JPH0613196B2 - Method and apparatus for creating three-dimensional objects - Google Patents

Description

Description: TECHNICAL FIELD The present invention is an improvement of a method and apparatus for forming a three-dimensional object from a fluid medium, and in particular, a three-dimensional object can be formed quickly, reliably, accurately and economically. As possible, it relates to stereolithography applying lithography to the production of three-dimensional objects.

[Conventional technology]

When manufacturing a component made of plastic or the like, it is usual to design the component first, and then make a prototype of the component with difficulty. All of these require considerable time, labor and expense. This design is then reviewed and this tedious process is often repeated until the design is optimized.

After the design is optimized, the next step is its manufacture. In most productions, plastic parts are injection molded. Due to the extremely high design time and cost of tools, injected plastic parts are usually only practical in mass production. Other methods such as direct machining, vacuum forming and direct forming can be utilized to produce plastic parts. However, these methods are usually cost effective only for short term production, and the manufactured parts are of poorer quality than the injection molded parts.

Recently, a very good method of creating a three-dimensional object in a fluid medium has been developed. The fluid medium is selectively hardened by a radiation beam that is selectively focused at a predetermined intersection within the three-dimensional volume of the fluid medium. A typical device for forming such a three-dimensional object is U.S. Pat. No. 2,775,78.
5, No. 4,041,476, No. 4,078,22
No. 9 and No. 4,238,840 No. 4,288,86
No. 1, JP-A-56-144478, Hideo Kodama, "Automatic three-dimensional shape creation method as a method for displaying three-dimensional information" (IEICE Transactions, VOL.J64-C No.4, April 1981), Hideo
Kodama, Automatic method for manufacturing a three-
dimensional Plastic model with photo-hardening pol
ymer, Review of Scientific Instruments, 52 (11), Nov.1
981, and Alan J. Herbert, Solid Object Generation,
Journal of Applied Photographic Engineering, VOL
8, No. 4, August 1982. All of these devices use a variety of large multi-beam schemes to eliminate all other points in the fluid volume and create synergistic energy at selected points deep in the fluid volume. Rely on granting. In this regard, various conventional systems use a pair of electromagnetic radiation beams oriented such that they intersect at a particular coordinate. In this case, the various beams may have the same or different wavelengths, or the beams may cross the same point sequentially, rather than simultaneously. However, in all of these cases, only the beam intersections receive energy to an energy level sufficient to achieve the hardening process necessary to form a three-dimensional object in the volume of the fluid medium.

(Problems to be Solved by the Invention) However, unfortunately, such a three-dimensional molding apparatus has many problems in terms of resolution and exposure control. Of course, complex control conditions occur due to the reduced radiation intensity of the intersection as it moves deeper into the fluid medium and the reduced resolution of forming the image of the focused spot. Absorption, diffusion, dispersion and analysis methods,
Economically and reliably make it difficult to process deep in the fluid medium. Therefore, it was difficult to form an extremely thin layer, and automatic lamination was also difficult.

However, to be able to move from the design stage to the prototype stage and then to the final production quickly and reliably. In particular, there has been a long-felt need in the field of design and manufacture for such plastic parts to move directly from the computer design to the prototype virtually immediately and to economically and automatically mass-produce equipment. Still there.

Therefore, those involved in the development and manufacturing of three-dimensional plastic objects, etc., move from the design stage to the prototype stage, and then to the manufacturing stage, avoiding the complex focusing, alignment and exposure problems of conventional three-dimensional manufacturing equipment. We have found that it would be desirable to further improve upon the more agile, reliable, economical and automatic means of ensuring rapid transfer. The present invention meets all of these needs.

[Means and Actions for Solving Problems]

The invention provides for the surface of a fluid medium capable of changing its physical state in response to a suitable synergistic energy,
By forming successive adjoining cross-section laminates of this object, a new and improved apparatus for creating three-dimensional objects is provided. Successive laminates automatically and firmly integrate as they are formed to form the desired three-dimensional object.

By way of example, and not meant to be limiting, in the presently preferred embodiment, the present invention utilizes the computer generated graphics concept in combination with lithography. That is, applying lithography technology to the production of three-dimensional objects and producing three-dimensional objects directly from the instructions of the computer, design (CAD) with the help of the computer and computer assist Manufacturing (C
AM) simultaneously. The invention can be used to model and prototype in the design stage of product development, or as a manufacturing device, or for the formation of purely artistic objects.

