposing the layers according to the data descriptive of the object to form successive object cross-sections.
Claim 20
Independent Claim
123 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; an applicator for dispensing material over at least a portion of any previously formed object cross-sections to form layers of material, the applicator including a housing, a spinning member mounted within the housing, and a source of material for delivering material to the spinning member wherein the spinning member ejects the delivered material toward a surface of the previously formed object cross-sections; and a source of synergistic stimulation for exposing the layers according to the data descriptive of the object to form successive object cross-sections.
Claim 21
Independent Claim
136 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; forming a layer over at least a portion of a previously formed object cross-section including dispensing material from an applicator comprising a housing, a spinning member mounted within the housing, and a source of material for delivering material to the spinning member wherein the spinning member ejects the delivered material toward a surface of the previously formed object cross-section; exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form a successive object cross-section; and repeating said forming and exposing to form subsequent layers and cross-sections to form the at least portion of the object.
Claim 22
Independent Claim
136 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; forming a layer over at least a portion of a previously formed object cross-section including dispensing material from an applicator comprising a housing, a spinning member mounted within the housing, and a source of material for delivering material to the spinning member wherein the spinning member ejects the delivered material toward a surface of the previously formed object cross-section; exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form a successive object cross-section; and repeating said forming and exposing to form subsequent layers and cross-sections to form the at least portion of the object.
Claim 23
Independent Claim
151 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; a container for containing a volume of material having a working surface; an applicator for forming layers of material over at least portions of previously formed object cross-sections, the applicator having a bottom opening located in proximity to the working surface; a device coupled to the applicator for drawing up material from the working surface through the bottom opening and into the applicator; means for sweeping the applicator across at least a portion of at least some of the previously formed object cross-sections; and a source of synergistic stimulation for exposing the layers according to the descriptive data to form the at least portion of the object from a plurality of object cross-sections.
Claim 24
Independent Claim
151 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; a container for containing a volume of material having a working surface; an applicator for forming layers of material over at least portions of previously formed object cross-sections, the applicator having a bottom opening located in proximity to the working surface; a device coupled to the applicator for drawing up material from the working surface through the bottom opening and into the applicator; means for sweeping the applicator across at least a portion of at least some of the previously formed object cross-sections; and a source of synergistic stimulation for exposing the layers according to the descriptive data to form the at least portion of the object from a plurality of object cross-sections.
Claim 25
Independent Claim
172 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; containing a volume of material having a working surface; locating an applicator having a bottom opening in proximity to the working surface; forming a meniscus of material between the applicator and working surface; drawing up material from the working surface into the applicator through the bottom opening thereby at least partially filling the applicator; forming a layer over at least a portion of a previously formed object cross-section including dispensing material from the applicator by sweeping the applicator across at least a portion of the previously formed object cross-section; exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form an object cross-section adhered to the previously formed object cross-section; and repeating said forming and exposing to form subsequent layers and cross-sections to form the at least portion of the object.
Claim 26
Independent Claim
172 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; containing a volume of material having a working surface; locating an applicator having a bottom opening in proximity to the working surface; forming a meniscus of material between the applicator and working surface; drawing up material from the working surface into the applicator through the bottom opening thereby at least partially filling the applicator; forming a layer over at least a portion of a previously formed object cross-section including dispensing material from the applicator by sweeping the applicator across at least a portion of the previously formed object cross-section; exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form an object cross-section adhered to the previously formed object cross-section; and repeating said forming and exposing to form subsequent layers and cross-sections to form the at least portion of the object.
Claim 27
Independent Claim
142 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; an applicator for forming layers of material over at least portions of any previously formed object cross-sections, the applicator including a plurality of apertures for dispensing streams of material, the apertures having an effective spacing therebetween which is large enough so that the streams remain substantially independent before contacting the previously formed object cross-sections and which is small enough so that the streams merge substantially immediately after contacting the previously formed object cross-sections; means for sweeping the applicator across at least a portion of the previously formed object cross-sections; and a source of synergistic stimulation for exposing the layers according to the descriptive data.
Claim 28
Independent Claim
142 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; an applicator for forming layers of material over at least portions of any previously formed object cross-sections, the applicator including a plurality of apertures for dispensing streams of material, the apertures having an effective spacing therebetween which is large enough so that the streams remain substantially independent before contacting the previously formed object cross-sections and which is small enough so that the streams merge substantially immediately after contacting the previously formed object cross-sections; means for sweeping the applicator across at least a portion of the previously formed object cross-sections; and a source of synergistic stimulation for exposing the layers according to the descriptive data.
