CN1242293A - Method and apparatus for data manipulation and system control in selective deposition modeling system - Google Patents

Abstract

A variety of support structures and build styles for use in Rapid Prototyping and Manufacturing systems are described wherein particular emphasis is given to Thermal Stereolithography, Fused Deposition Modeling, and Selective Deposition Modeling systems, and wherein a 3D modeling system is presented which uses multijet dispensing and a single material for both object and support formation.

Description

Make the method and apparatus of data operation and system's control usefulness in the local deposits formation system

The application is dividing an application of Chinese patent application 96198255.1.

1, technical field

The invention relates to forming three-dimensional (3D) object and make the technology of data operation and moulding control, be about hot stereolithography (TSL more specifically, ThermalStereolithography) system, consolidation deposition modeling (FDM, Fused DepositionModeling) method and apparatus of data manipulation of adopting in system or other local deposits moulding (SDM, the Selective DepositionModeling) system and formation control.

2, background technology

Can adopt various different measure to realize that automatic or semi-automatic three-dimensional body produces, promptly imitates fast type and processing (Rapid Prototyping ﹠amp in recent years; Manufacturing, RP﹠amp; M), its characteristics are that each all forms and the thin layer of adhesion sets about carrying out the foundation of 3D object with the 3D computer data of the morphogenetic object of layered laminate to describe by a plurality of.These thin layers be referred to as sometimes section, the structure of object layer, object layer, object layer or be called layer (is to show so words if context clearlys show the consolidated structure of suitable shape) simply.Each thin layer is represented section of this three-dimensional body.Usually thin layer is formed and is bonded to a folded previous thin layer that forms and bond.At some RP﹠amp; In the M technology, the technology that has proposed be different from the strict process of setting up in layer but the only part of an initial thin layer forms and before the remainder of this initiation layer at least one thin layer in succession be formed at least in part.

According to such measure, building up of three-dimensional body is to use the layer that continues mutually that do not condense, flowable materials to be added to working surface, with desirable pattern these layers are stood the synergism excitation partly then, so that these layers are frozen into the object thin layer of the object thin layer that is bonded to previous formation partly.Material is added in will can not become the interval of object coating portion and will become the interval both sides of the part of object thin layer on the working surface in this measure.The representative of this measure is optical three-dimensional molded object (SL), described in U.S. patent No.4575330 (Hull).According to an embodiment of stereolithography, this synergism excitation is the ray from the UV laser instrument, and material is a photopolymer.Another example of this measure is local laser sintered (SLS), and as U.S. patent No.4, described in 863,538 (Deckard), wherein synergism is actuated to from CO ₂The IR ray of laser instrument and material is sintered powder.The 3rd example is that three dimensional printing (3DP) and direct housing form casting (DSPC), as U.S. patent No.5,340,656 and 5,204, illustrated among 055 (Sachs etc.), wherein synergism excitation is a chemical adhesive, and material applies the powder that particle that chemical adhesive is bonded together is formed by the part.

According to second such measure, the formation of object is to form the object thin layer by one after the other cutting the section with desired shape that loses object and making big or small chi material.Usually in practice, cardboard was piled up and is bonded to the cardboard of previous cutting before they are cut, but also may pile up and bond before cut.The representative of this measure is layering object processing (LOM), and as U.S. patent No.4, described in 752,352 (Feygin), wherein material is a paper, and it is CO that the cardboard nicking is become the means of desired shape and size ₂Laser instrument.U.S. patent No.5,015,312 (Kinzie) also is at LOM.

According to the 3rd such measure, the formation of object thin layer be with not solidified, flowable material with desired layout selectively attached to the zone that will become the part of object thin layer on the working surface.Selectively between the setting stage or thereafter this is done that local material cured of adhering to is bonded to formation that the front forms and stacked object thin layer on follow-up object thin layer.Repeat these steps then and build up object layer by layer one by one.This object forms technology and be referred to as local deposits moulding (SDM) on kind.The key distinction between this measure and first measure is that material only will be become the zone of object coating portion selectively attached to those.The representative of this measure is that consolidation deposition modeling (FDM) is as U.S. patent No.5,121,329 and 5,340, described in 433 (Crump), but but wherein material be scattered in the environment of flow temperature that temperature is lower than this material with flow state, then make it to cool off after-hardening again.U.S. patent No.5,260,009 (Penn) have introduced second example of this technology.The 3rd example is jet particle processing (BPM, Ballistic Particle Manufacturing), U.S. patent No.4,665,492,5,134,569 and 5, illustrate among 216,616 (Masters) that wherein particle is directed to the section that the locality forms object.The 4th example is U.S. patent No.5, the hot optical three-dimensional molded object of describing among 141,680 (Almquist etc.) (TSL).

Using SDM (and other RD﹠amp; M constitutes technology) time, be used to generate the various distinct methods of practical object and the appropriateness of equipment and depend on several factors.Because these factors generally can not be all desirable simultaneously, depends on the compromise of specific needs and environment so select suitable process technology and associated method and apparatus to involve.Some factors that should consider comprise: 1) equipment cost, 2) operating cost, 3) speed of production, the 4) degree of accuracy of object, 5) body surface smooth finish, 6) form the material character of object, 7) expection of object uses 8) make the possibility of secondary treating for obtaining different material characters, 9) simplification of Ying Yonging and operator restriction, 10) required or desirable running environment, 11) security and 12) post-processed time and strength.

Have for a long time and necessaryly can optimize simultaneously these parameters as much as possible for more effectively constituting three-dimensional body in this respect.As first example, when adopting as above-mentioned local deposits forming technique (SDM) (for example hot lithography) when constituting object, equipment cost can be kept or reduce to the while with lowering equipment time and file setup time to need to increase the object speed of production.A key issue of this respect is that requirement has the high efficiency technical that generates and handle composition data.Another key issue is the needs that are suitable for supporting the support data of the object during the moulding about generation.Whether other problem also relates to Control Software and exists, they handle mass data in real time, can compensate the flame-out or fault of spray, can adjust data and make it, and formation style and deposition technique to the geometric configuration sensitivity can be provided effectively by the desired sequence visit.The suitable formation style and the supporting construction that need to use among the SDM of data generation technique have introduction in U.S. patented claim NO.08/534813.

Thereby, exist feel for a long time but fail to satisfy to obtaining data and controlling the needs of SDM with the method and apparatus that overcomes the shortcoming in the prior art.

This illustrate all patents that this joint quotes all at this in conjunction with the parameter in being described in detail.

Here the appendix A of attached row illustrates formation used in the preferred SDM system and supports style.This appendix is the duplicate of the U.S. patented claim No.08/__ that submits to simultaneously, corresponding to the outline No.USA142 of 3D system.

Below the application this in conjunction with as the detailed description as a reference:

Date of application	Application number	Exercise question	State
				??95.9.27	??08/534813	For forming the local deposits forming method and the equipment of three-dimensional body and support	Unsettled
??95.9.27	??08/534447	Make the method and apparatus of data operation and system's control in the local deposits formation system	Unsettled
				??95.9.27	??08/535772	Local deposits moulding material and method	Unsettled
??95.9.27	??08/534477	Local deposits forming method and system	Unsettled

According to hot optical three-dimensional molded object and the long-pending forming technique of some hot retrogradation, three-dimensional body is by being built up layer by layer by heat to the material that spreads with the dispenser branch backward that can flow.This material can be used as semi-continuous material stream and spreads or also can be used as single drop by the dispenser branch and divided and spread.Be used as at material and be appreciated that in the situation that semicontinuous fluid branch spreads and allow more undemanding working surface standard.U.S. patent No.5 has introduced the embodiment of previous hot stereolithography in 141,680, is used as reference here.Hot optical three-dimensional molded object is specially adapted in the environment of office because of it can adopt nullvalent, nontoxic material.And, the processing that utilizes these materials to form object need not to relate to uses ray (as the UV ray, the IR ray, visible light and/or laser beam) with material be heated to inflammable temperature (as in some LOM technology along the cross section incendiary material), activating chemical (as single polymers, photopolymer) or poisonous chemicals (as solvent), complicated cut the factor that erosion machinery or the like may produce noise or cause serious harm when the maloperation.Only material is heated to flowable temperature particulate-material and make it cooling and form object partly again and can replace.

U.S. patented claim No.08/534,813 main targets are can be according to the TSL principle by should be in formation and the supporting way and the structure of preferred local deposits moulding (SDM) system.Also narrated for be used for other SDM system and formation and the supporting way replaced for the work that is used for other RP § M systems.

U.S. patented claim No.08/535,772 at the applied preferred material of the preferred SDM/TSL of aftermentioned system.Some equivalent material and method also have been discussed.

U.S. patented claim No.08/534, the 447th, the application's mother application becomes the data conversion technology that adopts according in the applied support of preferred local deposits moulding (SDM) system of TSL (hot optical three-dimensional molded object) principle and the object data at being used for data conversion with the 3D object.This is carried out the application of quoting also at the various data processing, Data Control and the system's control technology that are used to control preferred SDM/TSL described later system.Also introduced for application in the SDM system and for replacement data operative technique and the control technology used in other RP § M systems.

The application's assignee, 3 D Systems Inc. also is particularly everyone of other U.S. patented claims of a system and U.S. patent in the optical three-dimensional molded object part in this field of RP § M field.During here elaborating, following total application and U.S. patent be cited as a reference.

Application number	Theme	The state or the patent No.
			08/148,544	The basic composition of hot optical three-dimensional molded object is described	5501824
08/484,582	Indicate the basic composition of optical three-dimensional molded object	Unsettled (4,575,330 DIV)
			08/475715	The various recording techniques of using among the SL are described, comprise the material dispenser that to make local deposits by many orifices	Unsettled (5,358,673 DIV)
08/479,875	Various LOM type formation technology are described	Unsettled (5,192,559 DIV)
			08/486,098	The technology of buckling deformation and this distortion of various minimizings is described	Unsettled (5,104,592 DIV)
08/475,730	Be illustrated as the 3D data branch of obtaining profile data and open technology, utilize logical layer relatively to define downwards, make progress and continuum.Also introduced the technology that about initial CAD design is proofreaied and correct wide compensation and produced various object configurations.	Unsettled (5.192469 DIV)
			08/480670	Illustrate that a previous SL divides chip technology, comprise the vector compensation and proofread and correct width compensation	Unsettled (5,184,307 DIV)
08/428,950	The various formation technology of using among the SL are described, are included as the oscillation sorting that forms semisolid and solid body and relate to, the various formation patterns of vectorial alternation sum vector offset	Unsettled (mother's application of WO95/29053)
			08/428,951	Indicate the multilayer while alignment technique that is used for SL, comprise vertical relatively more interval and because the error correction of overcorrection of making the Z direction.The technology of utilizing the etch program to determine the horizontal separation interval that comprises has been discussed in other level in relatively	Unsettled (mother's application of WO95/29053)
08/405,812	The SL recoat coating technique that utilizes energy of vibration is described	Unsettled
			08/402,553	The SL recoat coating technique that utilizes floating rule and fluid level control technology is described	Unsettled (5,174,931 DIV)
08/382,268	Several SL recoat coating techniques are described, be included as form down one deck not coagulated material utilize ink-jet to come the related technology of spreading material partly.	Unsettled (mother's application of PCT application No.US96/01451)
			07/182,801	The supporting construction that SL uses is described	4,999,143
07/183,015	Be illustrated as the stress that reduces in the SL object and in object, dispose the cavity	5,015,424
			07/365,444	SL formation, purification and the later stage alignment technique concentrated are described	5,143,663
07/824,819	The various characteristics of large-scale SL equipment are described	5,182,715
			07/605,979	Be illustrated as the technology that strengthens SL body surface smooth finish, comprise that the film that adopts with than the combination of thick structure layer fills layer and curved plane	5,209,878
07/929,463	Illustrate that powder coated is to strengthen surface smoothness	5,234,636
			07/939,549	Rely on equilibrium stress and shrinking zone to reduce the formation technology of the buckling deformation among the SL	5,238,639

Summary of the invention

The present invention realizes multiple can the solution alone or in combination about formed the technology (method and apparatus) that data product used in the 3D object, data management and system control relevant many problems by the local deposits moulding.Although mainly be at the SDM technology.The technology of discussing later also can multitude of different ways be used the RP § M technology of above-mentioned other so that the processing power of coming enhanced system by advanced person's data management and generation technique.And the technology of explanation here can also be applied to adopting the SDM system of one or more formations and/or propping material, one or more material of spreading partly wherein, wherein other material can not elected the ground spreading, wherein can adopt or can not adopt the temperature of raising to assist their to make local deposition to material whole or part.