Here, "stereolithography" is a method and apparatus for making an object by "printing" thin layers of a curable material, eg, an infrared curable material, on top of each other.
A movable spot beam of programmed UV light is used to illuminate a surface or layer of UV curable liquid to form a solid cross-section of an object on the surface of the liquid. afterwards,
The object is constructed in a programmed manner by moving it one layer thickness away from the surface of the liquid and then forming the next cross section and adhering to the layer immediately preceding it. Continue this process until the entire object is formed.

With the method of the present invention, almost any shape of object can be formed. Complex shapes are easier to create by using the action of a computer to generate program instructions and then send the program signals to the stereolithography machine.

Of course, other types of curable fluid media, such as particle irradiation (electron beam, etc.), spraying material through a mask, or chemical reactions with ink jets, or incident and radiation other than UV radiation, The practice of the invention with suitable synergistic energies does not depart from the scope of the invention.

By way of example, in practicing this invention, the body of a fluid medium that is capable of solidifying in response to a given energy is first contained in any suitable container to produce successive cross-section laminates therein. Limits the selected working surface of the fluid medium, such that A suitable type of synergistic energy, such as a UV spot or the like, is then applied as a graphic pattern to the identified working surface of the fluid medium to form a thin solid discrete layer on this surface. When the layers are formed, successive adjacent layers that represent adjacent cross-sections of the three-dimensional object that each layer is going to create are automatically overlapped with each other to integrate the layers and form the desired three-dimensional object. To form. In this regard, when the fluid medium hardens and the solid material is formed into a thin laminate at the work surface, a suitable platform on which the first laminate is fixed, typically by means of any suitable actuator, It is moved away from the work surface in a programmed form under the control of a microcomputer or the like. In this way, the solid material initially formed on the work surface is moved away from this surface and fresh liquid flows into the work surface. UV programmed part of this new liquid
The light spots convert it to a solid material defining a new laminate which is adhesively bonded to the material adjacent to it, the immediate previous laminate. This process continues until the entire three-dimensional object is formed.
After this, the formed object is removed from the container and the device is ready to make another object identical to the first one, or an entirely new object generated by the computer.

The three-dimensional modeling method and apparatus of the present invention has many advantages over the methods currently used to make plastic objects. That is, the method of the present invention does not require design layouts and drawings, or machining drawings and tools. Designers can work directly on the calculator and stereolithography equipment, and when satisfied with the design displayed on the calculator's output screen, can manufacture the part for direct inspection. If the design has to be modified, this can easily be done through a calculator,
Then, to make sure the design change was correct,
You can make another part. If your design requires several parts with interacting design parameters, you can quickly change all of the parts' moldings and recreate them,
The method of the present invention is further useful because the entire assembly can be repetitively made and inspected if desired.

Manufacturing can begin immediately after the design is complete, avoiding weeks and months between design and manufacturing. Final production rates and part costs should be similar to current injection molding costs for short term production, with lower labor costs than with injection molding. Injection molding is economical only when many identical parts are required. 3D modeling is useful for short-term production because it requires no tools and has a very short production setup time. Similarly, design changes and custom parts are easily obtained using this method. Because of the ease with which the parts can be manufactured, stereolithography allows plastic parts to be used in many places where metal or other material parts are now used. Moreover, a plastic model of the object can be quickly and economically made prior to the decision to make expensive metal or other material parts.

Therefore, the three-dimensional modeling method and apparatus of the present invention is a CAD or CAM capable of promptly, reliably, accurately and economically designing and manufacturing a three-dimensional plastic part or the like.
It answers a long-standing need for systems.

The above and other objects and advantages of the present invention will become apparent from the detailed description of the drawings below.

〔Example〕

Next, an embodiment of the present invention will be described with reference to the drawings. 1 and 2 are flow charts showing the basic method and apparatus of the present invention for creating a three-dimensional object by stereolithography.

Immobilized polymers by UV (UV) irradiation, electron beam visible light, invisible light irradiation, ink jets or other types of synergistic energy such as reactive chemicals applied through a suitable mask. Many liquid state chemicals are known that can be induced to transform into plastics. UV curable chemicals are currently used as high-speed printing inks.
It is currently used as an adhesive in the coating process of paper and other materials, and in other specialized areas.

