Stereolithographic method and apparatus for production of three dimensional objects using recoating parameters for groups of layers

Claim 1

A method of forming a three-dimensional object from a plurality of adhered laminae, comprising: forming successive layers of material adjacent to any last formed layers of material in preparation for forming subsequent laminae of the object, some of the successive layers being primary layers spaced one from the other by one or more secondary layers positioned intermediate thereto; defining at least first and second groups of layers, wherein the first group comprises a plurality of primary layers and the second group comprises one or more secondary layers located between the pair of successive primary layers in the first group; selectively exposing the primary layers to form at least majority portions of primary laminae in association therewith and to form at least portions of the secondary laminae; and selectively exposing the secondary layers to form at least minority portions of the secondary laminae in association therewith; wherein the exposure of the primary layers and secondary layers results in adhesion of laminae to previously formed laminae so as to form the object from a plurality of adhered laminae; wherein the formation of the first group of layers is controlled by a first set of recoating parameters and the formation of the second group of layers is controlled by a second set of recoating parameters that is different from the first set.

Claim 2

A method of forming a three-dimensional object from a plurality of adhered laminae, comprising: forming successive layers of material adjacent to any last formed layers of material in preparation for forming subsequent laminae of the object, some of the successive layers being primary layers spaced one from the other by one or more secondary layers positioned intermediate thereto; defining at least first and second groups of layers, wherein the first group comprises a plurality of primary layers and the second group comprises one or more secondary layers located between the pair of successive primary layers in the first group; selectively exposing the primary layers to form at least majority portions of primary laminae in association therewith and to form at least portions of the secondary laminae; and selectively exposing the secondary layers to form at least minority portions of the secondary laminae in association therewith; wherein the exposure of the primary layers and secondary layers results in adhesion of laminae to previously formed laminae so as to form the object from a plurality of adhered laminae; wherein the formation of the first group of layers is controlled by a first set of recoating parameters and the formation of the second group of layers is controlled by a second set of recoating parameters that is different from the first set.

Claim 15

A method of forming a three-dimensional object from a plurality of adhered laminae, comprising: defining a number S of successive layers as a set; defining a plurality of set of layers; defining a plurality of groups of layers, wherein the groups contain one or more layers from each of the plurality of sets; associating recoating parameters with each of the defined groups; forming successive layers of material adjacent to any last formed layers of material in preparation for forming subsequent laminae of the object, wherein the recoating parameters utilized for forming a particular layer are dictated by recoating parameters specified for the group that contains the specific layer; selectively exposing the layers to form at least portions of the lamina associated therewith to form the object from a plurality of adhered laminae.

Claim 16

A method of forming a three-dimensional object from a plurality of adhered laminae, comprising: defining a number S of successive layers as a set; defining a plurality of set of layers; defining a plurality of groups of layers, wherein the groups contain one or more layers from each of the plurality of sets; associating recoating parameters with each of the defined groups; forming successive layers of material adjacent to any last formed layers of material in preparation for forming subsequent laminae of the object, wherein the recoating parameters utilized for forming a particular layer are dictated by recoating parameters specified for the group that contains the specific layer; selectively exposing the layers to form at least portions of the lamina associated therewith to form the object from a plurality of adhered laminae.

Claim 17

An apparatus for forming a three-dimensional object from a plurality of adhered laminae, comprising: means for forming successive layers of material adjacent to any previously formed layers of material in preparation for forming subsequent laminae of the object, some of the successive layers being primary layers spaced one from the other by one or more secondary layers positioned intermediate thereto; means for defining at least first and second groups of layers, wherein the first group comprises a plurality of primary layers and the second group comprises one or more secondary layers located between successive pairs of primary layers; means for selectively exposing the primary layers to form at least majority portions of primary laminae in association therewith and to form at least portions of the secondary laminae; and means for selectively exposing the secondary layers to form at least minority portions of the secondary laminae in association therewith; wherein the exposure of the primary layers and secondary layers results in adhesion of laminae to previously formed laminae so as to form the object from a plurality of adhered laminae; wherein the means for forming forms the first group of layers under the control of a first set of recoating parameters and forms the second group of layers under the control of a second set of recoating parameters that is different from the first set.