Present technique can be applied to the SDM system, at this, constituent material (for example coating or ink) by to increase solvent (being suitable for the solvent of concrete material) as water, alcohol, acetone, paint thinner or other and make and become flowable for carrying out spreading, these materials behind spreading can by remove solvent (for example, will by the heating of spreading material, with the material spreading advance part be evacuated the formation of (being vacuum) indoor or simply with the enough time with solvent evaporation).Alternatively and/or additionally, constituent material (as coating) can be to become in nature, and at this, the increase of the shear force on the material can be used to assist its spreading, and perhaps this variability can be used to aid in material simply keep its shape after by spreading.Alternatively and/or additionally, material can be in nature reactive (for example, photopolymer, thermopolymer, one or two part epoxy materials, such as one of previous materials and wax formula or the combined combined material of thermoplastic) or coagulable when making up at least with other materials (as the plaster of paris and water), wherein, material by the excitation of application specifies rightly (for example behind spreading, heat, EM ray (visible light, IR, UV, X ray etc.), the reactive chemistry goods, the second portion of two part epoxies, second or a plurality of part of one combination) react, at this, constituent material and/or combination of materials become and solidify.Certainly, hot stereolithography material and spreading technology can be individually or with above-mentioned substitute utilization combination.And, can adopt various different spreading technology, for example make spreading by single or multiple ink discharge devices (comprise hot melt ink jet, foam jet etc., and the single or multiple holes extruding jet nozzle or the shower nozzle of continuous or semicontinuous stream).

First purpose of the present invention provides to the three-dimensional body data conversion being become the method and apparatus of profile data.

Second purpose of the present invention provides and comprises the method and apparatus of generation object that the three-dimensional body data conversion is become the method and apparatus of profile data.

The 3rd purpose of the present invention provides by the three-dimensional body data and obtains the method and apparatus that supports data.

The 4th purpose of the present invention provides and is included as method and apparatus method and apparatus and utilize the generation object of these support data during object forms that obtains to support data.

Desired is that above-mentioned purpose can be realized by different aspect of the present invention respectively, and attached purpose of the present invention will be referred to the various combination of above-mentioned independent purpose so that can be obtained the income of synergism by combination technique.

Other orders of the present invention instructions thus will very brightly be met.

The rough indication of accompanying drawing

Fig. 1 is the figure of a preferred hot stereolithography system:

Fig. 2 a, 2b show the orifice plate of the printhead of Fig. 1 with two different angles;

Fig. 3 be Fig. 1 the complanation device than detailed icon;

Fig. 4 illustrates adjacent nozzle and adjacent gratings relative spacing in the ranks on the orifice plate;

Fig. 5 illustrates the pixel grid of the data resolution of define system;

Fig. 6 a～6d illustrates several over print schemes;

Fig. 7 illustrates first embodiment of the invention;

Stl file of Fig. 8 a, 8b explanation intersects with the branch plate plane;

Fig. 9 illustrates that boolean extracts the effect of computing;

Figure 10 illustrates the second embodiment of the present invention;

Figure 11 a explanation triangle is in the ordering of Z direction;

Figure 11 b, 11c illustrate effective leg-of-mutton selection;

The replacement form of Figure 12 a～12c explanation expression profile data;

Figure 13 a～13c explanation transition data are inserted the table with the different scanning line correlation;

Figure 14,15 illustrates in greater detail boolean and extracts computing;

Figure 16,17 illustrates Boolean adds, subtracts and crossing operation;

Figure 18～21 are illustrated as the two-stage processing that utilizes the middle layer to generate support;

Figure 22 is illustrated as and generates three phase process that support;

Figure 23～26 explanation will be started/stop data and be deposited method in abutting connection with word in;

The method that Figure 27 a～27b, 28a～28b, 29a～29b and 30a～the table data allocations storer of transition is started/stopped to the 30b explanation to expression;

Figure 31 explanation is represented the character that successive scanning is capable with the equal number transition;

Figure 32 explanation is by the caused quantization error of the pixelation of starting/stopping data;

Figure 33 illustrates the conversion of RLE data to transform data;

Figure 34 a～34c explanation is used for constituting the data of support;

Figure 35 a illustrates the hypothesis about the part slope that makes in the preferred embodiment of the present invention;

Figure 36 a～36c explanation is used for the annular buffer of the invention process;

Figure 37 illustrates a hybrid supporting construction;

Figure 38 a～38b explanation two sampling Style patterns;

Part/support intersection that Figure 39 a, 39b and 39c explanation take place sometimes;

How Figure 40 a～40c represents the example of Apply Styles file;

Figure 41 a～41f represents other pattern pattern;

Figure 42 a～42f represents biasing;

Figure 43 illustrates the code line sequence of regulation;

Only contingent resolution problem of injection counter is passed through in Figure 44 explanation;

Figure 45 a～45b explanation increases the algorithm of the resolution on the direction of scanning by using two counters;

Figure 46 a shows along imaginary level and the side view that contains gapped object based on the interval that forms different supporting constructions;

Figure 46 b shows the side view of the object of Figure 46 a the when gap is filled by the various types supporting construction; With

Figure 47 illustrates the notion form of RLE file.

As discussed earlier, the application is at being applicable to the support technology of local deposits moulding (SDM) system and data manipulation technology and system's control technology of formation technology for realization.Particularly preferred SDM system is hot stereolithography (TSL) system.The detailed description of the preferred embodiment of the invention will begin with the explanation of the preferred TSL system of suitably describing implementation detail.To preferred formation and support technology, being described in more detail of the composition of preferred material and characteristic, optimum decision system and various replacement schemes seen before face in conjunction with the US patented claim No.08/534 that quotes, 447,08/535,772 and 08/534,477.Also discussed in a plurality of fronts in conjunction with application of quoting and patent those think especially directly relevant for or the replacement system of suitable SDM, TSL or FDM.Like this, the data manipulation technology of back and system's control technology will be regarded as and can be applicable to various SDM, TSL and FDM system rather than only limit to and combine with example described here.

The preferred equipment of explanation SDM/TSL among Fig. 1.This equipment has a spreading platform 18 that spreading head 9 (example is the porous ink jet injector head) and complanation device 11 be set on it.This spreading platform is coupled to X framework 12 slidably by parts 13.X framework 12 controllably at directions X, also be referred to as main scanning direction and move forward and backward spreading platform 18.The motion of X framework is under the control of a control computer or microprocessor (not shown).And, in a side of platform 18 and/or the fan (not shown) doing vertical air blast and use is being installed between complanation device 11 and the spreading head 9 to help spreading material and the cooling of lining base and can keep desirable formation temperature.Certainly other the fan and/or the mount scheme of other cooling systems also are available, comprise adopting spraying plant directly vaporizable liquid (as water, alcohol or solvent) to be sprayed onto on the object surfaces.Cooling system can relate to the active or passive techniques that is used to dispel the heat, and can be desirablely being made of in the temperature range the computer-controlled spreading material is maintained of combining with temperature sensing device.

Spreading head (being printhead) 9 be for to be constituted to the commercially available printhead that is used to spray hot melt ink (as thermoplast or wax-like materials), and be modified and be used for the three-dimensionally shaped system that printhead wherein stands back and forth operation and acceleration.This printhead modification comprises that group structure one is airborne and accumulates mechanism so that acceleration can be accumulated material displacement minimum in the mechanism to this.In a preferred embodiment, this is for to include the commercially available 96 nozzle printhead Model No.HDS96i that accumulate modification, and by Spectra Corp, Nashua HEWampshire) provides.But printhead 9 provides material with flow state by a Material Packaging Handling Subsystem (material package and control subsystem, not shown in the figures).The US patented claim No.08/534 that this material package and control subsystem are quoted in front has explanation in 477.In a preferred embodiment, whole 96 nozzles on this by computer controlled make when each hole (being nozzle) located rightly by orifice plate 10 selectively liquid droplets drop is dispensed onto desired place.In the practice, preferably each nozzle per second is sent about 12000 to 16000 orders, according to nozzle location and deposit desired each nozzle ejection of choice of location order (spreading drop) or do not spray (not spreading drop) as material.Spray order in the practice and also preferably send to all nozzles simultaneously.Like this, in a preferred embodiment, head is selected starting nozzle by computer control so that can penetrate the drop of melted material simultaneously by the one or more holes in the orifice plate 10.Certainly will be understood that, in alternate embodiment, can adopt the nozzle of varying number, different nozzle frequencies can be arranged and under proper environment, also can not start injection simultaneously.

Orifice plate 10 makes droplets of materials spray below can be by the spreading platform installing on the spreading platform 18.Explanation orifice plate 10 among Fig. 2 a and the 2b.In a preferred embodiment, as shown in Fig. 2 a, orifice plate (being the row in hole) be installed into approximately perpendicular to main sweep direction interpolation (as directions X) and be constituted to have N=96 the holes that can do indivedual controls (be marked with 10 (1), 10 (2) ... ... 10 (96).Each dispenser (being nozzle) is provided with a piezoelectric element, is impelling a pressure wave to propagate by material when an electric starting impulse is added to this element.This pressure wave makes by material liquid of hole emission.These 96 dispensers are controlled by control computer, and the latter controls the speed of the starting impulse that is added to each indivedual dispenser and regularly also controls the speed and the timing of the drop of being launched by the hole thus.Referring to Fig. 2 a, the spacing between the hole in the preferred embodiment " d " is about 8/300 inch (about 26.67mils or 0.677mm).Like this, effective length " D " of orifice plate is about (N * 8/300 inch)=(96 * 8/300 inches=2.56 inches (65.02mm) when 96 holes.One preferred embodiment utilizes the scanning of grating to come positions printhead and hole material is spread in desirable dropping liquid place.The print processing of each layer is finished by the relative motion between a series of printheads and desirable dropping point.Print and generally when printhead is done the relative motion of main scanning direction, take place.Be the typical motion of small incremental relatively on sub scanning direction when no spreading takes place subsequently.And then the inversion scanning on sub scanning direction carries out spreading once more subsequently.The alternation procedure that repeats this main sweep and subscan is until the deposition of finishing thin layer.Alternate embodiment can be done very little subscan campaign simultaneously carrying out main sweep.Because along on the clean sweep velocity of auxiliary direction of advocating peace very big-difference being arranged usually, so such replacement scheme remains and makes deposition (being that main sweep keeps vertical substantially with sub scanning direction) on subvertical main scanning line.Other alternate embodiment can adopt the combination of vector scan technology or vector scan and raster scanning.Other alternate embodiment can adopt the off plumb sub scanning direction of advocating peace to utilize the algorithm that makes drop do suitable displacement simultaneously.

In alternate embodiment, printhead can be mounted to such an extent that main scanning direction is non-perpendicular angle.This situation is as shown in Fig. 4 b, and printhead is installed in main scanning direction with angle " α " here.Distance of separation between this replacement scheme situation mesopore is reduced to d '=(d * sin α) by d and effective length of new printhead is reduced to D '=(D * sin α).When spacing d ' equaled desirable print resolution on the sub scanning direction (perpendicular to the direction of main scanning direction), this angle [alpha] was considered to " leading angle (Saber angle) ".

If spacing d (as when adopting a preferred embodiment) or d ' (as in some preferred alternate embodiment the time) are not the desirable secondary resolutions (printhead is not in leading angle) of printing, just must select desired resolution so that d or d ' are the integral multiple of desired resolution.Equally, when printing, all there is spacing on the main scanning direction and between the sub scanning direction adjacent nozzle with α ≠ 90 °.This spacing is by d "=d * cos α is definite.This spacing d of main scanning direction " then when being selected as the integral multiple (supposition spray place be dispensed in the rectangular grid) of d ', desirable leading seal resolution also requires to have the printing effect of optimization.This can become in other words, and angle [alpha] is selected as to make d ' and/or d " (preferably both sides) can produce the desirable subscan resolution of advocating peace when being divided by with suitable integer M and P.The advantage that adopts preferred printhead orientation (α=90 °) is can have any desirable resolution and still to keep optimum efficiency simultaneously at main scanning direction.

Can utilize a plurality of printheads in other alternate embodiment, they are arranged (stretching at sub scanning direction) end-to-end and/or lean against privately and pile up (main scanning direction is stacked).Printhead can make the hole aim at so that they are printed on delegation at main scanning direction when stacked back-to-back, they is offset mutually so that along different main scanning line spreading materials.Can wish particularly to make back-to-back that printhead is offset desirable smooth every trade spacing mutually at sub scanning direction, so that the main sweep number of pass times that must carry out becomes minimum.In other alternate embodiment, the data of determining the deposition place can can't help to determine the pixel location of a rectangular node, and by by the pixel location of a certain other mode arrangement (for example skew or stagger arrangement).Say that more specifically deposition position can completely or partially be done the change of layer to layer so that can carry out the skew one whole layer of partial-pixel drip position or the part of one deck according to the characteristics in the zone of desiring to add injection.