The three-dimensional modeling is a technique for reproducing a graphic object using various methods. Currently, examples include photo reproduction, xerography and microlithography as used in the manufacture of microelectronic circuits. Computer generated graphics displayed on a plotter or cathode ray tube are also in lithographic form, and the image is a computer encoded image of the object.

Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) are techniques that apply the power of a computer to the design and manufacturing process. A typical example of CAD is in the field of electronic printed wiring design. in this case,
The computer and plotter draw the design of the printed wiring board C given the design parameters as data inputs to the computer.
A typical example of an AM is a numerically controlled milling machine, where a computer and milling machine machine metal parts when given appropriate programming instructions. Both CAD and CAM are important and are rapidly growing technologies.

The main object of this invention is to utilize the idea of computer generated graphics in combination with UV curable plastics to perform CAD and CAM at the same time and make three-dimensional objects directly from computer instructions. Is. This invention is called three-dimensional modeling, and can be used for shaping a template and a prototype in the design stage of product development, or as a manufacturing apparatus, or as an artistic shaping.

The three-dimensional modeling method of the present invention is broadly described in FIG. Step 10 of FIG. 1 represents making individual laminates representing the cross-section of the three-dimensional object to be formed. Step 11 is normally performed only if Step 10 is performed correctly, but combines adjacent laminates formed one after the other to form the desired three-dimensional programmed object of the device. , Selectively cure.
Therefore, the three-dimensional modeling apparatus of the present invention is characterized by the incident radiation,
Each responds to an appropriate synergistic energy, such as an electron beam, irradiation of other particles, an ink jet, or a chemical agent applied by spraying through a mask adjacent to the surface of the fluid, respectively physics. A two-dimensional object is created by creating a cross-sectional pattern of the object to be formed on a selected surface of a fluid medium, such as a UV curable liquid, whose physical state can be changed. Successive adjacent laminates representing successive adjacent cross-sections of the object are automatically formed and integrated to create a graded layered or laminar configuration of the object, and during such forming process, the fluid medium A three-dimensional object is formed and lifted from a substantially planar or sheet surface.

The method described above is described in more detail in FIG.
In FIG. 2, step 12 requires the inclusion of a fluid medium that can solidify in response to a predetermined reactive energy. Step 13 applies this energy to the selected fluid surface as a graphic pattern to form a thin solid discrete layer on the surface. Each layer represents an adjoining cross section of a three-dimensional object to be created. It is desirable that each such layer be made as thin as possible during the practice of this invention to maximize the resolution of the three-dimensional object being formed and to accurately reproduce it and further reduce production time. For this reason, the ideal theoretical state is that an object is created only on the selected working surface of the fluid medium, and an infinite number of laminated plates is obtained, and the thickness of each laminated plate is less than zero. Hardened depth that is extremely small (eg 1 mm
Below). By using such a thin layer, it is possible to improve the accuracy of the formed object, and it is possible to form a molding portion having no support on the surface. Of course, in practical use of this invention, each laminate is a thin laminate, but with proper bonding when adhering to adjacent laminates that define other cross-sections of the object formed to form the cross-section. The thickness should be as strong as possible.

In step 14 of Figure 2, successive adjacent layers or laminates are superimposed upon each other as they are formed, and the various layers are integrated to form the desired three-dimensional object. When the present invention is practiced normally, when the fluid medium is hardened and a solid material is formed to form one laminated plate, the laminated plate is moved away from the working surface of the fluid medium, and the previously formed laminated plate. The next laminate is formed in a new liquid that replaces, so that each successive laminate is superimposed (by the natural adhesion of the hardened fluid medium) on all other cross-section laminates. . For this reason, the process of manufacturing such a cross-section laminated board is repeated many times until the whole three-dimensional object is formed. The object is then removed and the device is ready to manufacture another object. This object may be the same as the previous object, or it may be a completely new object by replacing the program controlling the 3D modeling device.

FIGS. 3 to 8 show various apparatuses suitable for carrying out the three-dimensional modeling method shown in the flowcharts of FIGS. 1 and 2.