Claim 29
Independent Claim
159 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; forming a layer over at least a portion of a previously formed object cross-section by dispensing material from an applicator having a plurality of apertures for dispensing streams of material, the apertures having an effective spacing therebetween which is large enough so that the streams remain substantially independent before contacting the previously formed object cross-section and which is small enough so that the streams merge substantially immediately after contacting the previously formed object cross-section; sweeping the applicator across at least a portion of the previously formed object cross-section; exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form a successive object cross-section; and repeating said layer-forming and layer-exposing to form the at least portion of the object.
Claim 30
Independent Claim
159 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; forming a layer over at least a portion of a previously formed object cross-section by dispensing material from an applicator having a plurality of apertures for dispensing streams of material, the apertures having an effective spacing therebetween which is large enough so that the streams remain substantially independent before contacting the previously formed object cross-section and which is small enough so that the streams merge substantially immediately after contacting the previously formed object cross-section; sweeping the applicator across at least a portion of the previously formed object cross-section; exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form a successive object cross-section; and repeating said layer-forming and layer-exposing to form the at least portion of the object.
Claim 31
Independent Claim
258 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; containing a volume of material having a working surface; determining a minimum region of the working surface including performing a Boolean union operation on data descriptive of the last formed cross-sectional region of the object and data descriptive of at least one other cross-sectional region of the object preceding the last formed cross-sectional region of the object; forming a layer over at least the minimum region of the working surface including moving a coating device over at least the minimum region of the working surface; exposing the layer to a source of synergistic stimulation according to the descriptive data to form a successive object cross-section; and repeating said forming and exposing a plurality of times to form the at least portion of the object; wherein the coating device is not moved over the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; wherein the recoating device has a direction of movement over the last formed cross-section; and wherein, for at least some layers, the layer is formed over a last formed cross-section which has an extent which is less than an extent of the at least one cross-section formed prior to the last formed cross-section in the direction of movement.
Claim 32
Independent Claim
258 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; containing a volume of material having a working surface; determining a minimum region of the working surface including performing a Boolean union operation on data descriptive of the last formed cross-sectional region of the object and data descriptive of at least one other cross-sectional region of the object preceding the last formed cross-sectional region of the object; forming a layer over at least the minimum region of the working surface including moving a coating device over at least the minimum region of the working surface; exposing the layer to a source of synergistic stimulation according to the descriptive data to form a successive object cross-section; and repeating said forming and exposing a plurality of times to form the at least portion of the object; wherein the coating device is not moved over the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; wherein the recoating device has a direction of movement over the last formed cross-section; and wherein, for at least some layers, the layer is formed over a last formed cross-section which has an extent which is less than an extent of the at least one cross-section formed prior to the last formed cross-section in the direction of movement.
Claim 33
Dependent Claim
29 words
The method of claim 21 additionally comprising locating the coating device beyond a region to be exposed when forming a next cross-sectional region following the last formed cross-sectional region.
Claim 34
Independent Claim
224 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; a container for containing a volume of material having a working surface; means for determining a minimum region of the working surface including means for performing a Boolean union operation on data descriptive of the last formed cross-sectional region of the object and at least one other cross-sectional region preceding the last formed cross-section of the object; a coating device for forming layers over at least the minimum region of the working surface; and a source of synergistic stimulation for exposing the layers according to the descriptive data; wherein the coating device does not move over the entire working surface during the formation of at least some layers; wherein a region coated by the coating device is different for at least some of the layers formed; wherein the coating device is moved with a direction of movement over the last formed cross-section; and wherein, for at least some layers, the layer is formed over a last formed cross-section which has an extent which is less than an extent of the at least one cross-section formed prior to the last formed cross-section in the direction of movement.
Claim 35
Independent Claim
224 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; a container for containing a volume of material having a working surface; means for determining a minimum region of the working surface including means for performing a Boolean union operation on data descriptive of the last formed cross-sectional region of the object and at least one other cross-sectional region preceding the last formed cross-section of the object; a coating device for forming layers over at least the minimum region of the working surface; and a source of synergistic stimulation for exposing the layers according to the descriptive data; wherein the coating device does not move over the entire working surface during the formation of at least some layers; wherein a region coated by the coating device is different for at least some of the layers formed; wherein the coating device is moved with a direction of movement over the last formed cross-section; and wherein, for at least some layers, the layer is formed over a last formed cross-section which has an extent which is less than an extent of the at least one cross-section formed prior to the last formed cross-section in the direction of movement.