Current preferred printing technique is at main scanning direction per inch 300,600 and 1200 dropping liquids with in the deposition of sub scanning direction per inch 300 dropping liquids.

Referring to Fig. 1 and 3, complanation device 11 is heated swivelling idler 18a that a band makes texture (for example protuberance) surface.Its function is fusing, transports and remove the material of front spreading layer so that make it level and smooth, the layer that forms at last is set to desirable thickness and will last cambial clean upper surface be set to desired horizontal (be the following skim that forms object desirable working surface, be working level).Digital 19 indicate firm layer of material by print-head deposition.Swivelling idler 18a is installed to the spreading platform and is made it by the below of platform in the outstanding enough amount of Z direction can touch the material 19 at desired level place below the orifice plate.In a preferred embodiment, this amount is set in the scope of 0.5～1.0mm.The rotation of roller 18a is cleared away material, remaining its level and smooth surface 20 of wake flow down from the layer with the several 21 firm depositions that indicate in the drawings.Material 21 is bonded to the bump surface of this roller, touches swabbing pig 22 up to it and just is removed.As shown, swabbing pig 22 is provided to " strike off " material 21 effectively by roller surface.This material, then obtained because it remains flowable by said material package and processing subsystem among the US patented claim No.08/534477, thus or be removed or done recycle.

Referring to Fig. 1, also be provided with part and constitute platform 15.The three-dimensional body or the part that on this platform 15, indicate with parameter 14 in the pie graph.This platform 15 is coupled to Y framework 16a and 16b slidably, the latter under the control of computing machine may command platform 15 in Y direction (being direction of index or sub scanning direction) to-and-fro movement.This platform also is coupled to the Z framework 17 that the may command platform moves up and down in the Z direction under computer control (normally downward step by step during constituting processing).

For constituting the section of a part, the Z framework is guided and will part constitutes platform 15 and do motion with respect to printhead 9, so as with the last formation of part 14 (promptly by spreading with may be through smooth) section places suitable amount under the orifice plate 10 of printhead.Printhead and Y framework are impelled on XY constitutes the zone inswept one or repeatedly (printhead sweeps back and forth at directions X, and the Y framework is at this object that partly forms of Y direction translation) then.The layer and the arbitrary and support its associated of the last formation of object is defined as depositing down the working surface of skim and associated arbitrary support.The nozzle of printhead comes deposition materials to constitute the following skim of object to spray by desirable pattern and sequence with layer attitude of doing to register of front spreading when the translation of XY direction.During spreading is handled, removed with state discussed above by the flattened device of the part of the material of spreading.Repeat X, Y and Z motion, spreading and planarization process, cause is a plurality of elect spreading and bond layer set up object.In an alternative embodiment, planarization steps can be independent of the spreading step and carry out.In a further embodiment, the complanation device does not use all layers and may only be used for layer selecteed or at interval.

As noted, indicate printhead to follow a grating mode in a preferred embodiment.Show the one example among Fig. 4.As shown, grating mode by a series of be the capable R of grating (1), the R (2) of main scanning direction operation at directions X ... R (N) forms and arranges along Y direction (being direction of index or sub scanning direction).Grating is capable to be spaced from each other apart from d, in a preferred embodiment, is 1/300 inch (about 3.3mils, or about 83.8 μ m).Because the hole standoff distance d of printhead, be about 26.67mi1s (0.6774 μ m) as discussed, and because the capable desired quantity of grating can be expanded distance greater than orifice plate length at shift direction, about 2.56 inches (65.02mm), so printhead must be through repeatedly capable so that can scan all desirable gratings by next inswept working surface.

This is finished by two following step process.The first step by 8 times, is transfer amount d at main scanning direction by a Y framework on the printhead working surface at every turn.In second step, the Y framework shifts and equals long distance (2.5600+dr (0.0267 inch)=2.5867 inches (65.70mm) of orifice plate.Repeat then this two step handle up to all desirable gratings are capable all be scanned till.In other words, preferred two step process are first steps of passing through with the alternate main scanning direction of amount of movement that equals the capable resolution of desired grating on the sub scanning direction till by capable being scanned of all gratings between the initial row of two adjacent nozzle spreadings.Then, second step was to make very big direction of index increment.The spacing that this big direction of index increment equals between printhead first and metapore adds a grating line space.First and second steps be carried out repetition up to direction of index increment and the row that is scanned be enough to for form all required gratings of object section capable on deposition materials (be included as and form any required support of follow-up section).

For example, in passing through for the first time, printhead is instructed to raster row R (1) (by the hole among Fig. 4 10 (1)), R (9) (by hole 10 (2)), R (17) (by hole 10 (3)) etc.Indicate the Y framework on direction of index, to move then and constitute platform apart from dr (grating is capable).In next passed through, printhead can be instructed to scan R (2) (by 10 (1)), R (10) (by 10 (2)), R (17) (by 10 (3)) etc.Carrying out again passing through for 6 times by back transfer distance dr with the Y framework like this, until finishing 8 scanning altogether at every turn.

At this moment, to be scanned, then will indicate the Y framework to move and constitute total length+dr that platform equals orifice plate, the amount of 2.5867 inches (65.70mm) if any more grating is capable.Repeating this above-mentioned two step process then all has been scanned until all gratings are capable.In alternate embodiment, can make other Y increment, comprise along Y-axis and make negative, positive increment of motion.It is capable that this can be used to scan the grating that is jumped at first.This will with the technology associated that is referred to as " interlocking " be described further.

The injection of jet orifice is by the rectangular bitmap control that is maintained in control computer or other storage arrangements.This bitmap is made up of a memory cell grid, and wherein each memory cell is to being applied to working surface one pixel, wherein the row of grid main scanning direction (directions X) along stretching and grid be listed in sub scanning direction (Y direction) along stretching.Wide (i.e. the distance therebetween) of row (spacing on the Y direction) may be different with wide (or length i.e. therebetween distance) of row (spacing on the directions X), require to have different data resolutions at X with the Y direction.In alternate embodiment, have uneven pixel size in one deck or between the layer, wherein one of wide and the long or both sides of pixel change with pixel location.In other replacement schemes, also have other configuration of pixels forms.For example the pixel on the adjacent lines can be in the part of the spacing between the pixel of skew main scanning direction on the main scanning direction, so that their central point is not aimed at the central point of pixel in the adjacent lines.This a part of value can be 1/2 so that their central point can aim at the pixel edge of adjacent lines.It can be 1/3 or certain other values so that two or more in the middle of the row pixel be disposed in pixel between main scanning direction is by the row of doing to rearrange.In some replacement schemes again, pixel is arranged and be can be depending on by the geometric configuration of object in the spreading or supporting construction.For example when forming the predetermined supporting form of wanting the gap between the bridge joint support column a part of, may wish the arrangement of displacement pixel.The realization of these and other pixel arrangement scheme can not sprayed each pixel place but to can be according to the pixel jet mode of the pixel place injection at desirable selectable interval at random, predetermined or that change based on the pattern of object by revising group of pixels structure or definition more high-resolution configuration of pixels (on X and/or Y) and adopting.

So that (Main Directien Pixels MDP) defines data resolution in the main scanning direction by the principal direction pixel.MDP can describe by pixel length or by the long number of picture elements of per unit.In a preferred embodiment, MDP=300 pixel/inch.Equally can auxiliary direction pixel (SDP) data resolution in the definition sub scanning direction, and SDP is wide or describe with the quantity of the long pixel of unit with pixel.In a preferred embodiment, SDP=MDP=300 pixel/inch (26.67mils/ pixel, or 677.4 μ m/ pixel), SDP is equaling or to be not equal to grating spacing in the ranks, and MDP can equal or be not equal to along the spacing between the place of dropping liquid in succession of each scan line.In succession grating gap in the ranks can be defined as secondary dropping liquid place (Secondary Drop location, SDL), and along the spacing between the capable dropping liquid place in succession of each grating can be defined as main dropping liquid place (Main Droplocations, MDL).Be similar to SDP and MDP, SDL and MDL can long dropping liquid or the definition of dropping liquid spacing in every unit.

If SDP=SDL promptly has man-to-man corresponding relation between data on the sub scanning direction and dropping liquid place, pixel pitch equals the capable spacing of grating.If MDP=MDL then between data on the main scanning direction and dropping liquid place, have man-to-man corresponding relation.

Have the dropping liquid of Duoing if SDL and/or MDL separately greater than SDP and MDP, then need to spray than data, thereby needs are used to facilitate will be by the drop of spreading more than one for each pixel.The spreading of these extra drops can adopt one of two methods, perhaps at the some spreading drop between the center of pixel in succession (drop " ID " promptly), perhaps directly the top at pixel center spreading (being direct dropping liquid " DD ").Under these two kinds of situations, this technology is called " over print ", and cause material foundation faster and alleviation to relate to the restriction of the Machine Design of maximum sweep rate and rate of acceleration, because slowly still can obtain same Z foundation in mobile print head and/or the object.Fig. 6 a to 6d shows ID over print and non-over print, i.e. difference between the DD over print.Fig. 6 a shows the single dropping liquid 60 and a relevant solidification zone 62 that centers on it in printhead is done to be deposited when direction 64 moves.On the other hand, Fig. 6 b shows the same area in processed, but adopts ID over print technology, this moment when printhead is made direction 64 and is moved and single data point deposit two dropping liquids 60 and 66 explicitly.The sedimentary province that is filled up by this two dropping liquid is represented as district 68.Fig. 6 C represents the similar situation to one 4 dropping liquid ID over print schemes, and wherein dropping liquid is indicated by numeral 60,70,66 and 72, and sedimentary province is by 76 expressions, and the direction of scanning still shows with 64.Fig. 6 d shows the similar situation to delegation's pixel 78,80,82,84,86 and 88, and wherein several 90 show the length of the sedimentary province of no over print, and several 92 show the sedimentary province length when the one 4 dropping liquid ID over print technology of employing.Can say blanketly that more than the ID over print increases by about 1/2 to just the additional pixels less than 1 is long its zone that is employed.Certainly, the over print dropping liquid that is utilized is many more, and the vertical-growth of pixel region will be many more.

If SDL and/or MDL are separately less than SDP and/or MDP, dropping liquid will spray in the place that exists less than data, at least during given passing through of this printhead.This data cases can be used to realize the pixel technology of skew pixel discussed above and/or non-homogeneous size.

Fig. 5 shows-N is capable * and the grid of M row.As shown, the row in the grid is marked by R (1), R (2) ... R (N), the row in the grid then be marked with C (1), C (2) ... C (M).Also show the pixel that constitutes grid.These are denoted as P (1,1), P (1,2) ... P (M, N).

For constituting a section, at first to represent the Data Loading bitmap of desirable section (and support of any desired formation).Suppose, as in the preferred embodiment, adopt single formation and propping material, if wish, then just be carried out suitable mark (for example loading) if do not think deposition materials then utilize opposite mark (for example binary zero) with binary one corresponding to the memory cell in this place at a given pixel place deposition materials.If use multiple material, then be carried out suitable mark corresponding to the unit of depositional site and indicate not only that place, dropping liquid place also indicates the material pattern of desiring to add deposition.For ease of being for data processing, can with the packed data of definition object or the Support on-off place of each scan line (for example along) and the fill pattern statement that will be used to the specific region as logical process deduce be used to spray the spreading nozzle final bitmap represent.The capable mode with previous explanation of grating that constitutes grid is dispatched to each indivedual hole.Then, a particular bore is instructed to a pixel is sprayed or do not spray according to its tagged situation of corresponding unit in bitmap.

As discussed above, printhead can be with many different resolution deposition drops.SDP=SDL=300 pixel and dropping liquid/inch in a preferred embodiment of the invention.But MDP is desirable three values in this preferred embodiment: 1) MDL=300 dropping liquid/inch and MDP=300 pixel/inch; 2) MDL=600 dropping liquid/inch and MDP=300 pixel/inch, or 3) MDL=1200 dropping liquid/inch and MDP=300 pixel/inch.When MDL to the ratio of MDP greater than 1 the time, the intermediate location (ID over print) that the extra dropping liquid of every pixel is made between the pixel center takes place.With current preferred printhead and material, every dropping liquid volume is about 100 picoliters.Generate the dropping liquid that has 2mil (50.8 μ m) diameter approximately.With current preferred printhead, maximum injection frequency is about 20kHz.The ground of comparing is 16kHz in its frequency of the injection rate 1200dpi of 13ips, and this is within tolerance limit.

Be illustrated as among Fig. 7 and produce the data be applicable to that the part in the local deposits formation system (for example hot stereolithography system) constitutes, comprise first preferred embodiment that generates the data that representative supports.As shown, the method is transformed into sli file 32 beginnings to utilize boolean's layer burst (Boolean Layer Slice) to handle (with module 31 expressions) with stl file 30.US patent that this boolean's layer fragment process and STL and SLI form are quoted in the above and application (as US patented claim NO.08/475, have explanation in 730 (the doing ' 730 later on).