As mentioned previously, "stereolithography" is a method and apparatus for making solid objects by successively "printing" thin layers of curable material, such as UV curable material, one above the other. UV illuminating the surface or layer of a UV curable liquid
A movable, spotted beam of light is used to form a solid cross-section of an object on the surface of a liquid. After this, in a programmed form, the object is moved away from the surface of the liquid by one layer thickness to form the next cross section, and the object is defined by gluing it immediately before and with the layer. Continue this process until the entire object is formed.

With the method of the present invention, almost any type of object shape can be created. By using the action of the computer to generate program instructions and send this program signal to the stereolithography machine, complex shapes can be made more easily.

A presently preferred embodiment of the three-dimensional modeling apparatus is shown in side cross-sectional view in FIG. The container 21 is filled with UV curable liquid 22 or the like to define the selected work surface 23. A programmable source such as UV light 26 creates a UV spot 27 in the plane of surface 23. The movement of a mirror or other optical or mechanical element (not shown) that is part of the light source 26 may cause the spot 27 to move across the surface 23. The position of the spot 27 on the surface 23 is controlled by a calculator or other programming device 28. The movable lifting table 29 inside the container 21 can be selectively moved up and down. The position of the platform 29 is controlled by the computer 28. When this device operates, 30a, 30
A three-dimensional object 30 is formed by stepwise stacking integrated laminated plates as shown by b and 30e.

The surface of the UV curable liquid 22 is kept at a certain height inside the container 21 so as to cure the liquid and convert it into a solid material a spot 27 of UV light or any other suitable type. Of reactive energy in a programmed manner across the work surface 23. When the liquid 22 hardens to form a solid material, the platform 29, which was initially just below the work surface 23, is lowered from this work surface in a programmed manner by a suitable actuator. In this way, the initially formed solid material will come under the surface 23 and a new liquid 22 will flow into the surface 23, a portion of this new liquid programmed UV light spot 27.
Is converted into a solid material by means of which this new material is adhesively bonded to the material below it. Three-dimensional object 3
Continue this process until all 0s are formed. The object 30 is then removed from the container 21 and the device is ready to make another object. Then, another object can be created, or a new object can be created by replacing the program in the computer 28.

The curable liquid 22, such as a UV curable liquid, must have some important properties. (A) This is a usable U so that a practical object formation time can be obtained.
It must be cured quickly with a V light source. (B) It must be adhesive so that successive layers adhere to each other. (C) Its viscosity should be low enough that fresh liquid material should quickly flow into the surface when the lift moves the object. (D) It should absorb UV so that the layer formed is reasonably thin. (E) A liquid that is reasonably soluble in a solvent that is in the liquid state, is reasonably insoluble in the same solvent in the solid state, and that is UV curable liquid and partially cured liquid from the object after the object is formed. Should be able to be washed off. (F) It should be as non-toxic and non-irritating as possible.

The cured material must have the desired properties once it is in the solid state. These properties are the same as in the normal use of other plastic materials and are related to the application. Color, texture, strength, electrical properties, flammability and flexibility are properties to consider. Moreover, in many cases
Material cost is also important.

The UV curable material used in the presently preferred embodiment of a practical three-dimensional modeling device (eg, FIG. 3) is a potting compound that is a modified acrylate manufactured by Loctite, Ltd. (Potting Compound) 363. This typical U
A method of making a V-curable material is disclosed in US Pat. No. 4,100,14.
No. 1 is described.

That is, the UV curable materials described above can be cured by free radical copolymerization using a myriad of known initiators as free radicals. Such initiators include peroxides such as hydrogen peroxide; organic peroxides such as benzoylmethylketone peroxide peroxide; azo compounds such as 2,2'-azobis (isobutyronitrile). Cumene hydroperoxide,
hydroperoxides such as t-butyl hydroperoxide, methyl ethyl ketone hydroperoxide;
Peresters such as t-butyl perbenzoate and t-butyl peracetate that are hydrolyzed to peracid compounds; photosensitive compounds such as benzophenone and benzoin ether are included. Light source 26 forms the desired details of an object. It produces UV light spots 27 that are as small as possible and that are strong enough to cure the UV curable liquid that is used as quickly as practical. The source 26 is configured to turn on and off and to be programmable so that the focused spot 27 moves across the surface 23 of the liquid 22. Thus, as the spot 27 moves, it cures the liquid 22 to a solid, which is placed on the surface much like a chart recorder or drafting machine uses a pen to draw a pattern on paper. Draw a solid pattern.