Claim 36
Dependent Claim
59 words
The apparatus of claim 23 Boolean operation performs the operation between (1) a last-formed cross-sectional region, (2) a cross-sectional region to be exposed next, and (3) at least one cross-sectional region formed below additionally comprising means for locating the coating device beyond a region to be exposed when forming a next cross-sectional region following the last formed cross-sectional region.
Claim 37
Dependent Claim
16 words
The apparatus of claim 17 wherein the device coupled to the applicator comprises a vacuum pump.
Claim 38
Dependent Claim
16 words
The apparatus of claim 17 wherein the device coupled to the applicator comprises a fluid pump.
Claim 39
Dependent Claim
18 words
The method of claim 18 wherein said drawing up material comprises evacuating an internal portion of the applicator.
Claim 40
Dependent Claim
20 words
The method of claim 18 where said drawing up material comprises operating a pump which pulls material into the dispenser.
Claim 41
Dependent Claim
23 words
The apparatus of claim 3 wherein the material is a photopolymer and the source of synergistic stimulation is a source of electromagnetic radiation.
Claim 42
Dependent Claim
11 words
The method of claim 9 wherein the material is a photopolymer.
Claim 43
Dependent Claim
23 words
The apparatus of claim 13 wherein the material is a photopolymer and the source of synergistic stimulation is a source of electromagnetic radiation.
Claim 44
Dependent Claim
11 words
The method of claim 14 wherein the material is a photopolymer.
Claim 45
Dependent Claim
23 words
The apparatus of claim 15 wherein the material is a photopolymer and the source of synergistic stimulation is a source of electromagnetic radiation.
Claim 46
Dependent Claim
11 words
The method of claim 16 wherein the material is a photopolymer.
Claim 47
Dependent Claim
23 words
The apparatus of claim 19 wherein the material is a photopolymer and the source of synergistic stimulation is a source of electromagnetic radiation.
Claim 48
Dependent Claim
11 words
The method of claim 20 wherein the material is a photopolymer.
Claim 49
Dependent Claim
11 words
The method of claim 21 wherein the material is a photopolymer.
Claim 50
Dependent Claim
23 words
The apparatus of claim 23 wherein the material is a photopolymer and the source of synergistic stimulation is a source of electromagnetic radiation.
Claim 51
Independent Claim
262 words
A method of forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; containing a volume of material having a working surface; deriving a tailored coating region of the working surface for a layer including deriving combined extents of: (1) a region exposed when forming a last formed object cross-section, and (2) a region exposed when forming at least one object cross-section formed prior to forming the last formed object cross-section; forming a layer of material in preparation for forming a successive object cross-section, including moving a recoating device to aid in the formation of a coating over the tailored coating region; exposing the layer to synergistic stimulation according to the data descriptive of the object to form the successive object cross-section; and repeating said layer forming and exposing a plurality of times to form the at least portion of the three-dimensional object; wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; and wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
Claim 52
Independent Claim
262 words
A method of forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: supplying data descriptive of the object; containing a volume of material having a working surface; deriving a tailored coating region of the working surface for a layer including deriving combined extents of: (1) a region exposed when forming a last formed object cross-section, and (2) a region exposed when forming at least one object cross-section formed prior to forming the last formed object cross-section; forming a layer of material in preparation for forming a successive object cross-section, including moving a recoating device to aid in the formation of a coating over the tailored coating region; exposing the layer to synergistic stimulation according to the data descriptive of the object to form the successive object cross-section; and repeating said layer forming and exposing a plurality of times to form the at least portion of the three-dimensional object; wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; and wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
Claim 53
Dependent Claim
37 words
The method of claim 39 additionally comprising ultimately locating the recoating device beyond a region of the working surface to be exposed when forming a next object cross-section immediately following the formation of the last object cross-section.
Claim 54
Dependent Claim
30 words
The method of claim 39 wherein the at least one cross-section formed prior to the last formed cross-section is at least two cross-sections formed immediately preceeding the last formed cross-section.