Then the .SLI file is input to the .SLI form and produces the module 33 that supports data.The .SLI data that support with the sign of several 34 entitling in module 33 with the .SLI data convergence that is marked with several 32 sign object.The result must characterize the .PFF file 36 of object and bearing edge.

The PFF file in module 37 according to the section planning technology of describing in the application that utilizes ' 730 aforementioned of pattern file 38 determined patterns in addition " work shows section line ".The intersection point of section line and object and bearing edge is used for preparing .RLE file 39.

The embodiment problem of being correlated with is a speed therewith.As shown in Fig. 8 a, 8b, this process relate to make .STL file 46 with divide plate plane (as among Fig. 8 a by several 47 indicate) intersect the segment table that produces each section, as indicating with several 48 among Figure 46.With the section ordering, remove inner section then, suitable end points is connected together to form polygon 49.

This processing is very time-consuming, because for making section quantity of the comparison that ordering must be carried out and polygon being done the required time of Boolean calculation.For example to the table of N section, ordered steps needs N ²Inferior comparison.And the processing that a polygon that comprises the N section is made Boolean calculation also needed N ²Inferior computing.Owing to these two reasons, form processing possibility and length, several hours usually of composition data.But an advantage of this kind measure is because edge section is ranked into complex table, comes these edges are dripped wide compensation so can apply for the mode of the compensation routine of proposition to be similar in ' 730.

For second preferred embodiment overcoming these problems as shown in Figure 10.As shown .STL file 40 at first is compressed into .CTL file 42 by module 41.The processing that the .STL File Compress is become the .CTL file is at aforementioned US patented claim No.08/428, introduces in 951.Secondly, according to the style information 43 that provides as input in module 44, the mode of application explanation is with the .CTL file fragmentation in ' 730 by being similar to, and different is, and only will to draw section line be that top layer formula data output to RLE (that is encoded distance of swimming) file.

At first, described in Figure 11 a, the triangle quilt that constitutes the .STL file is in the classification from top to bottom of Z direction do.Particularly, point out that triangle is classified by the decline order to each leg-of-mutton maximum Z value as label 50.As shown, leg-of-mutton order is A, B, C, D.

Desired classification from top to bottom is different with the classification that indicates as Figure 11 a medium size 51 from bottom to top, and wherein triangle is classified by the rising order of leg-of-mutton maximum Z value.The order of gained is B, C, A, D as shown.

To each minute chip level, determine an effective triangle table by utilizing a current level indicator and a transposition pointer.The transposition pointer is given the triangle table of deciding grade and level through one, and any be higher than fully when the triangle of prime promptly without a moment's thought.If triangle is caught by current level indicator, just be added into this table.Continue this processing and point to a triangle that is lower than fully when prime up to the transposition pointer.At this moment, effective triangle table of this grade is finished.Level indicator is changed to next lower level continuation processing of indication then.

Figure 11 b illustrates the processing of current level indicator when level 52a.Transposition pointer 53 advances from left to right, and this is added into effective triangle table with two triangles that intersect when prime (by indicating with number 54a among the figure).Continue this process then and point to triangle 55a until the transposition pointer.Because this triangle fully under prime, is handled when transposition pointer 53 points to triangle 55a and is stopped.

Processing when Figure 11 c explanation level indicator advances to grade 52b.The transposition pointer is reset to zero, and then advances from left to right.Each triangle more than this grade is ignored, and is added to effective triangle table by each crossing triangle of this grade.Among the figure, these triangles indicate with label 54b.When the transposition pointer points to triangle 55b, finish dealing with because it be run into be positioned at first triangle below this grade fully.

Divide the relevant section that forms in one group of X-Y plane of effective triangle of chip level to each with this grade.By triangle define entity and be oriented to outside this entity district (as at this in conjunction with as a reference US patent No.5, explanation in 059,359,5,137,662,5,321,662 and 5,345,391) section that gets of result also has orientation.By these sections, needn't they be ranked into the border loop, just can utilize with ' 730 applications in the identical work of the description algorithm that breaks obtain characterizing the .REL data of object section.

Figure 12 a illustrates the polygon statement (section is sorted to form Boundary Loop) of a section, and Figure 12 b illustrates .RLE (distance of swimming of the coding) expression of same section.Be to generate data, the polygon statement is capped with a plurality of gratings, is the picture element scan row, is that pixel rows intersects to produce on the point of polygon statement and starts/stop his-and-hers watches, each joining and an on/off indicator associated at grating then.Capable to a given grating, the on/off indication of joining alternately enters or withdraws from an entity to indicate this scan line between break-make.Among Figure 12 b, " on " part that for example successive scanning is capable is marked by several 56 (1), 56 (2), 56 (3) ... and 56 (11).

The pixel format of representing among this .RLE form and Figure 12 c is different, wherein, and the data representation of each point in the entity to separate.The problem relevant with the data statement of this form is size.For example, at 300DpI (per inch dropping liquid), 10 inches section needs 9 * 10 ⁶The information of position.

The processing that generates the .RLE data for the object section illustrates in Figure 13 a～13c.Shown in Figure 13 a, to each section, the section of the number of being marked by 57 among the figure for example produces one and is marked with several 58 table array, and wherein, each table in the array is stretched over the scan line of a given Y level corresponding to one at directions X.Then, consider each section in the section again, indicate intersecting between each section and the scan line, and will represent these crossing data to be added in the array separately table.For example Figure 13 b shows that the increase of his-and-hers watches is indicated with several 59 among the figure by considering a section.

The specific data item that is added to table for each " Y " place comprises two parts information: quantitative volume (QV) value and the X-place of intersecting.It is 2 that the joining that section increases in the Y direction has QV.It is-2 that the joining that section reduces in the Y direction has QV.If section is initial or finish at one scan row place, intersect and see " partly hitting " as, promptly the Xiang Guan QV section of depending on still reduces for increase or is 1 or is-1 in the Y direction.Figure 13 b for example, section 1 increases in the Y direction.Thereby intersect relevant QV value and be respectively 1,2,2,2 and 2 (supposing the end points of this scan line section of not linking 1) with this section and successive scanning are capable.And section 1 is respectively 126,124,122,120 and 118 with the X place that successive scanning intersects in the ranks.As shown, the number that is added to this array promptly engages these values.

Figure 13 c explanation is by considering section 2 increases of being done to array.This section increases in the Y direction, and two in succession scan line begin and finish.The X place of the first scan line joining is 144, and the second scanning behavior 126.In conjunction with these values two additions of this array are indicated by several 60 (1) and 60 (2).

Can understand the purpose of partly hitting by consideration to Figure 14.As shown each scan line all with QV value by being associated, the operating QV summation associated that when scan line passes this section, is updated at every turn with the joining of section.If scan line is in entity inside, operation QV value is 2, and as it outside entity, the QV value is 0.Like this, when scan line outside entity and when passing the border, inevitable implication is exactly that scan line is now within entity.Operation QV summation just should be upgraded to indicate it with 2 value and be now in entity, on the contrary, if scan line within entity, and passes the border, then Bi Ran implication is that this scan line is now outside entity or entered in second physical objects with first overlapped object.Then-2 and 2 value should be added to the operation summation to indicate this transition.

If scan line passes a summit, pointed as the some A in Figure 14, the scan line actual definition is two sections when entering entity.Thereby every section only increase by one 1 value to operation QV summation.The QV value relevant with these summits that Here it is remains 1 or-1 reason.

Should indicate, also might scan line pass a summit and do not change the state of QV value in service.As indicated in the some B of Figure 14, the section that forms the summit has QV value-1 and 1 in joining respectively.Result's operation QV summation that scan line is relevant therewith is constant.Quote previously about the other information of quantitative volume (QV) is visible ' the 730US patented claim.

After the scan line joining to all sections had been added to table, the table that is about to each scan line was by the X sequential storage that rises.Use boolean then and extract the correct section after Boolean calculation that routine is extracted each scan line.

The preferred routine of extracting is to keep an operation QV number, wherein, in the table each in succession the QV value of data point be added to the operation summation.Any when operation QV summation is 0 (promptly being transitted towards 2 by 0) has the data point of 2 QV, and promptly " starting point " and any when the operation summation is 2 (promptly adjourning 0 by 2 tables) have the data point of-2 QV, promptly " stop " point, all are saved.This processing illustrates in Figure 15, wherein, indicates its step in succession with number 61～67.Be marked with among the figure several 68 currentitem pointer be used to specify in the original table in succession.Be marked with several 70 " kept " table among the figure and also be used to preserve the initial sum halt that satisfies above-mentioned condition.As shown,, only preserve the first initial point, i.e. (start20) and last halt, i.e. (stop89) by this processing.The result obtains explaining the capable .RLE data of section of an object.All row that this technology are applied to all sections just obtain the .RLE of object is explained.

The polygon statement that forms the object section should be understood that, in order to need not and will be categorized into multilist (as illustrated in the patent of ' 622) for formed section by triangle and burst Plane intersects.As discussed, section being categorized into multilist is a very time-consuming operation.But also should be understood that formed .RLE data be in addition when the .STL file not by rightly in conjunction with or combination one by one when separating (being that this .STL file contains overlapping object parts).

.RLE the benefit that surpasses the polygon statement is that Boolean calculation is simple and much rapid.Boolean's extraction algorithm had been discussed.Other are several to also have Boolean adds, subtract and crossing computing.

For carrying out these computings most effectively, represent that with absolute condition the .RLE number is favourable than representing with relative conditon.For example, 100 beginnings and the row of 30 pixels that stay on should be represented with a pair of starting/halt in the X position, wherein, and 100 beginnings and 130 stop in the position in the position.Like this,, will be expressed as followsin for the .RLE data that are marked with several 72 among .RLE data that are marked with several 71 capable A among the figure and the figure referring to Figure 16: A=[(start20), (stop48), (start60), (stop89)], B=[(start3), (stop78)].

The Boolean add of calculating these two row is to merge these two groups of data, remains on the combined statement of directions X classification simultaneously.The result is (start20), (start37), and (stop48), (stop60), (stop78), (stop89)].After this combined statement stands boolean's extraction algorithm previously discussed, wherein, for example, the starting place is assigned as 2 QV value and stops the place and is assigned as-2 QV value, and only those cause QV to be transitted towards 2 (start) by 0 or are held by 2 points that are transitted towards 0 (stop).The result is marked with the data of several 73 expression Boolean add A+B to [(start20), (stop80)] among Figure 16.

Calculating boolean of this two row, to subtract with relevant Boolean add computing discussed above be same step, different is two tables by and before the symbol of QV value of the table that reduced of quilt become by anti-phase feasible starting transition and stop transition and on the contrary.The operation result of A-B is marked with several 74 in Figure 16.

The boolean that calculate two row are intersected and are the step same with additive operation, and different is extracts routine and begin execution with-2 initial Q V value.Intersecting of A and B is marked with several 75 in Figure 16.

The two dimension Boolean calculation also is easy to carry out.To 2 dimensional region, each is by a plurality of capable statements of preferably expressing with absolute condition of .RLE.Boolean calculation is undertaken by boolean's row operation that each right in succession corresponding row in each zone is carried out in succession.Figure 17 illustrates this process.Be marked by one group of row representative district A of several 76, and be marked with one group of row representative district B of several 77.It is several 78 that the Boolean add A+B in this two zone is marked by, and is marked by 79 and the boolean in this two district subtracts A-B.

On the other hand, adopting the shortcoming of the .RLE data relevant with the polygonal number certificate is amounts of required storer.For store each layer with high-resolution .RLE form, may surpass the memory capacity of 100MB easily to a canonical dissection.This is too big to main memory, even and need the big like this file of storage also be debatable on disk.This problem by by after between the order that constitutes of the part of upwards advancing and the order that constitutes supporting construction of carrying out from top to bottom described later difference complicated.

As will be discussed, need an output file for constituting to support, wherein, to each section, a .RLE explanation is used to this section and the boolean sum of each section on current section.Basically, this technology is to calculate the .RLE explanation of section and the boolean between the .RLE statement of " the current summation " of this section is subtracted, that is the boolean sum of all layers on anterior layer.The pseudo-code of this basic fundamental of expression among Figure 18, wherein: the function that get_part (level) refers to provide the .RLE of the section of regulation level to explain; (current-total=areaA Part-for-Layer=areaB) refers to provide the function that is subtracted the result of district A by district B as boolean to boolean-subtract; And boolean-add (areaA, areaB) function that refers to provide district A and distinguish the Boolean add between B.