The light source 26 of the presently preferred embodiment stereolithography apparatus uses a 350 watt short arc mercury lamp located within the housing and provides a light output of the housing of 1 mm diameter U.
Focused on the end of a V-transparent optical fiber bundle (not shown). The end of the bundle closer to the mercury lamp was water cooled and an electronically controlled shutter plate was provided between the lamp and the end of the bundle to allow the light passing through the bundle to be turned on and off.
The bundle length was 1 m and the light output was sent to a lens tube with a quartz lens to focus the UV into a spot. Light source 26 is capable of producing spots slightly smaller than 1 mm in diameter and has a long wave UV intensity of about 1 watt / cm ² .

In the apparatus of FIG. 3, the surface 23 is kept at a constant height, and a means for replenishing this material is provided after the object is removed, so that the focal spot 27 stays sharply focused on a constant focal plane. Thus, it can be ensured that the resolution in forming a thin layer along the working surface is maximized. In this respect, a focus is formed on the work surface 23 so as to obtain a strong region, and the work surface 23 diverges rapidly to a low intensity to limit the depth of the curing process, and the thinnest suitable for an object to be formed. It is desirable to have a cross-section laminate. This is best accomplished using a lens with a short focal length, with source 26 as close to the work surface as possible to maximize divergence in the focus cone into the fluid medium. As a result, the resolution is substantially higher.

HP manufactured by Hewlett-Packard Company
Move to light source 26 using a Model 9872 Digital Plotter (not shown). Insert the lens tube into the plotter pen
It is mounted on the cartridge and the plotter is driven by the calculator 28 using normal graphic commands. The shutter is controlled by the HP-P3497 data acquisition / control device using computer instructions.

Physically any other form of light source 26 or equivalent may be used. Scanning can be accomplished using an optical scanner, which eliminates the need for optical fiber bundles and digital plotters. Ultimately, UV lasers are a better light source than short arc lamps. The speed of the stereolithography process is limited primarily by the intensity of the light source and the response of the UV curable liquid.

An elevator platform 29 is used to support and hold the object 30 being formed and move it up and down. Typically, after one layer has been formed, the object 30 is moved beyond the level of the next layer (overdipped into the liquid medium), leaving the surface 23 where the solid was formed. Allow the liquid 22 to flow into the temporary cavity, then return to the correct height for the next layer. As a result, the liquid 22 flowing into the void retreats as the tide draws and becomes a layer having a predetermined thickness. This allows for automatic lamination of extremely thin layers.
The requirements for the platform 29 are that it can be moved as programmed with appropriate speed and accuracy, and that it is strong enough to withstand the weight of the object being formed. In addition, manual fine adjustment of the position of the lift is useful during the setting stage as well as when removing the object.

The lifting table 29 of the embodiment shown in FIG. 3 is a table mounted on an analog plotter (not shown). This plotter is driven by a HP-P3497 type data acquisition / control device having a digital-analog converter therein under the program control of the computer 28.

The computer 28 of the three-dimensional modeling apparatus of the present invention basically has two functions. First, it assists the operator in designing a three-dimensional object in such a way that it can be created. Second, it translates this design into the proper commands for stereolithography and sends out these commands as the object is formed. In some applications, an object design exists and the computer's only function is to issue the appropriate instructions or commands.

In the ideal case, the operator can design the object and view it in three dimensions on the CRT screen of the calculator 28. When the operator has finished designing, he commands the computer 28 to make the object, and the computer issues the appropriate commands for the solid modeling.

In the actually used example of the present invention, the computer 28 is H-
P9816, using a basic operating system. A typical program is given in the attached references. In this system, the operator
-Program with P graphic language (command structure for 3497A) and basic language commands. The operator must also set the appropriate exposure time and speed for UV cure time. In order to operate this device, write a program to create an image of an object and drive the three-dimensional modeling device to create this object.

The drive of the platform 29 can be mechanical, pneumatic, hydraulic or electrical, and optical or electronic circuit feedback can be used to precisely control its position. Lift 29
Is typically made of glass or aluminum,
Any material to which the cured plastic material adheres is suitable.