Claim 55
Dependent Claim
48 words
The method of claim 41 wherein each of the at least two cross-sections formed immediately preceeding the last formed cross-section has a thickness and wherein a summed thickness of the at least two cross-sections is at least as great as a thickness of a predefined shallow troublesome depth.
Claim 56
Dependent Claim
37 words
The method of claim 42 additionally comprising ultimately locating the recoating device beyond a region of the working surface to be exposed in forming a next object cross-section immediately following the formation of the last object cross-section.
Claim 57
Dependent Claim
46 words
The method of claim 39 wherein the extent for moving and ultimately locating the recoating device is based on inclusion of a preset minimum distance beyond the combined extents of: (1) the last formed cross-section, and (2) the cross-section formed prior to the last formed cross-section.
Claim 58
Dependent Claim
54 words
The method of claim 44 wherein the extent for moving and ultimately locating the recoating device is additionally based on inclusion of a preset minimum distance beyond the combined extents of: (1) the last formed cross-section, (2) the cross-section formed prior to the last formed cross-section, and (3) a cross-section to be formed next.
Claim 59
Dependent Claim
11 words
The method of claim 43 wherein the material is a photopolymer.
Claim 60
Independent Claim
207 words
A method of forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: forming a layer of building material in preparation for forming a successive object cross-section, including moving a recoating device over (1) a region exposed when forming a last-formed object cross-section, and (2) a region exposed when forming at least one cross-section formed prior to the last formed cross-section; and exposing the layer to synergistic stimulation to form the successive object cross-section; and repeating said forming and exposing a plurality of times to form the at least portion of the three-dimensional object; wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; and wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
Claim 61
Independent Claim
207 words
A method of forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: forming a layer of building material in preparation for forming a successive object cross-section, including moving a recoating device over (1) a region exposed when forming a last-formed object cross-section, and (2) a region exposed when forming at least one cross-section formed prior to the last formed cross-section; and exposing the layer to synergistic stimulation to form the successive object cross-section; and repeating said forming and exposing a plurality of times to form the at least portion of the three-dimensional object; wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; and wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
Claim 62
Dependent Claim
37 words
The method of claim 47 additionally comprising ultimately locating the recoating device beyond a region of the working surface to be exposed in forming a next object cross-section immediately following the formation of the last object cross-section.
Claim 63
Dependent Claim
30 words
The method of claim 47 wherein the at least one cross-section formed prior to the last formed cross-section is at least two cross-sections formed immediately preceding the last formed cross-section.
Claim 64
Dependent Claim
48 words
The method of claim 49 wherein each of the at least two cross-sections formed immediately preceding the last formed cross-section has a thickness and wherein a summed thickness of the at least two cross-sections is at least as great as a thickness of a predefined shallow troublesome depth.
Claim 65
Dependent Claim
37 words
The method of claim 50 additionally comprising ultimately locating the recoating device beyond a region of the working surface to be exposed in forming a next object cross-section immediately following the formation of the last object cross-section.
Claim 66
Dependent Claim
44 words
The method of claim 51 wherein the extent for moving and ultimately locating the recoating device comprises inclusion of a preset minimum distance beyond the combined extents of: (1) the last formed cross-section, and (2) the cross-section formed prior to the last formed cross-section.
Claim 67
Dependent Claim
52 words
The method of claim 51 wherein the extent for moving and ultimately locating the recoating device additionally comprises inclusion of a preset minimum distance beyond the combined extents of: (1) the last formed cross-section, (2) the cross-section formed prior to the last formed cross-section, and (3) the cross-section to be formed next.
Claim 68
Dependent Claim
11 words
The method of claim 51 wherein the material is a photopolymer.
Claim 69
Independent Claim
225 words
A method of forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: forming a layer of building material in preparation for forming a subsequent object cross-section, including: (1) moving a recoating device over a region exposed when forming a last-formed object cross-section, (2) locating the recoating device beyond a region to be exposed in forming a next cross-section of the object, and (3) locating the recoating device beyond the combined extents of (1) and (2) by a predetermined amount; exposing the layer to synergistic stimulation to form the successive object cross-section; and repeating said forming and exposing a plurality of times to form the at least portion of the three-dimensional object; wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; and wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
Claim 70
Independent Claim
225 words
A method of forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: forming a layer of building material in preparation for forming a subsequent object cross-section, including: (1) moving a recoating device over a region exposed when forming a last-formed object cross-section, (2) locating the recoating device beyond a region to be exposed in forming a next cross-section of the object, and (3) locating the recoating device beyond the combined extents of (1) and (2) by a predetermined amount; exposing the layer to synergistic stimulation to form the successive object cross-section; and repeating said forming and exposing a plurality of times to form the at least portion of the three-dimensional object; wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; and wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
Claim 71
Dependent Claim
45 words
The method of claim 55 wherein said moving the recoating device comprises moving the recoating device over (1) the region exposed when forming a last-formed object cross-section, and (2) a region exposed when forming at least one cross-section formed prior to the last formed cross-section.