Be illustrated as now and make to constitute and support and need not the globality of part and make current sum data can be stored the into memory management algorithm of storer simultaneously.This optimization algorithm carries out in two stages.

In the phase one,, keep the operation summation of the boolean sum of layer partly simultaneously by the initial layer of considering this part one by one in the top of part.After running into one deck, by the zone and the current summation (the operation summation that promptly is updated) of working as the boolean Calais computation layer between the zone of anterior layer of calculating by preceding two-layer operation summation.But do not store current sum data, but only store current sum data the centre to all layers, promptly every N layer one deck, N can be 100 here.Give up remaining current sum data.

Explanation is at this phase one that is marked with several 81 relevant support among part 80 and the figure among Figure 19.The top-down of the current summation of each individual layers generated be marked by severally 82, be marked by several 83 in the middle of these.Figure 20 explanation is used for the pseudo-code of this phase one, and wherein: the get-part function is to illustrate among previous relevant Figure 18, and the boolean-addition function is to illustrate in the front discussion Boolean calculation.

Subordinate phase is to select a middle layer and all layers between this middle layer and next middle layer are carried out the calculating from top to bottom of current summation in the mode that illustrates previously.By then output from bottom to top of the data that the part and the current sum data of each layer are formed.Finish this moment, can remove current middle layer and the data between it and next lower middle layer, and this processing is being repeated in next higher middle layer.

Subordinate phase is described among Figure 21, wherein compares that similar elements adopts same numeral with Figure 19.4 steps that show being marked by of this subordinate phase several 84～87.In step 84, the current summation (being marked by several 88 in the drawings) of all layers between the middle layer 14 and 15 (for example part or the end of object) is determined and stored.Then in step 85, the support that utilizes the aftermentioned method to be identified for these layers is exported again.Then remove 14 and 15 part and sum data.In step 86, part between 13 and 14 and the sum data (being marked with several 89 among the figure) determining and store each layer.In step 89, these layers are determined that support and output are used for constituting at last.Data of these layers of cancellation then.This process is repeated in each middle layer.

Should be understood that this algorithm greatly reduces the required storer of support generative process.If N is two numbers of plies in middle layer in succession, the 2N of the number of plies (because needing part and summation) in the middle of the then once stored number of plies will equal.If T is the summation number of layer, is stored the number of plies and just equals T/N+2N.Just obtaining the best storage device when the square root of N=(T/2) uses.To one 5000 layers summation, best middle number of plies N is 50 like this.Total number of plies that any moment must store is 200.

The middle layer that is expanded to secondary by aforementioned algorithm can further reduce storage requirement.As shown in Figure 22, algorithm carries out with number in the figure 90,91 and 92 specified three phases.Phase one (being marked as 90), determine the first order in middle layer.Subordinate phase (indicating), between two first intergrades, determine second intergrade with 91.Then phase III (indicating 92 among the figure), determine and store the current summation of all layers between two in succession second middle ranks.After the support of calculating these layers, discarded data repeat this processing to next second intergrade.When all second intergrades relevant with current first intergrade are all handled, promptly handle next first intergrade.

If progression is N in the middle of first, the second middle progression is M, and then the storage requirement of three phase process is (T/N)+(N/M)+2M for this reason.If T=5000, N=288, M=14, then the number of plies that once must store is 66.Because this three phase process increases computing time, so unless preferably the two-stage handle and relate to extremely thin layer or a large number of layer, three phase process may be desirable in this case.

As discussed, the .RLE data of a given layer are started and stop transition by one group forms, each transition is linked in pass, an X place.Data for example illustrated in fig. 23 are corresponding to following starting and stop the place, and grating is capable respectively with the capable A=[(start20 of grating of parameter number 102,104,106 and 103 appointments), (stop48), (start60), (stop89)]; With with the parameter number capable B=of 112 and 114 gratings that indicate ((start35), (stop72)).For the method for storing this data is made up of the chained list that starts/stop transition.As indicated in the pseudo-code among Figure 24.Compare with an array, chained list is more superior, because it is easy to realize dirigibility and accommodation on the required transition number of every row.Problem is that it causes using the small memory piece of a large number of dynamic assignment, and this is owing at least three tangible reasons can make mis-behave widely.At first, dynamic memory allocation is very time-consuming because it requires system call.Secondly, each dynamic storage is than the hidden danger with storer overload relevant with being used for the book of final entry.The 3rd, the message unit that is close in logic is disposed in the non-adjacent storer, causes a large amount of fast cache errors.

For addressing these problems, preferably adopt another kind of data structure form.When resolution was 1200DPI, the transition in the canonical dissection can characterize by 15 bits.Like this, the word of one 32 bits (being with 2 Spare bits) can be used to represent one start/stop right.This data structure shows with pseudo-code in Figure 25.Whether " Last " (at last) mark be used for indicating this to start/stop is that this group is used for last of specific scan line.If this " Last " bit is set to logical one.If not, this bit is set to logical zero.In the case, next in the sequence starts/stops being stored into tight adjacent memory cell.This scheme makes and a large amount of transition points can be stored in the adjacent memory block that each transition can have two bytes.Figure 26 provides the example of this transition scheme, wherein similar elements be marked by with Figure 23 in used same code name.As shown, go A by two transition to forming: [(start20), (stop48)] and [(start60). (stop89)], element 102,104,106 and 108 is stored in the 32 adjacent bit words as shown." last " bit 122 in first word is reset to logical zero and is useful on the additional data of this scan line with the indication heel, simultaneously " last " bit 124 of second word be set for logical one to indicate no additional data heel.Row B only is made up of starting/stop the place a list, is indicated as being [(start37), (stop78)] and is marked with several 112 and 114 respectively, and wherein last bit 126 is set to logical one is not had the additional data of following so that indicate capable B.Label 132,134 and 136 refers to other application bits relevant with each 32 bit words.

These .RLE data initially are not to be generated as above-mentioned merging form, but as about discussing among Figure 13 a～13c, the initial form that is generated as non-merging, and then be transformed into the form of merging.

In a word, a memory block is allocated for the storage transition.Initial (" current grating is capable " pointer or " current table " pointer) and one that a plurality of pointers are used for the data relevant with each grating indicates the beginning (" next available place " or " next place, space pointer " that is not assigned with storer.Each 4 bytes (32 bit) word in this memory block is defined as: 15 bits at first are used to store the X place of transition, and second 15 bit is used for storing the qV of transition.The 31st bit is used to define one and indicates " by the using " mark whether this word has been arranged and has used.The 32nd bit is used for defining whether an item that indicates this word is last transition item that makes the associated given scan line of this word.The starting point, the capable storage data that can be of each grating are assigned with one or more word.When the transition to each edge section enter memory block, they be added to they deduced the table of grating line correlation.

Be added in the capable table of grating at the transition point that each is new, may run into several cases.At first, if with the capable memory block of a given grating in do not have the transition data, just the transition data are added to this grating capable with " current list index " relevant word.The second, if the transition data are present in the relevant word of the capable and current list index of given grating.(promptly " following word " sees whether it is utilized then to check the word of following the transition pointer (promptly to this current list index) to the last record of this scan line.As be not utilized, promptly in the new transition data of this input.The 3rd, if this " following word " is occupied, then check this current list index word (i.e. " previous word ") before to see whether it is utilized.As do not have, then current list index and word of all transition data that are recorded (capable to this grating) displacement also are added to new transition point data by the end of the table of displacement.The 4th, if " previous word " occupied all transition data (comprising the current list index to this row) that will be capable to this grating move to and indicate the word of " next may place " pointer, added new transition data, indicated the original word place and the place of " next feasible place " pen travel after following just mobile word and the quilt word that adds of the transition that can be used to add new data.

Can make various modification to the process of describing above.For example, can adopt the word of all size, can change bit configuration, can change the original allocation amount capable to each grating, can avoid the capable original allocation of each grating is fully to handle the input section to need to distribute as the additional capable memory cell of grating, can increase the application that additional step improves control store, or the like.

Above-mentioned processing is made example in the following description and correlogram.Figure 27 a, 27b illustrate this processing according to the identical data of gained among Figure 13 (wherein same parts employing same numeral).The storer 93 in very big zone is assigned with the transition with preservation .RLE, and pointer 101 is used to indicate next available memory word (32 bit).In this example, word format comprises following Bit Allocation in Discrete: 15 bits, 142 records at first are used to deposit the value of X position transition, the qV value of second 15 bit 144 record transition.The 31st bit 146 is for indicating " being employed " mark whether word has been assigned with and has used.Whether the 32nd bit 148 is the last mark of the transition of the capable last record of grating, i.e. " end " mark for indicating transition.

Figure 27 a explanation is in situation about arbitrary transition data being added to storage before 93.Be procedural reason, as will be clear later, first word in illustrated regional 93 is labeled as and utilizes." next place, space " pointer 101 points to second word in this district.Then, set up pointer array 58, wherein all pointers all are initialized to and make it " be employed " bit to be set to zero.As discussed above, each pointer connects with the one scan line correlation and is used to first word relevant with this scan line (promptly to first transition) allocate memory ground dot element.This pointer is called as " current table " pointer because its point to just consider in the relevant transition tabel of current scan line in first word.For the transition with a specific scan line are added to array, if the pointer in the array is when having on the word that " being employed " bit is set to logical zero one, the place of pointer promptly is counted as idle and transition is assigned to this memory word.Figure 27 b shows that first transition have been transfused to the situation of the storer that into is used for 5 scan lines.

Figure 28 a, 28b illustrate that the transition of the scan line of " being employed " mark that has non-zero on the position of " current table " pointer 94 add processing.Figure 28 a shows that 2 have been transfused to as the word 150 and 160 that belongs to the scan line relevant with current list index 94.Word 150 comprises the bit place 150,154,156 and 158 with same definition relevant with the bit 142,144,146 and 148 of Figure 27 b.Equally, word 160 comprises bit place 162,164,166 and 168.Element 156 and 166 provides the value of " being employed " mark.Whether element 158 and 168 indicates word (being transition) is the last transition of being write down up till now in the current table.Can find out that it is not last word that element 158 indicates this word 150, and 168 to indicate 160 are last used words in the current table.At first, " being employed " mark (being marked by several 96 in Figure 28 a) in the next word 170 of check after current transition tabel finishes is to understand fully whether this word can utilize.If this " is employed " mark and is set to logical zero, this word promptly can be used for storing new transition details.If be set to logical one, then this word is unavailable.If as shown in Figure 28 a, be available, then new transition details can be inserted this word.Show among Figure 28 a that current table is added into new transition and revises.Among Figure 28 a, new transition details 97 is added to word 170.The value of " end " identification element 168 is become by " 1 " and is " 0 ", and the end mark element 178 of word 170 is given pre-value " 1 ", because 170 is the end word of current table now.

If next word after the end of current transition tabel is unavailable, then check the initial availability that is right after the front word before of current transition tabel.This check is undertaken by the value that assessment is right after " being employed " mark of front word.If available (being indicated by " 0 " value), then whole table are moved a word backward.And new transition are placed in the position of the word that just has been eliminated.This process wherein is marked with same numeral with Figure 28 a, 28b components identical as shown in Figure 29 a, 29b.As shown in Figure 29 a, " current table " pointer and word 150 associated, this table finishes with word 160, next word (being marked with several 170 among the figure) after the ending of current table is unavailable (because the value " 1 " in the element 176), and the word (being marked with several 180) that is right after before table initial is available (because " 0 " value in the element 186).These estimate disconnected conclusion shown in Figure 29 b, and the wherein previous transition value relevant with word 150 and 160 come respectively and word 180 and 150 associated by displacement." current table " pointer also is displaced to word 180, and new transition information is added to the word 160 of present usefulness.As another result, " end " mark is kept relevant with word 160, though it no longer with * value 60 transition relevant (previous element 162, new element 152) but with * be worth 12 transition relevant (previous element 172, new element 162).In other words, move a word behind the whole current table, new transition 97 are stored in the place that is eliminated.

If there is not free space (being the word and the real ending that contains list notation that follows this word closely of the tight front of current list index) before or after the current transition tabel, whole current table promptly is replicated into the initial space of word by " next available place " appointment, and new transition are added to the end that is replicated table.Then, " being employed " mark of original memory word of stored table is reset and indicates these original memory words and may be used by the scan line table that is right after the front and follow these original places closely now.Figure 30 a, 30b illustrate this process, wherein relative Figure 28 a, 28b, and the same element of 29a, 29b adopts same label.