In some cases, the computer 28 is not needed and a simpler dedicated programming device can be used, especially if only simple shapes are to be built. Alternatively, computer controller 28 may simply execute instructions generated by another, more complex computer. This is the case when using some stereolithography equipment to create the object and using another to initially design the object to be formed.

A computer controlled pump (not shown) can be used to maintain a constant level of liquid 22 at work surface 23. The necessity is due to the following reasons. That is, when the liquid is exposed (exposed), it contracts due to a change in its volume and the liquid level changes. When the lift table 29 moves into the liquid, the volume of the liquid changes, which changes the liquid level. Since the thickness of the liquid layer is determined by the depth of the layer immediately before being formed below the liquid level, if the liquid level is not kept constant, the thickness of the layer actually formed is desired. This is because the thickness of the layer is different from that of the layer, and a layer having an accurate thickness cannot be formed. A well-known suitable liquid level detection device and a feedback circuit are used to drive the fluid pump or the liquid displacement device to move out of the fluid medium as it moves deeper into the fluid medium. A solid rod (not shown) can be driven to level the amount of change in fluid volume and maintain a constant fluid level on surface 23. Instead of this, the light source 2
6 can be moved with respect to the sensed liquid level 22 to automatically maintain a sharp focus on the work surface 23. All these alternatives can be easily accomplished by conventional software working with computer controller 28.

After the three-dimensional object 30 is formed, the lifting table 29 is raised and the object is removed from the table. Typically, this is followed by ultrasonic cleaning of the object, such as acetone, in a solvent that does not dissolve the hardened solid medium but the liquid state of the uncured fluid medium. The object 30 is then placed under a strong ultraviolet flood, typically a 200 watt / inch UV curing lamp, to complete the curing process.

In addition, several containers 21 can be used when practicing this invention. Each container carries a different type of curable material and can be automatically selected by the stereolithography machine. In this case, the various materials may be differently colored plastics, or may have both insulating and conductive materials available for the various layers of the electronic component.

Other embodiments of the invention will now be described with respect to the other drawings, wherein like reference numerals are used throughout the drawings to refer to like parts of the preferred embodiment of the invention shown in FIG. There is.

FIG. 4 shows another type of three-dimensional modeling apparatus. In this case, the UV curable liquid 22 or the like floats on the heavier UV transparent liquid 32. Liquid 32 is immiscible with curable liquid 22 and does not wet it. As an example,
Ethylene, glycol or heavy water is suitable for the intermediate liquid layer 32. In the device of FIG. 4, as shown in the device of FIG. Instead of getting into the fluid medium, a three-dimensional object 30 is lifted from the liquid 22.

The UV light source 26 of FIG. 4 focuses the spot 27 on the interface between the liquid 22 and the immiscible intermediate liquid layer (release liquid agent) 32. The UV radiation passes through a suitable UV transparent window 33 made of quartz or the like, which is supported on the bottom of the container 21. The curable liquid 22 is provided as a very thin layer on top of the immiscible layer 32, and therefore should ideally be made to be a very thin laminate, in order to limit the depth of cure. Instead of relying solely on adsorption or the like, it has the advantage of directly limiting the layer thickness. For this reason, the forming region is more sharply limited, and when the apparatus of FIG. 4 is used, a certain surface is formed more smoothly than that of the apparatus of FIG. Moreover, the UV curable liquid 22 requires less volume and it is easier to replace one curable material with another.

The device of FIG. 5 is similar to the device of FIG.
V source 26 is absent, instead of programmed source 26 and focused spot 27, collimated wide UV
A light source 35 and a suitable aperture mask 36 are used. The opening mask 36 should be placed as close as possible to the work surface 23 and the UV source 3
Collimated light from 5 passes through the mask 36,
The working surface 23 is exposed, thus making successive adjoining laminates, as in the embodiment of FIGS. 3 and 4. However, by using the fixed mask 36 that represents the sectional shape of the object to be formed, a three-dimensional object having a constant sectional shape can be obtained. When changing this cross-section, a new mask 36 for that particular cross-section must be replaced and properly aligned. Of course, the mask can be replaced automatically by providing a web of masks (not shown) that are moved one after the other to align with surface 23.

