Cartridge for solid imaging apparatus and method

Abstract

A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build. The invention also provides for tilting the build elevator to reduce air entrainment and for releasing the build from the image plane.

Description

technical field [0001] The present invention relates to solid imaging devices and methods. Background technique [0002] Solid imaging devices have been used for rapid prototyping of product development models and, more recently, in manufacturing operations. Solid imaging devices typically produce three-dimensional objects from fusible powders or photocurable liquids by exposure to radiation in response to computer control. The data representing the thin cross-sectional layers of the three-dimensional object provides the computer with control parameters for a procedure that typically automates the building of the object in layers. A laser or other radiation source suitable for solid imaging sequentially irradiates individual thin layers of build material, in response to the layer-by-layer conversion of the material into a solid to create a solid imaged product. [0003] Solid imaging is sometimes referred to as "rapid prototyping" and includes different techniques such as ...

AI Technical Summary

Problems solved by technology

[0004] Despite the development of various devices and methods for solid imaging, there are still many shortcomings to be addressed

The devices and methods used to perform solid imaging tend to be somewhat characterized by excessive moving parts and complex systems which can require considerable effort to care, maintain and operate

Laser imaging and UV imaging systems tend to be costly, making these systems impractical for many applications

Complicated and tedious alignment steps to align radiation source and image plane reduce efficiency and increase cost

Large volumes of liquid resin used in stereolithography are expensive and can be contaminated with cured resin clumps

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