Claim 72
Dependent Claim
30 words
The method of claim 56 wherein the at least one cross-section formed prior to the last formed cross-section is at least two cross-sections formed immediately preceeding the last formed cross-section.
Claim 73
Dependent Claim
47 words
The method of claim 57 wherein each of the at least two cross-sections formed immediately preceeding the last formed cross-section has a thickness and wherein a summed thickness of the at least two is at least as great as a thickness of a predefined shallow troublesome depth.
Claim 74
Dependent Claim
11 words
The method of claim 56 wherein the material is a photopolymer.
Claim 75
Independent Claim
294 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: a memory device for receiving data descriptive of the object; a container for holding a volume of material having a working surface; a computer configured to derive a tailored coating region of the working surface for a layer including deriving combined extents of: (1) a region exposed when forming a last formed object cross-section, and (2) a region exposed when forming at least one object cross-section formed prior to forming the last formed object cross-section; a recoating device for forming a layer of material in preparation for forming a successive object cross-section, a recoating device control system for moving the recoating device to aid in the formation of a coating over the tailored coating region; an exposure system for exposing the layer to synergistic stimulation according to the data descriptive of the object to form the successive object cross-section; and a control system for repeatedly operating the recoating device and exposure system a plurality of times to form the at least portion of the three-dimensional object; wherein the recoating device is controlled to move over less than the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; and wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
Claim 76
Independent Claim
294 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: a memory device for receiving data descriptive of the object; a container for holding a volume of material having a working surface; a computer configured to derive a tailored coating region of the working surface for a layer including deriving combined extents of: (1) a region exposed when forming a last formed object cross-section, and (2) a region exposed when forming at least one object cross-section formed prior to forming the last formed object cross-section; a recoating device for forming a layer of material in preparation for forming a successive object cross-section, a recoating device control system for moving the recoating device to aid in the formation of a coating over the tailored coating region; an exposure system for exposing the layer to synergistic stimulation according to the data descriptive of the object to form the successive object cross-section; and a control system for repeatedly operating the recoating device and exposure system a plurality of times to form the at least portion of the three-dimensional object; wherein the recoating device is controlled to move over less than the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; and wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
Claim 77
Dependent Claim
41 words
The apparatus of claim 60 wherein the recoating device control system ultimately locates the recoating device beyond a region of the working surface to be exposed when forming a next object cross-section immediately following the formation of the last object cross-section.
Claim 78
Dependent Claim
45 words
The apparatus of claim 60 wherein the computer is configured to derive a tailored coating region of the working surface wherein the at least one cross-section formed prior to the last formed cross-section is at least two cross-sections formed immediately preceding the last formed cross-section.
Claim 79
Dependent Claim
63 words
The apparatus of claim 62 wherein the computer is configured to derive a tailored coating region of the working surface wherein each of the at least two cross-sections formed immediately preceding the last formed cross-section has a thickness and wherein a summed thickness of the at least two cross-sections is at least as great as a thickness of a predefined shallow troublesome depth.
Claim 80
Dependent Claim
41 words
The apparatus of claim 63 wherein the recoating device control system ultimately locates the recoating device beyond a region of the working surface to be exposed in forming a next object cross-section immediately following the formation of the last object cross-section.
Claim 81
Dependent Claim
46 words
The apparatus of claim 60 wherein the recoating device control system ultimately locates the recoating device to a position which is a preset minimum distance beyond the combined extents of: (1) the last formed cross-section, and (2) the cross-section formed prior to the last formed cross-section.
Claim 82
Dependent Claim
53 words
The apparatus of claim 65 wherein the recoating device control system ultimately locates the recoating device to a position which is a preset minimum distance beyond the combined extents of: (1) the last formed cross-section, (2) the cross-section formed prior to the last formed cross-section, and (3) a cross-section to be formed next.