Figure 30 a illustrates word 170 after the end 160 of current table and the word 180 that contains word 150 fronts of current list index, and both all can not utilize because " being employed " mark 176 and 186 is set to " 1 ".Figure 30 a also illustrates the word 200 of discovery " next available place " pointer.The transition point of all scan lines having been imported followed in word 200.The result does not have new transition can be input to these places 150 and 160 that are surrounded by the transition relevant with this scan line in continuous memory cell to current scan line.As shown in Figure 30 b, whole current table (originally being assigned to the transition in word 150 and 160) is replicated into by in the initial zone of the specified word of next place, space pointer 10 200." being employed " mark (indicating with several 100 among Figure 30 b) in the old storer is reset and can utilizes now to indicate this storer.Current list index 94 is updated and points to word 200, and new transition 97 are added to the end word 220 of table." next available place " pointer (being marked with several 101) is updated the word 230 that points to the word 220 that follows the transition 97 (i.e. Biao end) that contain last input closely.Certainly, if desired, can keep one or more blank words in the transition 97 of word 220 last inputs and between by the word of " next available place " pointed.

In view of this scheme of character of .RLE data effective especially.Because data are used to illustrate solid geometric object, specific to scan capable transition number usually identical with transition number on the adjacent lines one.These characteristics as shown in Figure 31.Begin to represent an object section from the top, represent that wherein spaced grating is a scan line.Represent the transition number relevant with this scan line on the right of each scan line.Like this, if wish transition are added to a specific scan line, most transition will be added to an adjacent scan lines.When a memory areas is idle, as illustrated in the text that Figure 30 a, 30b are followed, then neighboar lists will have the transition that can be stored in this zone mostly.As illustrated in Figure 28 a, 28b and 29a, 29b and the corresponding text.Like this, very big memory array forms and is less than when adopting random data the gap that produces.And will make from the error that is stored in the data in the cache memory less.

In all sections when all processed, table is as a result done the directions X classification.Extract by aforementioned manner then and make the row that correct boolean handles, and deposit the row that is extracted with aforesaid merging form.

This embodiment directly need not angular transformation composition plate plane a .STL file operation, can avoid some quantization error so at least.But owing to divide plate plane only to be distributed in vertical direction and, and can import some vertical and level quantization because horizontal transition are limited to pixel edge with varying level by producing the .RLE data.The example that shows these contents among Figure 32 shows grating capable 302,304,306,308,310,312 definite with 314 the quantification relevant with expression on/off transition point 322,324,326,328,330,332 and 334.The capable center line of each grating is shown by the dotted line separately relevant with the edge section 300 that passes a plurality of pixels.Zone, figure center line the right is considered within the object, and left area is looked at as outside object.Can be selected to represent the limit of object to the capable only single transition pixel of each grating, and have how many pixels to be intersected by the edge regardless of on this row.Though there are many approach at the edge that will form object for definite which pixel, described method is to the capable pixel of selecting the edge pixel conduct to contain capable line segment of grating and center line of a given grating.In the situation on the border between capable center intersection strictly two pixels of grating, determining to value in object (promptly solid) also is non-object (promptly hollow).As represented, be determined hollow emphatically to grating capable 302,306,310 and 314.

Have many transition and select replacement scheme.For example, can make any pixel that worked all be taken as by the generation of selecting transition selects to focus on solid for the part of object.On the contrary, can by the generation of selecting transition only make those fully the part that is looked at as the entity district of the pixel within object boundary select to focus on hollow.As replacement scheme in the middle of, can get transition average of front two replacement schemes.For the other scheme of determining the transition place can be that the frontier district pixel is determined solid or hollow area percent etc.Particularly those relate to the technology described in the branch chip technology and help to realize some these technology to utilize the patent before quoted and application.As last example, a replacement scheme can be that pixel is done to cut apart and based on one or more the determining of whether section being intersected subpixel.But no matter what method of employing, Zong wish that the method that is used for part and supports both sides is consistent.

The compensation data technology

Utilization is with the end points shift-in of transition or shift out the end points that guarantees simultaneously from adjacent segment and do not intersect and just can easily compensate.For example, support and to touch a part, can be expanded, then subtract the .RLE data that obtain describing the Support as boolean by current sum data to the .RLE data of this part for avoiding one.In addition, current sum data can be expanded, and it is poor as the current sum data and the boolean between the partial data of expansion to calculate the support data.That is, can be poor as the boolean between current sum data and the partial data to supporting data computation.Then, will support the data expansion.And the boolean that the actual support data are calculated as support data that are expanded and initial protion data is poor.

For the compensation that the dropping liquid size along the direction of scanning adjusts can easily be carried out, as long as DPI is the high-resolution greater than the dropping liquid diameter.Compensate for slower difficulty on the Y direction.But also can finish step by step less than the increment of 300DPI.

It is useful the .RLE data conversion being become vector data.As shown in Figure 33, unless this technology is to have intermediate point (this situation is unallowed) between the two, connect two continuous " ON (leading to) " point or continuous " OFF (break) " put and form vector.For example in Figure 33, allow tie point a and some a but do not allow tie point a to a some c.Reason is that a b is between 2 o'clock.

Support the generation of data

Explanation now generates the preferred process of the data that are used for supporting construction.The data that provided of the above-mentioned data manipulation technology of reason begin herein.As above-mentioned, data operation system provides object (being part) data and " summation " data to each layer.The partial data of one given layer is a series of starting and the halt of the adjacent grating that distributes of the XY of the part of this layer of definition in capable." summation " data of one given layer are a series of startings and the halts in the adjacent gratings row of the boolean sum between the XY boolean of arbitrary desired support of the part of this layer of definition and this layer.

These data are as shown in Figure 34 a-34c.Figure 34 a explanation is to " peanut " shape each layer (being the section thin layer) 1 to 10 a partial data P[1 separately partly that is presented in the Z-X plane] to P[0].Among Figure 34 a to each section P[1] to P[10] only represent that a single RLE is capable.Initial transition are marked by " ← " symbol, stop to become suitable " → " symbol that then is marked with.Can find out that partial data is followed the tracks of the border (being scope) of this one.

Figure 34 b explanation is to " summation " data T[1 separately of each layer 1 to 10 of this part] to T[10].It also stops the transition definition with initial sum.But different with partial data, it not necessarily follows this portion boundary.As discussed above, are boolean sums to " summation " data of a given layer to the partial data of all layers more than given layer.

Figure 34 c explanation is to the part of a given layer and the view profile (in X-Y plane) of sum data.These data are marked with P[i respectively] and T[i], comprise a plurality of startings of arranging along the irregular row in the X-Y plane and stop transition.In a preferred embodiment, this irregular be about to be oriented be parallel to X-axis.But as directed other irregular row orientations also are possible.

In a preferred embodiment, adopt the object of combination and sum data to come one deck ground to determine to start and stop transition for supporting.If in all districts that need support, adopt the support of unimodality, can be defined poor as between the part number of the sum data of one deck and this floor just can use all single support patterns of determining each floor in the district.On the other hand,, discuss in 813 as US patented claim No.08/534, according to object arbitrary towards last and/or the surface that faces down near or away from degree the supporting construction of different types to be adopted in the different location may be favourable.And, leave object boundary how far to adopt different support patterns also may be favourable according to interval on one deck.Assist to define the US patented claim No.08/428 that quotes previously of Support can be applicable to the present invention, introduced in 951 and be used to carry out level technology relatively.For example, adopt two kinds of different support patterns, use when being lower than prone surface number layer interval for one, another is used for other.On the other hand, two actual support patterns can be combined with the 3rd " do not have support " pattern, wherein, do not have the zone of supporting within 1 or 2 pixel that pattern may be used on being in the portion boundary district, perhaps wherein, the above part surface of object is as the normal greater than a certain critical perpendicular line.The embodiment scheme that many other a plurality of support patterns of employing can be arranged, they are according to here in conjunction with disclosure for referencial use (US. patented claim No.08/475 particularly, 730,08/480,670,08/428,951 and 08/428,950) can easily realize.In addition, also can be applicable to of disclosing here can be referred to as inner object and support, and wherein, can adopt single or multiple support pattern in the processing for the interior section that forms object.Such technology is for example being watered and is being used in the stereolithography of pattern formula for making wax-pattern, and the US patented claim No.08/428 that formerly quotes has introduction in 950.

For how further explanation can provide following example to different supporting area definition of data, it is corresponding to US. patented claim NO.08/534, and example is supported in the mixing of explanation in 813.According to this example, can see three types of supports: the fine fibre shape post that separate by checker board pattern (1); (2) 3 * 3 more solid pixel pillars support; (3) middle or transition bed.

Suppose that layer " n " will be established, this technology determines exactly how the each several part of layer " n " approaches of object towards last and/or prone surface.In the present embodiment, if the part of layer " n " within " r " on the prone surface layer (for example 5-10 layer) or one towards on " u " layer (for example 5-10 layer) on surface within, the support that then will set up the checkerboard type class for this part; If apart from prone surface " S " (s=r+1) with " t " layer between (for example 6-10 layer or 11-15 layer) and apart from the surface that makes progress of one side greater than " u " layer (for example 5-10 layer), the bridge-type class support in the middle of then will setting up; If apart from the surface that makes progress of one side greater than " u " layer (for example 5-10 layer) and apart from a surface that faces down greater than " t " layer (for example 10-15 layer) then will set up 3 * 3 pillars and support.

Figure 46 a-46b illustrates above-mentioned example, shows the identical side view that has the object in a gap between the surface that the one side at object makes progress and the surface that one faces down.Figure 46 a surface is along the side view of imaginary level and the zone that forms different supporting constructions thereon.Figure 46 b shows the side view when being filled with the different types supporting construction according to the gap of the imaginary level of Figure 46 a and interval layout.

More specifically, Figure 46 a shows to comprise prone body surface 402 that interval 404,410,408 and 406 spacing is separated and towards last body surface 400.Interval 404 are positioned within " u " layer on last surface 400, and interval 406 are positioned within " r " layer of prone surperficial 402.Interval 408 are positioned at apart between prone surperficial 402 " r " and " t " layer, and be positioned at simultaneously apart from towards last surface 400 greater than " u " layer.Interval 401 be positioned at simultaneously apart from towards last surface 400 greater than " u " layer and apart from face surface 402 down greater than " t " layer.Interval 404 and 406 will be formed with checkerboard type and support, and interval 408 will be formed transition type support (for example completely crued) and interval 410 will be formed the support of 3 * 3 pillars.Layer 414,412,424 and 416 is expressed and is formed on separately within interval 404,406,408 and 410.These layers will be formed the supporting construction of single formula on its whole area.The opposing party's surface layer 418,420 and 422 is shown that part is positioned among the district 404 and 410,410 and 408 and 408 and 406 respectively.Therefore, these layers will distribute according to the XY of the each several part of layer and be formed supporting construction with different types.

Figure 46 b show respectively prone surperficial 402 and towards on surface 400 on and under solid body district 432 and 430. District 404 and 406 is indicated as being with chessboard (pixel is logical, and a pixel is disconnected) and supports and fill.District 410 is specified 3 * 3 pillars and supports (3 pixels are logical, and 3 pixels are disconnected) filling.District 408 is specified by the solid area that supports and is filled.

This embodiment can form expression by equation.In expressing these equations, adopt following term:

Cn (D): the area element of layer n, the support that should set up " checkerboard type " classification when determining on it by prone surface;

Cn (U): the area element of layer n, on it by by the support that when last surface is determined, should set up " checkerboard type " classification;

Bn (D): the area element of layer n, the wherein support that should set up " bridge joint " classification when determining by prone surface;

Sn: the area element of layer n, set up 3 * 3 pixel post classifications on it and support;

P1: part is at the area element of section " 1 ";

Pn: part is at the area element of section " n ";

Tn: sum data is at the area element of section " n ";

∑: boolean's summation of area element;

+: the boolean sum of area element;

-: the boolean of area element is poor;

∩: the boolean of area element is intersected;

R: the number of plies below the CONSTRUCTED SPECIFICATION of facing down that support to form with checkerboard type;

U: with checkerboard type support to form towards the number of plies more than the last CONSTRUCTED SPECIFICATION;

S: transition type supports the following number of plies=r+1 in prone surface of termination;

T: transition type supports the following number of plies in prone surface that begins to locate.

According to the connotation of these terms, the following equation definition is the method for optimizing that layer " n " is determined support according to present embodiment: $\left(1\right)C_n\left(D\right)=\underset{t=n-1}{\overset{n-1}{\mathrm{\Σ}}}{P}_t-P_n$ $\left(2\right)C_n\left(U\right)=\underset{t=n-1}{\overset{n-2}{\mathrm{\Σ}}}(P_t-P_n)\∩T_n$ $\left(3\right)B_n\left(D\right)=\underset{t=n-1}{\overset{n-t}{\mathrm{\Σ}}}{P}_t-C_n\left(D\right)-P_n-C_n\left(U\right)$

(4)S _n＝T _n-P _n-C _n(D)-C _n(U)-B _n(D)

Equation (1) expression, its upper strata is by the area of the layer of being determined by prone surface " n " of setting up the support of checkerboard type classification, by the Boolean add of the partial data of getting layer " u " above " r " layer, the boolean's difference between the partial data of the data of this addition area of calculating expression and layer " n " is calculated then.