FIG. 6 also shows a three-dimensional modeling apparatus similar to that described previously with reference to FIG. However, instead of the light source 26 and the focal spot 27, a cathode ray tube (CRT) 38, an optical fiber faceplate 39 and water or other template layer 40 is provided. Therefore, the image supplied from the computer 28 to the CRT 38 forms a formed image on the UV emitting emitter surface of the tube, where it passes through the optical fiber layer 39 and the template layer 40,
It enters the working surface 23 of the fluid medium 22. In all other respects, the apparatus of FIG. 6 forms a succession of cross-section laminates that define the desired three-dimensional object to be formed, just like the embodiments described above. 7 and 8 are. The three-dimensional modeling device is shown in which the platform 29 has additional degrees of freedom so that different surfaces of the object 30 can be exposed for other construction methods. Similarly, this three-dimensional modeling method can be used as an "add-on" method.
The 9 can be used to pick up and position another part for the supplemental stereolithography process. This point, the seventh
The apparatus shown in FIGS. 8 and 9 is identical to that of FIG.
The apparatus of FIGS. 8 and 9 differs in that the platform 29 has a second degree of freedom for rotation, either manually or automatically controlled about the pivot pin or hinge member 42. In this respect,
FIG. 7 shows the adjustable lifting platform 29a in the normal position, and FIG. 8 shows the platform 29a rotated 90 °, so that on one side of the three-dimensional object 30 an additional
The auxiliary structure 41 formed by three-dimensional modeling can be selectively formed.

A practical three-dimensional modeling device has additional components and subsystems other than those previously described for the device shown schematically in FIGS. 3-8. For example, a practical device has a frame and housing and a control panel.
Further, it may also have means to shield the operator from excess UV and visible light, and may also have means to allow the object 30 to be seen while being formed. Practical devices have safeguards to control ozone and harmful fumes as well as high pressure safety protection and interlocks.
Such a practical device also has means for effectively shielding sensitive electronic circuits from noise sources.

As described above, many other devices can be used to carry out the stereolithography method of the present invention.
For example, instead of the UV light source 26, an electron source, a visible light source,
A laser light source, a short arc light source, a high energy particle light source, an X-ray source or other radiation source can be used, using a suitable fluid medium that hardens in response to a particular type of reactive energy, such as a photopolymerizable material. be able to. For example, alpha octadecyl acrylic acid slightly prepolymerized using UV light can be polymerized using an electron beam. Similarly, poly (2,3-dichloro-1-profile acrylate) can be polymerized using an X-ray beam.

〔The invention's effect〕

The stereolithography method and apparatus of the present invention have many advantages over the methods currently used to manufacture plastic objects. The method of the present invention does not require the design layout and drawings, nor the fabrication drawings and tools. The designer can work directly with the computer and the three-dimensional modeling device, and when he is satisfied with the design displayed on the output screen of the computer, in order to directly consider it,
The parts can be manufactured. When a design has to be changed, it can be easily made through a computer and then another component can be made to verify that the change was correct. If a design requires several parts with interacting design parameters, the design of all parts can be quickly modified and recreated. Thus, the entire assembly can be repeatedly made and inspected, if desired, so that the method of the invention is even more useful.

After the design is complete, manufacturing of the component can begin immediately, avoiding weeks and months between design and manufacturing. It should be similar to the final production speed and cost of parts, the cost of current injection molding for short term production, and can be much cheaper than injection molding. Injection molding is economical only when many identical parts are needed. Stereolithography is useful for short-term production. This is because no tools are required and the production set-up time is extremely short. Similarly, using this method,
Design changes and custom parts are easily available. Because of the ease of making the parts, stereolithography allows plastic parts to be used in many places where metal or other material parts are now used. Moreover, the plastic model of the object can be quickly and economically made before making the decision to manufacture the more expensive metal or other material parts.

Although various stereoscopic modeling apparatuses for carrying out the present invention have been described above, it is clear that they have a common idea of drawing an almost two-dimensional surface and lifting a three-dimensional object from this surface. .

This invention promptly produces three-dimensional plastic parts, etc.
It meets the long-standing need for CAD and CAM devices that can be reliably, accurately and economically designed and manufactured.

While we have shown and described specific forms of the invention, it will be apparent that various modifications can be made within the scope of the invention. Therefore, the present invention is not limited to the description of the claims of the present application.