Claim 83
Dependent Claim
27 words
The apparatus of claim 64 wherein the material comprises a photopolymer and the exposure system includes a source of synergistic stimulation comprising a source of electromagnetic radiation.
Claim 84
Independent Claim
228 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: a recoating device for forming a layer of building material in preparation for forming a successive object cross-section; a recoating device control system for moving the recoating device over: (1) a region exposed when forming a last-formed object cross-section, and (2) a region exposed when forming at least one cross-section formed prior to the last formed cross-section; and an exposure system for exposing the layer to synergistic stimulation to form the successive object cross-section; and a control system for repeatedly operating the recoating device and the exposure system a plurality of times to form the at least portion of the three-dimensional object; wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; and wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
Claim 85
Independent Claim
228 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: a recoating device for forming a layer of building material in preparation for forming a successive object cross-section; a recoating device control system for moving the recoating device over: (1) a region exposed when forming a last-formed object cross-section, and (2) a region exposed when forming at least one cross-section formed prior to the last formed cross-section; and an exposure system for exposing the layer to synergistic stimulation to form the successive object cross-section; and a control system for repeatedly operating the recoating device and the exposure system a plurality of times to form the at least portion of the three-dimensional object; wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; and wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
Claim 86
Dependent Claim
41 words
The apparatus of claim 68 wherein the recoating device control system ultimately locates the recoating device beyond a region of the working surface to be exposed in forming a next object cross-section immediately following the formation of the last object cross-section.
Claim 87
Dependent Claim
47 words
The apparatus of claim 68 wherein the recoating device control system is configured to move the recoating device over: (1) a region exposed when forming a last-formed object cross-section, and (2) a region exposed when forming at least two cross-sections formed immediately preceding the last formed cross-section.
Claim 88
Dependent Claim
64 words
The apparatus of claim 70 wherein the recoating device control system is configured with a predefined shallow troublesome depth parameter and wherein each of the at least two cross-sections formed immediately preceding the last formed cross-section has a thickness and wherein a summed thickness of the at least two cross-sections is at least as great as a thickness of the predefined shallow troublesome depth.
Claim 89
Dependent Claim
41 words
The apparatus of claim 71 wherein the recoating device control system ultimately locates the recoating device beyond a region of the working surface to be exposed in forming a next object cross-section immediately following the formation of the last object cross-section.
Claim 90
Dependent Claim
46 words
The apparatus of claim 72 wherein the recoating device control system ultimately locates the recoating device to a position which is a preset minimum distance beyond the combined extents of: (1) the last formed cross-section, and (2) the cross-section formed prior to the last formed cross-section.
Claim 91
Dependent Claim
53 words
The apparatus of claim 72 wherein the recoating device control system ultimately locates the recoating device to a position which is a preset minimum distance beyond the combined extents of: (1) the last formed cross-section, (2) the cross-section formed prior to the last formed cross-section, and (3) a cross-section to be formed next.
Claim 92
Dependent Claim
25 words
The apparatus of claim 72 wherein the material comprises a photopolymer and the exposure system includes a source of synergistic stimulation that produces electromagnetic radiation.
Claim 93
Independent Claim
245 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: a recoating device for forming a layer of building material in preparation for forming a subsequent object cross-section; a recoating device control system for: (1) moving a recoating device over a region exposed when forming a last-formed object cross-section, (2) locating the recoating device beyond a region to be exposed in forming a next cross-section of the object, and (3) locating the recoating device beyond the combined extents of (1) and (2) by a predetermined amount; an exposure system for exposing the layer to synergistic stimulation to form the successive object cross-section; and a control system for repeatedly operating the recoating device and exposure system a plurality of times to form the at least portion of the three-dimensional object; wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; and wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
Claim 94
Independent Claim
245 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: a recoating device for forming a layer of building material in preparation for forming a subsequent object cross-section; a recoating device control system for: (1) moving a recoating device over a region exposed when forming a last-formed object cross-section, (2) locating the recoating device beyond a region to be exposed in forming a next cross-section of the object, and (3) locating the recoating device beyond the combined extents of (1) and (2) by a predetermined amount; an exposure system for exposing the layer to synergistic stimulation to form the successive object cross-section; and a control system for repeatedly operating the recoating device and exposure system a plurality of times to form the at least portion of the three-dimensional object; wherein the recoating device is moved over less than the entire working surface during the process of forming at least some layers; wherein an extent of movement of the recoating device is different for at least some of the layers formed; and wherein the at least portion of the object includes a first object cross-section formed prior to a second object cross-section, which first object cross-section extends beyond an extent of the second object cross-section in a direction of movement of the recoating device when forming a layer above and adjacent to the first object cross-section.
