Three dimensional printing using photo-activated building materials
a technology of photoactivated building materials and three-dimensional printing, applied in the field of three-dimensional printing using photoactivated building materials, can solve the problems of easy breakage or crumbling of articles in the area in which the binding liquid is absorbed, and the technique may be hampered,
Inactive Publication Date: 2005-10-13
BURGESS ROBERT
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However, such a technique may often be hampered by the binding liquid's somewhat uneven absorption by the build material as well as uneven application of the binding liquid due to mechanical application inefficiencies.
When binding liquid is not applied to a portion of the build material, that portion is structurally weak.
When the article fabricated by the build material-binding liquid process is completed, such an article may readily break or crumble in the area in which binding liquid was not applied.
Also, where the binding liquid is not evenly absorbed or is unevenly applied, distortion may occur in the fabricated article.
In addition, the use of a single point source, the laser beam, for hardening the photopolymer is inefficient and may not effectively harden all of the photopolymer, producing an object that has weakened areas.
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[0013] The present invention provides an efficient method, a system and an article fabricated using the method for fabricating an article using photo-activatable building material. In the present invention, light-emitting centers are fabricated as an array of photon sources whose size, wavelengths and intensity can be designed and optimized for particular applications. The details of the number of light centers and their spacings are determined as a function of the resolution required to fabricate a particular size of the article design in accordance with known requirements for photo-initiated polymerization. For example, if a thicker phototresist is to be utilized, more light-emitting centers with higher intensity may be added to decrease the fabrication time. Alternatively, if a higher resolution of article dimensions is required, shorter wavelength photon sources with lower intensity may be utilized to photo-polymerize a thinner photoresist layer. A three-dimensional structure of...
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Abstract
The present invention provides a method, article of manufacture and system for fabricating an article using photo-activatable building material. The method includes the steps of applying a layer of the photo-activatable building material to a preselected surface, scanning the layer using a plurality of light-emitting centers to photo-activate the layer of photo-activatable building material in accordance with a predetermined photo-initiation process to obtain polymerization of the building material, wherein scanning is accomplished at a predetermined distance using a predetermined light intensity, and repeating the steps of applying the layer, with each layer being applied to an immediately previous layer, and scanning the layer with the plurality of light-emitting centers to polymerize the building material until the article is fabricated.
Description
BACKGROUND OF THE INVENTION [0001] The present invention relates to fabrication of articles, and in particular, fabrication of articles using a sequential layering technique. [0002] Recently, three-dimensional prototypes of articles have been fabricated by applying a layer of build material to a base, and then applying a binding liquid to the build material to bind the build material, with the two steps being repeated until the article has been completed. However, such a technique may often be hampered by the binding liquid's somewhat uneven absorption by the build material as well as uneven application of the binding liquid due to mechanical application inefficiencies. When binding liquid is not applied to a portion of the build material, that portion is structurally weak. When the article fabricated by the build material-binding liquid process is completed, such an article may readily break or crumble in the area in which binding liquid was not applied. Also, where the binding liq...
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IPC IPC(8): B29C35/08B29C41/02B29C67/00B41J2/16G01G3/13G01N27/00G01N29/14G01N29/34G03F7/00G03F7/16G03F7/20
CPCB29C35/0805B29C67/0055G01G3/13G05B2219/49018G01N29/348G01N2291/106G03F7/0037G01N29/14B33Y10/00B29C64/106
Inventor BURGESS, ROBERT
Owner BURGESS ROBERT