Equation (2) shows, its upper strata is by the area by the layer of determining towards last surface " n " of setting up the support of checkerboard type classification, by the Boolean add of getting the partial data of " u " layer under the layer " n ", the data of calculating this addition area of expression are poor with the boolean of the partial data of layer " n ", then calculate these data again and the difference between the sum data of layer " n " is calculated.This last computation purpose is for supporting in fact avoiding during no part layer setting up on " n ".

Equation (3) shows that its upper strata is by the area on the layer of being determined by prone surface " n " of setting up the bridge joint support, by 1) be taken on the layer " n " by the boolean summation of layer " S " to the partial data of " t "; With 2) by suing for peace of step 1) data difference be illustrated on layer n and will go up the data that will set up partly area own its data (under the prone surface and) and presentation layer " u " of setting up the area that checkerboard type supports towards more than the upper surface.Mainly be that this equation is determined the priority between bridge connected and checkerboard type support.Its requirement, towards on " u " layer on surface within and in the area within " S " to " t " on prone surface (for example one curved surface area) continuously, this priority will be given the foundation of pre-checkerboard type support.

At last, equation (4) is for setting up the area that 3 * 3 pixel cylindricalitys support on the layer " n ", by getting the partial data of layer " n " and determining these data and 1) to the partial data of layer " n ", 2) to set up the data of the area that checkerboard type supports on the presentation layer " n ", and 3) represent that boolean's difference that desire it on sets up between the data of area of the layer " n " that bridge connected supports is next definite.

Obvious by top discussion, can come definitional equation to each zones of different that requires to form dissimilar supporting constructions.Figure 37 shows that one requires the arch formula of different formation patterns supporting construction to be arranged moving closer to face down at surperficial 24 o'clock.As pointed out that this arch formula supported with surface 23 beginnings, this can be one to constitute the surface of (foundations) platform, object towards a last surperficial or surface relevant with the support of previous formation.Here this supporting construction is to have the mixing support that forms required many (for example more than 10) different support pattern for it.Certainly, the checkerboard type that also may increase multilayer between the top of this arch and supported prone surface supports.

In case data are determined, next step in the processing is the data that form the form that outputs to control computer.As the control computer of discussing will load these data and object data in bitmap to drive printhead and X, Y and Z framework.

Adopt Style (pattern) file for this purpose, each is at the object structures and the supporting construction of each classification.Style file to a given object or support pattern is will set up object and support the core schema that repeats in the whole area of classification.The Style file is used to modulate the formation pattern relevant with the given area.This data modulation technique has been simplified data manipulation and storage requirement.For example the Style file relevant with the support of " checkerboard type " classification in the present embodiment is 2 * 2 pixel modes shown in Figure 38 a.As second example, supporting relevant Style file with 3 * 3 pixel pillars in this optimal embodiment is 4 * 5 pixel modes shown in Figure 38 b.Certainly, many other Style patterns also are possible.These Style patterns repeat one by one, usually so that (X, Y) place (0,0) beginning is so that determine the repeat pattern in XY space.This comprehensive pattern with object and Support are stopped transition data associated to the initial sum of layer.The combination of Style fileinfo and object information can occur in data and be sent to and also can occur in after the transmission before the control computer.Generally, object and style information are combined into a single data set after both all are sent to control computer.Now, the preferred Style file of part correlation only is one 1 * 1 entity pixel mode therewith, and the inside that indicates this part is always solid.

At present, optimal the duplicating of pattern is fixed in the X-Y plane.About best 3 * 3 support modes, the result is that some 3 * 3 pixel post weakens at segment boundary.This effect is as shown in Figure 39 a.As shown, the part 30 of 3 * 3 pixel posts and 31 is not because they are established near segment boundary 32.This two support as a result has the surface area that reduces.Problem is little because the information of this part will form the other parts of each post that forms partly if these posts are not spread back by segment boundary.But, constitute with this part contacted support and tend to damaging object surface smooth finish, cause other problem thus.

Supporting under the partially retracted thus situation, the way of head it off is the pattern of duplicating to be changed make 3 * 3 supports can follow this segment boundary.This measure is as indicated among Figure 39 b.The change gradually of support column position can be adopted as the skew pixel mode of explanation in the US patented claim 08/534,813 and realize.

As mentioned above, another problem of Fa Shenging is that 3 * 3 support columns are configured directly contact of part therewith sometimes sometimes.This problem of explanation among Figure 39 c.As shown, supporting 33 is established to such an extent that directly contact (support 34 represented of this cut-open view only is to be the explanation of integrality purpose) with part 33 below part.To the solution of this problem is to move a pixel after these are supported or more will the support thus partly separates.This only can finish as long as this support adjustment initial sum is stopped the transition data.In the present embodiment, be selective in view of getting compromise this adjustment: support a pixel by returning, the surface area of post will reduce, and may cause the accumulation problem.

Preferably have some explanation of necessary do about what carry out that boolean calculates.As discussing, the data that relate in these calculate are formatted into a series of initial sum and stop transition.See that this form makes them can make a series of algorithm calculations to help boolean and calculate.For example, in two groups of transition data, carrying out boolean's difference operation, only need the starting of layer and stop transition subtracting calculation as arithmetic mutually.The result improves computing velocity greatly.Its reason is, is essentially N according to the Boolean calculation that relates to N data point of polygonal number certificate ²Inferior computing, the arithmetical operation that utilizes initial sum to stop the transition data then is proportional to N basically.

On the other hand, middle the Boolean add data that layer " n " is calculated, that is on the layer " n " and the Boolean add of the partial data between following " r " and " u " layer, " s " and " t " more than layer " n " layer can not be used for any processing subsequently.Reason is to lack the storer relevant with the Boolean add computing, as shown in the formula indicated: $\left(5\right)\underset{n}{\overset{n-L}{\mathrm{\Σ}}}l=L\left(\mathrm{arithmeric}\right)$ $\left(6\right)\underset{n}{\overset{n-L}{\mathrm{\Σ}}}=l\left(\mathrm{Boolean}\right)$

As show, adopt arithmetical operation and in the n item to may effect being arranged by the final total value that subduction is fallen when one deck calculates down.On the other hand, adopt Boolean calculation, then the n item not necessarily has any influence.Like this, this effect is unnecessary when lower floor is calculated is fallen by subduction.

Though above equation (1) produces accurate result to (4), they may bring excessive computing time.Like this, in some cases, may wish to adopt the equation that can draw approximation but only need less calculating.The gradient on dependence hypothesis a part of surface in the layer (for example 10 layers, about 10-20mils) to determined number is reindexing not, perhaps all represents insignificant variable in the cross section place in any variation that makes progress, and can avoid excessive calculating.In other words, this supposition is that part surface is not done rapidly or rapid variation.This point illustrates in Figure 35 a, 35b.Figure 35 a shows that one supposes consistent part therewith.Can find out that the gradient that is marked as 8 part surface among the figure is through the given number of plies for example 10 layers of not reindexing, i.e. direction.On the other hand, Figure 35 b show one with the direction of surperficial gradient not reindexing suppose inconsistent part.But, depend on the variable quantity in the surperficial XY position, the change on the direction may cause insignificant variation in the cross section place.As finding out, the gradient that is marked with the part surface of S ' among the figure is passed through for example 10 layers of reindexing.To a given number of plies, thin more this hypothesis of layer may be kept more.

As making as above hypothesis, just can utilize following formula to reduce required digital computation: $\left(7\right)C_n=(P_{n-1}-P_{n-2}-P_n)\∩T_n$ $\left(8\right)B_n=P_{n-1}-P_{n-5}-C_n-P_n$ (9)S _n=T _n-P _n-C _n-B _n

Replace boolean's summation of the area of each section in foundation such in the original equation (1) to (4) one zone, the section information of this interval upper and lower section is only taken from these equation utilizations.If it is correct that this hypothesis always remains, these formula just produce accurate result, and in fact under any circumstance they all present extraordinary approximate.

Should be appreciated that to carrying out aforementioned calculation, need to use the data (for example t=10 during u=5, promptly needs 16 layers data) of taking from (t+u+1) layer simultaneously.This is because the support data of layer " n " are depended on to layer " n+1 " to " n+t ", layer " n-1 " to " n-a " and certainly to the part and the sum data of layer " n ".

But for keeping the form of these data for immediate access, it is favourable adopting annular buffer.As shown in Figure 36, annular buffer is wherein to store the part of t+u+1 layer (promptly 16 layers) and the annular buffer of sum data.(t=10 u=5) is the state of the impact damper of example with 16 layers in the time will carrying out the calculating of layer n for Figure 36 a explanation.The pointer that is marked with PTR among the figure is used to point to the just in question anterior layer of working as.As noted, layer " n+1 " to " n+10 ", " n " and " n-1 " to the data of " n-5 " are stored in the buffer.Second pointer that is marked with LAST among the figure is used to point to the last term in the buffer, here is the item to layer n-5.

After the calculating of finishing layer " n ", need to upgrade buffer and the calculating of layer " n+1 " is prepared for carrying out.For finishing this point, at first PTR is updated to make its sensing be used for the layer " n+1 " data.Then, for LAST data pointed are used to down the data rewriting of desiring to be added to buffer of one deck, here be layer " n+11 ".At last, LAST is updated the data of pointing to the last term of sight in becoming buffer, and this is used for layer " n-4 " here.These three result calculated of explanation among Figure 36 b.Figure 36 c explanation will be calculated the state of buffer constantly to layer n+2.Repeating this then handles until the calculating of finishing all layers.

Many replacement embodiments may be used to operate the 3D object data becomes the data that can be useful on running SDM equipment.For example, in an alternate embodiment scheme, utilize the Boolean calculation of polygonal number certificate is carried out aforementioned calculating, and do not adopt the transition data.In addition, the data of these all layers of part are stored simultaneously in the storer rather than in the annular buffer.Another is to adopt repeatedly supporting and accumulation rate partly by next balanced fine fibre shape of printhead.

Should also be understood that to be that data, i.e. Bn (U) are supported in transition by calculate bridge data towards last surface.The transition that these data can be used between surperficial initial fine fibre shape support that object simultaneously makes progress and setting 3 * 3 pillars support is thereon supported.And should be appreciated that if just needn't calculate Cn (U) data dividually with Cn (D) data to both Style file is identical.If this two Style file trends towards difference certainly, then to keep the data of two classifications.

Should also be understood that and utilize alternative three of having discussed of this theme invention on a given layer, to set up any amount of support pattern or classification.This can be only by increasing additional Style file and being that the definite area equation that will set up new classification support thereon can be finished.

Constitute pattern and support pattern

This is that optimum data handles, preferably normal pattern is not formed and embedded the RLE data, because can make the RLE file excessive and to make data processing be unpractical aspect the time.Here advantageously keeping object prints until genetic horizon with accurate exposure mode (being sedimentation model) is irrelevant with support section information.As above-mentioned, carve in due course, the profile data form of RLE information (for example with) is done boolean with suitable formation pattern mode intersect to determine will be used to define the accurate pattern of deposition details.

For example, this can be used to produce apace the checkerboard type pattern.Figure 40 a-40c explanation one example, wherein similar elements is carried out same numeral.Figure 40 a explanation to print desirable visual 28.As shown, this desired image is made up of two parts.It is a solid that first is marked with several 29.Second portion is marked with several 30 and wishes to be formed disconnected-Tong checkerboard type pattern.Owing to discussed, for image 30 is transformed into one by one pixel cellular mode may can not put up with slowly and storer nervous.The further operation of image 30 being made data may become the transition complexity slowly because of it being inserted prematurely cellular mode.Number is sent to memory storage (being hard disk or tape drive) also may be tied down because of it being remained so detailed form transition ground.Therefore, shown in Figure 40 b, the data of two kinds of patterns are carried out and keep or be transformed into entity form (minimum transition) it is sent to the digital signal processor that is used to control injection and X, Y, Z motion then for doing further operation.Then, shown in Figure 40 c, the data 31 relevant with parts 30 that become entity form are made logical (being that boolean is intersected) with honeycomb fashion/checkerboard type mode 32 becomes the desirable modulation format that is subjected to that expression desires to add the modulated section pattern of emission so that solid data changed.Become this last be subjected to modulation format after, preferably do not remake further data storage but be used to through or without the injection of further operatively controlling nozzle.In this example, the data that are used for parts 29 and 30 done now " or " handle the single bitmap that comprises whole desirable data with generation.It just is being exactly the injection that the data of this combination are used to drive printhead then.

