Systems and methods for fabricating three-dimensional objects

Abstract

Systems and methods for fabricating three-dimensional objects are disclosed. The system includes an optical imaging system providing a light source; a photosensitive medium adapted to change states upon exposure to a portion of the light source from the optical imaging system; a control system for controlling movement of the optical imaging system, wherein the optical imaging system moves continuously above the photosensitive medium. The method includes moving a maskless optical imaging system providing the light beam in a continuous sequence; presenting the light beam on a portion of the photosensitive medium; lowering a plate upon which the photosensitive medium resides; and applying a new layer of the photosensitive medium.

Description

[0001] Cross References to Related Applications

[0002] This application, pursuant to Title 35, United States Code, Section 119(e), claims priority to U.S. Provisional Application No. 61 / 723,991, filed November 8, 2012. This application is also a continuation-in-part of U.S. Patent Application No. 12 / 435,776, which, pursuant to 35 U.S.C. § 119(E), claims the U.S. Provisional Priority of application (Serial No.: 61 / 050,383). The entire content and substance of the above application is hereby incorporated by reference.

[0003] Statement Regarding Federally Sponsored Research or Development

[0004] This invention was made with government support under grants HR0011-07-1-0034 and HR0011-08-1-0075 awarded by the Defense Advanced Research Projects Agency (DARPA). The Federal Government has certain rights in this invention. Background technique

[0005] Rapid prototyping or solid mold-free manufacturing has become an increasingly important tool, and the technology has made sig...

Examples

Embodiment Construction

[0154] To facilitate an understanding of the embodiments, principles and features of the invention, which will be described herein below, reference is made to its implementation in the illustrative embodiments. In particular, they are described in the context of a continuously moving rapid modeling system and method.

[0155] However, embodiments of the invention are not limited to use in the described systems. Rather, embodiments of the present invention can be used when a three-dimensional modeled object (eg, a casting) is desired or required. Thus, the system described hereafter as a continuous moving rapid modeling system and method can also be used as a system for many applications and many size objects.

[0156] The following description of components making up various embodiments is intended to be illustrative rather than restrictive. Numerous suitable components which perform the same or a similar function as the materials described herein are intended to be within t...

[0001] Cross References to Related Applications

[0002] This application, pursuant to Title 35, United States Code, Section 119(e), claims priority to U.S. Provisional Application No. 61 / 723,991, filed November 8, 2012. This application is also a continuation-in-part of U.S. Patent Application No. 12 / 435,776, which, pursuant to 35 U.S.C. § 119(E), claims the U.S. Provisional Priority of application (Serial No.: 61 / 050,383). The entire content and substance of the above application is hereby incorporated by reference.

[0003] Statement Regarding Federally Sponsored Research or Development

[0004] This invention was made with government support under grants HR0011-07-1-0034 and HR0011-08-1-0075 awarded by the Defense Advanced Research Projects Agency (DARPA). The Federal Government has certain rights in this invention. Background technique

[0005] Rapid prototyping or solid mold-free manufacturing has become an increasingly important tool, and the technology has made sig...

Examples

Embodiment Construction

[0154] To facilitate an understanding of the embodiments, principles and features of the invention, which will be described herein below, reference is made to its implementation in the illustrative embodiments. In particular, they are described in the context of a continuously moving rapid modeling system and method.

[0155] However, embodiments of the invention are not limited to use in the described systems. Rather, embodiments of the present invention can be used when a three-dimensional modeled object (eg, a casting) is desired or required. Thus, the system described hereafter as a continuous moving rapid modeling system and method can also be used as a system for many applications and many size objects.

[0156] The following description of components making up various embodiments is intended to be illustrative rather than restrictive. Numerous suitable components which perform the same or a similar function as the materials described herein are intended to be within t...

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