[Brief description of drawings]

1 and 2 are flowcharts showing the basic idea used for carrying out the three-dimensional modeling method of the present invention, and FIG. 3 is a sectional view of the presently preferred embodiment of the apparatus for carrying out the present invention. 4 is a block diagram in combination with FIG. 4, and FIG. 4 is a sectional view of a second embodiment for carrying out the present invention.
FIG. 6 is a cross-sectional view of a third embodiment of the present invention, FIG. 6 is a cross-sectional view of yet another embodiment of the present invention, and FIGS. 7 and 8 are for incorporating a lift having multiple degrees of freedom. FIG. 7 is a partial cross-sectional view when the three-dimensional modeling device in FIG. 3 is changed. 21 ... Container, 22 ... UV curable liquid, 23 ... Work surface, 26 ... Light source, 28 ... Calculator, 29 ... Lifting platform,
30 ... an object.

Claims (8)

[Claims] 1. A method for automatically creating a three-dimensional object from a curable fluid medium, wherein data representing a cross section of a three-dimensional object to be created is created, and a curing irradiation generated in response to the data is generated. Exposing the fluid medium on a designated work surface to form a contoured first cross-section layer and moving the first cross-section layer into the fluid from the work surface beyond a predetermined level of the second cross-section layer. By automatically laminating the first cross-section layer to the work surface and then returning the first cross-section layer to a predetermined level toward the work surface to form the second cross-section layer with respect to the work surface. Exposed to curing radiation to form a second cross-section layer,
Curing irradiation sufficient to form a constituent layer in which the fluid medium has a thinness of 1.0 mm or less and which is partially supported by the first cross-section layer but has sufficient adhesiveness. And adsorbing the second cross-section layer to the first cross-section layer, thereby forming a three-dimensional object from a plurality of sequentially-bonded cross-section layers. 2. An apparatus for automatically creating a three-dimensional object from a curable fluid medium, which defines a device for generating data representing a cross section of the three-dimensional object to be created and a designated work surface, and is 1 mm. A fluid medium having the following thinness and having sufficient absorption for curing irradiation to form a constituent layer which is partially supported by the first cross-section layer but has sufficient adhesiveness. A container for accommodating; a curing irradiation source for exposing the fluid medium to curing irradiation in response to the data to form a cross-sectional layer having a contour on the working surface; and a second adhesive bonded to the first cross-sectional layer. In preparation for the formation of the cross-section layer, the first cross-section layer is automatically laminated to the first cross-section layer by moving the first cross-section layer from the working surface into the fluid beyond a predetermined level of the second cross-section layer, and then Place the first cross-section layer toward the work surface. And a device for automatically laminating the second cross-section layer to the working surface by forming the second cross-section layer against the working surface. A device that forms objects. 3. A device according to claim 2, wherein the fluid medium is a photopolymeric material and forms a three-dimensional object. 4. A device according to claim 2 for forming a three-dimensional object in which each said formed cross-section layer is sufficiently strong to maintain a unitary structure. 5. A device according to claim 2, wherein the fluid medium forms a three-dimensional object that responds rapidly to the curing radiation. 6. A device according to claim 2, wherein the fluid medium forms a three-dimensional object that absorbs curing radiation in the ultraviolet spectrum. 7. An apparatus according to claim 2 for forming a three-dimensional object that is adhered to the immediately preceding cross-section layer while each of the formed cross-section layers is exposed to radiation. 8. An apparatus for automatically creating a three-dimensional object from a curable fluid medium, at least one aperture mask representing a cross-section of the three-dimensional object to be formed, and a working surface designated with the fluid medium. And a container for accommodating the radiation medium for curing sufficient to form a partially supported constituent layer having a thickness of 1 mm or less; A curing radiation source for forming a contoured first cross-section layer on the work surface by exposing it to the radiation through the at least one aperture mask; and forming a second cross-section layer adhered to the first cross-section layer. In preparation, the first cross-section layer is automatically laminated to the first cross-section layer by moving the first cross-section layer from the working surface over a predetermined level of the second cross-section layer into the fluid, and then the first cross-section layer. Toward the work surface to a specified level. Apparatus for forming an automatic three-dimensional object comprising apparatus and the laminated on the first cross-sectional layer by forming the second cross-sectional layer to the working surface back.