Claim 95
Dependent Claim
44 words
The apparatus of claim 76 wherein the recoating device control system moves the recoating device over (1) the region exposed when forming a last-formed object cross-section, and (2) a region exposed when forming at least one cross-section formed prior to the last formed cross-section.
Claim 96
Dependent Claim
47 words
The apparatus of claim 77 wherein the recoating device control system is configured to move the recoating device over: (1) a region exposed when forming a last-formed object cross-section, and (2) a region exposed when forming at least two cross-sections formed immediately preceding the last formed cross-section.
Claim 97
Dependent Claim
64 words
The apparatus of claim 78 wherein the recoating device control system is configured with a predefined shallow troublesome depth parameter and wherein each of the at least two cross-sections formed immediately preceding the last formed cross-section has a thickness and wherein a summed thickness of the at least two cross-sections is at least as great as a thickness of the predefined shallow troublesome depth.
Claim 98
Dependent Claim
25 words
The apparatus of claim 78 wherein the material comprises a photopolymer and the exposure system includes a source of synergistic stimulation that produces electromagnetic radiation.
Claim 99
Independent Claim
152 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; a container for containing a volume of material having a working surface; an applicator for forming layers of material over at least portions of previously formed object cross-sections, the applicator having a bottom opening located in proximity to the working surface; a vacuum pump coupled to the applicator for drawing up material from the working surface through the bottom opening and into the applicator; means for sweeping the applicator across at least a portion of at least some of the previously formed object cross-sections; and a source of synergistic stimulation for exposing the layers according to the descriptive data to form the at least portion of the object from a plurality of object cross-sections.
Claim 100
Independent Claim
152 words
An apparatus for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising: means for supplying data descriptive of the object; a container for containing a volume of material having a working surface; an applicator for forming layers of material over at least portions of previously formed object cross-sections, the applicator having a bottom opening located in proximity to the working surface; a vacuum pump coupled to the applicator for drawing up material from the working surface through the bottom opening and into the applicator; means for sweeping the applicator across at least a portion of at least some of the previously formed object cross-sections; and a source of synergistic stimulation for exposing the layers according to the descriptive data to form the at least portion of the object from a plurality of object cross-sections.
Claim 101
Independent Claim
177 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising supplying data descriptive of the object; containing a volume of material having a working surface; locating an applicator having a bottom opening in proximity to the working surface; forming a meniscus of material between the applicator and working surface; using a vacuum pump to draw up material from the working surface into the applicator through the bottom opening thereby at least partially filling the applicator; forming a layer over at least a portion of a previously formed object cross-section including dispensing material from the applicator by sweeping the applicator across at least a portion of the previously formed object cross-section; exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form an object cross-section adhered to the previously formed object cross-section; and repeating said forming and exposing to form subsequent layers and cross-sections to form the at least portion of the object.
Claim 102
Independent Claim
177 words
A method for forming at least a portion of a three-dimensional object on a substantially cross-sectional basis from a material capable of physical transformation upon exposure to synergistic stimulation, comprising supplying data descriptive of the object; containing a volume of material having a working surface; locating an applicator having a bottom opening in proximity to the working surface; forming a meniscus of material between the applicator and working surface; using a vacuum pump to draw up material from the working surface into the applicator through the bottom opening thereby at least partially filling the applicator; forming a layer over at least a portion of a previously formed object cross-section including dispensing material from the applicator by sweeping the applicator across at least a portion of the previously formed object cross-section; exposing selected portions of the layer to synergistic stimulation according to the descriptive data to form an object cross-section adhered to the previously formed object cross-section; and repeating said forming and exposing to form subsequent layers and cross-sections to form the at least portion of the 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) | 2002-05-10 | 2002-11-09 | 2003-05-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2006-05-10 | 2006-11-09 | 2007-05-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2010-05-10 | 2010-11-09 | 2011-05-11 | $7700.00 | Window Closed / Lapsed |