Claim 18

An apparatus for forming a three-dimensional object from a plurality of adhered laminae, comprising: means for forming successive layers of material adjacent to any previously formed layers of material in preparation for forming subsequent laminae of the object, some of the successive layers being primary layers spaced one from the other by one or more secondary layers positioned intermediate thereto; means for defining at least first and second groups of layers, wherein the first group comprises a plurality of primary layers and the second group comprises one or more secondary layers located between successive pairs of primary layers; means for selectively exposing the primary layers to form at least majority portions of primary laminae in association therewith and to form at least portions of the secondary laminae; and means for selectively exposing the secondary layers to form at least minority portions of the secondary laminae in association therewith; wherein the exposure of the primary layers and secondary layers results in adhesion of laminae to previously formed laminae so as to form the object from a plurality of adhered laminae; wherein the means for forming forms the first group of layers under the control of a first set of recoating parameters and forms the second group of layers under the control of a second set of recoating parameters that is different from the first set.

Claim 19

An apparatus for forming a three-dimensional object from a plurality of adhered laminae, comprising: a coating system for forming successive layers of material adjacent to any previously formed layers of material in preparation for forming subsequent laminae of the object, some of the successive layers being primary layers spaced one from the other by one or more secondary layers positioned intermediate thereto; a computer programmed to define at least first and second groups of layers, wherein the first group comprises a plurality of primary layers and the second group comprises one or more secondary layers located between pairs of successive primary layers; an exposure system for selectively exposing the layers of material including exposing (1) the primary layers to form at least majority portions of primary laminae in association therewith and to form at least portions of the secondary laminae, and (2) the secondary layers to form at least minority portions of the secondary laminae in association therewith; wherein the exposure of the primary layers and secondary layers results in adhesion of laminae to previously formed laminae so as to form the object from a plurality of adhered laminae; wherein the coating system forms the first group of layers under the control of a first set of recoating parameters and forms the second group of layers under the control of a second set of recoating parameters that is different from the first set.

Claim 20

An apparatus for forming a three-dimensional object from a plurality of adhered laminae, comprising: a coating system for forming successive layers of material adjacent to any previously formed layers of material in preparation for forming subsequent laminae of the object, some of the successive layers being primary layers spaced one from the other by one or more secondary layers positioned intermediate thereto; a computer programmed to define at least first and second groups of layers, wherein the first group comprises a plurality of primary layers and the second group comprises one or more secondary layers located between pairs of successive primary layers; an exposure system for selectively exposing the layers of material including exposing (1) the primary layers to form at least majority portions of primary laminae in association therewith and to form at least portions of the secondary laminae, and (2) the secondary layers to form at least minority portions of the secondary laminae in association therewith; wherein the exposure of the primary layers and secondary layers results in adhesion of laminae to previously formed laminae so as to form the object from a plurality of adhered laminae; wherein the coating system forms the first group of layers under the control of a first set of recoating parameters and forms the second group of layers under the control of a second set of recoating parameters that is different from the first set.

Claim 21

An apparatus for forming a three-dimensional object from a plurality of adhered laminae, comprising: means for defining a number S of successive layers as a set; means for defining a plurality of set of layers; means for defining a plurality of groups of layers, wherein the groups contain one or more layers from each of the plurality of sets; means for associating recoating parameters with each of the defined groups; means for forming successive layers of material adjacent to any last formed layers of material in preparation for forming subsequent laminae of the object, wherein the recoating parameters utilized for forming a particular layer are dictated by recoating parameters specified for the group that contains the specific layer; and means for selectively exposing the layers to form at least portions of the lamina associated therewith to form the object from a plurality of adhered laminae.

Claim 22

An apparatus for forming a three-dimensional object from a plurality of adhered laminae, comprising: means for defining a number S of successive layers as a set; means for defining a plurality of set of layers; means for defining a plurality of groups of layers, wherein the groups contain one or more layers from each of the plurality of sets; means for associating recoating parameters with each of the defined groups; means for forming successive layers of material adjacent to any last formed layers of material in preparation for forming subsequent laminae of the object, wherein the recoating parameters utilized for forming a particular layer are dictated by recoating parameters specified for the group that contains the specific layer; and means for selectively exposing the layers to form at least portions of the lamina associated therewith to form the object from a plurality of adhered laminae.