Provide the data of RLE file to be included as to prototype and make formation/support modes style information that following discussion is used like that.As discussed above, the relation of RLE data and modulating data all stores the Style file that specific " pattern " promptly constitute pattern and finishes by using each.Figure 41 a～41c represents to constitute the example of pattern.Figure 41 a explanation is applicable to that constituting a kind of checkerboard type as the support of the classification of description in the US patented claim 08/534,813 constitutes pattern.Figure 41 b explanation is applicable to that formation also is the pattern that second classification described in US patented claim 08/534,813 supports.The pattern that constitutes entity is specified in Figure 41 c explanation.

Can also there be many other to constitute pattern, comprise that multiple-exposure constitutes pattern.As indicated among Figure 41 b, wherein, at the scan line that passes through middle curing alternate intervals in succession.In this example pattern 56 first by during be exposed, pattern 57 second pass through during the exposure.Show another example among Figure 41 e, wherein one by one by the back alternate intervals post be cured.In this example pattern 58 first by during be exposed, pattern 59 second by during be exposed.Figure 41 f illustrates the 3rd example, wherein, is being cured by the overlapping checkerboard type pattern in back one by one.Pattern 60 first by in be exposed, pattern 61 second by in be exposed.

For with associated between different pattern files and different object and Support, with the .RLE form do to become comprise to each not on the same group the formation pattern of the capable transition information of the grating that is sent to the model device assign.Figure 47 shows the notion formula form of .RLE file.

By this file layout, the user can be given to any formation pattern of the actual appointment of transition point to one.

The data biasing

Outside the bitmap of the correct pixel information that the injection that contains promising control nozzle is provided, data also must be able to be easy to be provided to injection equipment by the bitmap extraction with correct order.This must place data one extractible form to relate to the next step that data manipulation is handled.This next step is referred to as biasing.For example, can to data handled so that must information can be used for that though adjacent nozzle may not be positioned on the adjacent gratings row or even be positioned at simultaneously under the mark of same Building X their y gratings separately capable on the time, nozzle is sprayed simultaneously.Biasing itself is meant that data rearrange processing, its needs are for example to be placed in when being an angle (as shown in Fig. 2 b) with the direction of scanning when scanner head, in the time of will spraying simultaneously or sequentially when adopting a plurality of scanner heads, perhaps only be because nozzle is not the adjacent gratings row of being separated by.

Among Fig. 2 b, hole 10 (3) and 10 (4) for example, they are aimed in Fig. 2 a, have become at the direction of scanning top offset one apart from d at this ", and scanner head has an angle with respect to the direction of scanning.But spraying simultaneously to hit same X position for the used data demand nozzle 10 (3) and 10 (4) of the group structure of Fig. 2 a.And, adopt such data will cause distortion at the group structure of Fig. 2 b.Thereby in this example, must do biasing and proofread and correct this relative displacement data.

Problem is that related data volume is quite big, and biasing must be carried out in real time.For example, the ink nozzle in the classical group structure may only need 500ns by a given pixel.Like this, any bias treatment to the operation of indivedual pixels is not for just spending so long (on average) by consistent each pixel with data consumes speed.

One typically with the digital signal processor of 40MHz operation, a C31 processor for example, the cycle length with 50ns level.Therefore, if the time by arbitrary pixel place when the rank of 500ns, just only have 10 cycles to can be used for to a given pixel operation.Each processor instruction needs minimum one-period on the other hand.Be generally the waiting status of dealing with bus collision, streamline conflict and storer and need several cycles.Each instruction may the actual needs 2-4 cycle like this.Like this, in fact only about 3 instructions can be used to each pixel.

Problem is typically to operate for carrying out one, and it is logical one that an other pixel for example is set, and needs about 6 instructions.So just be difficult to accomplish that with pixel one by one be that operate on the basis.But require once to many pixels for example operation of 32 pixels operation.Some typical operations can comprise remove image, move image, output image, to two images carry out " with " or two images are carried out exclusive-OR operation.The instruction of this class pattern generally needs less instruction (2 or 3 rather than 6), once 32 pixels is moved.In a word, fast about 100 times of the operation of indivedual pixels is compared in their operation.

As discussed above, control computer is carried out burst .STL or .CTL file and is the function that variant section calculates the .RLE data.The data signal processor (DSP) that is coupled to printhead must be got this .RLE data, and it is gone compression, according to the nozzle arrangement biased data, then data is outputed to nozzle.As discussed, " biasing " is meant pictorial data operated with the configuration of compensating jet and the processing of other factors of possibility.Go possibly can't be handled fast enough after the compression by data, so preferably can when data still are in compressed format, handle (for example when it remains the .RLE form) to it.The saving time of another key selected, and data depositing in storer be should be contain 2 bytes or 4 word bytes of the pixel that hope separately can export simultaneously.

The bias treatment of data just only is to stop the suitable amount of transition and keep data relevant with the pixel of desiring to export simultaneously simultaneously in same word in direction of scanning displacement initial sum like this.And data are gone compression, and when the suitable place of intersection to directions X each other word are sent to printhead.

Figure 42 a, 42b, 42c, 42d and 42e illustrate this technology, and wherein similar elements is carried out same label.Figure 42 a illustrates the pixelation image of original section.These data in Figure 42 b explanation .RLE form.As shown, be marked by several 25 (1), 25 (2), 25 (3) among the figure ... the data that 25 (10) individual scanning is capable have been compressed into the data that expression starts and stop transition.Figure 42 c is illustrated as that the printhead that the relative scanning direction is had an angle is adjusted and the processing that makes this data-bias.The supposition printhead has 5 nozzles among this figure, and the drift angle makes individual nozzles make relative displacement one pixel by consecutive nozzle.Like this, 1 pixel of data relative scanning row 25 (1) displacements of scan line 25 (2), or the like.This processing proceeds to runs into scan line 25 (6).Owing to it be the 6th scan line incite somebody to action not with the 5th row with once by on be scanned, so should be capable relatively other row do displacement.But scan line 25 (7) relative scanning row 25 (6) displacements 1 pixel.1 pixel of scan line 25 (8) relative scanning row, 25 (7) displacements.1 pixel of scan line 25 (9) relative scanning row, 25 (8) displacements.

During this processing, the data of biasing are carried out " bundling " so that want the relevant data of simultaneous injection to be assembled a single word.These data are one by one gone compression then an a bundle.This processing of explanation among Figure 42 d.Each row 27 (1), 27 (2), 27 (3) ... the data of pixel in 27 (12) are represented the data that will spray simultaneously separately.Thereby the data of each these row are stored the word that into can individually visit, therefore can visit simultaneously.Bundle sign 26 was held one time one row ground progressively to pass through data in one minute.Run into go successively when respectively being listed as the compression (each transition is transformed an on/off bit, for example one time 32 bit).Referring to Figure 42 d, for example, divide the bundle sign to be positioned at row 27 (8).Thereby the data in these row are gone compression as shown.Remainder data in 27 (9) to 27 (12) still is a compressed format.But as discussed, data will be run into branch when sign bundle at it go compression.

Then one time one row ground of data outputs to printhead successively.Figure 42 e illustrates this process.As shown, dividing the bundle sign to be reset is used for then once more successively progressively by row 27 (1)-27 (12).This indicates the current row 27 (5) that are placed in as shown.Thereby the data of these row are output the row printhead.Data in all the other row 27 (6)-27 (12) are exported successively.

Fall and the nozzle ejection time

Data in above generation cause also having a key function to carry out before the spot deposition droplets of materials as desired.When data were loaded into ink gun and are used to spray, system must determine when that ink gun has arrived to dripping the solution space of material liquid.The injecting time that this is suitable, as in the US patented claim 08/534,813 of quoting previously the explanation, occur in fact sometimes the head be placed on the suitable deposition place before.This sprays compensation in advance and is called as the calibration time that falls.Yet system must determine when still that it is in and should send the suitable place that this shifts to an earlier date injection signal.Provide the details that this determines processing below.

For constituting, importantly want and to make nozzle ejection along any desired position on the direction of scanning with desirable scan line resolution.This may be problematic when adopting a scrambler to indicate actual X position.This moment, this scrambler may not have trigger pip in desired location.In fact this scrambler may be lower than the required resolution of printing.Wish that because the high-resolution scrambler is more expensive lower equipment cost is arranged, and because be restricted to a single resolution or be disadvantageous as the resolution of the multiple in grid gap.Wish to have other measures to be used for determining correct eject position.Accurate eject position as described below inserts to determine by carrying out distance according to an average velocity that calculates and one known time of process after last grid work between grid are capable.Spraying the place then promptly utilizes the insertion estimation of this known desirable spray site and physical location to determine.

X framework 12 (see figure 1)s are associated even to have a scrambler to be used for determining the position of printhead on the directions X so that the injection pulse of printhead is started between can be in due course.In a preferred embodiment,, utilize the glass plate of a number of being marked by 34 in Figure 43, on it, be carved with the row 33 of mutual spacing from 10 μ for realizing this function.And utilize a kind of light and optical diode detecting device (not shown) to determine when that these worked and interruption DSP when each printhead passes through one of these row.Also adopt pair of detectors (not shown) to indicate printhead to move to left or move to right.For avoiding disturbing DSP, utilize a digital hysteresis circuitry (diagram) to protect the influence that DSP is not subjected to wait because of vibration the pseudo-interrupt that causes because of vibration waits the signal that produces.Circuit DSP can determine the position of printhead within 10 μ thus, can also determine travel direction.

For can be, a counter be set whenever DSP begins counting during by one of above line in DSP to be narrower than the resolution printing of 10 μ.When counter arrived certain certain value, DSP just impelled generation one injection signal to trigger printhead.

One second counter also is set handles situation about illustrating among Figure 44.Be marked by several 35 signal T ₀-T ₄The signal that expression is produced during by row 33 shown in Figure 43 by the scrambler printhead on the contrary, is marked with several 36 row and indicates desirable eject position.For signal T ₀-T ₃These signals are all followed these signals separately.The problem that is produced is by signal T ₄And T ₄Illustrate.Because T ₄Actual in its respective signal T ₄Before, one second counter must be set and come then signal T ₃Produce this signal.

Be illustrated as the algorithm that produces injection signal among Figure 45 a～45b.As shown, produce among Figure 12 a during at printhead and be marked with 57 interruption by one of code line.Then in step 38, read a scrambler regularly (not shown) and with the print head position associated.This step is undertaken by several scramblers are capable.The gained data are stored.

In step 39, by the data of being stored with locational change to be divided by by the capable temporal variation of scrambler of regulation calculate the average velocity of printhead.Step 40 determine next spray place with scrambler at last the distance, delta D between capable.In step 41, this value is used to calculate the capable mistiming Δ t (1) up to next injection place of certainly last scrambler when considering a left side/right side compensation and falling the make-up time.

In step 42, this value is loaded into one first injection timing device, as discusses then, and this timer starts an injection pulse in the back in the past in this value.At step 43 (Figure 45 b), in the mode described at Δ t (1) to next eject position difference computing time Δ t (2).In step 44, check this value with investigate thoroughly next eject position whether be positioned at computing time next scrambler capable after.If then this injection pulse can be started outside next scrambler is capable.If not, in step 45, this value is loaded into the second injection timing device.Start by returning of interrupting in step 46.

Alternate embodiment can be used to encoder position is connected with sending of injection order.The expression more accurately that such replacement scheme adopts odd encoder grid place time signal to come the average velocity of driven sweep head.In this preferred embodiment, last 8 coding grid place time signals be carried out on average with produce one can with the relevant time signal in position at the 12nd coding grid back side.Front 8 coding grid place time signals are on average produced a time signal that can be associated with the 12nd coding grid back side.This, signal was used to be derived as the average speed value of scanning and printing head two averaging time.Spray distance, the average velocity between the place by determining the 4th coding grid back side and next, passed back time estimation nozzle in the past from the 4th coding grid back side and will be arrived the correct time of spraying the place, utilize this estimated time to start a timer, at this moment between gap back injection nozzle in the past.

Here finished the discussion of basic eject position enhancement algorithms.Should be appreciated that various enhancing and modification are feasible, comprise acceleration compensation, or utilize injection counter further to increase print resolution by the accessible growth of two counters relatively more than one according to printhead.

Though showed and illustrated embodiments of the invention and application, should be obvious to those skilled in the art that, the invention idea that does not deviate from here can be done many other modification.Therefore the present invention's other restrictions that except that the spirit of listed claim, do not have.

The local deposits moulding of formation three-dimensional body and support

Method and apparatus

The application is US patented claim No.08/534, and the part that 813 (95.9.27) submit continues.

Invention field

The invention relates to the technology that forms three-dimensional (3D) object and during forming, support these objects, more specifically about fast rapid-result prototype and processing (Rapid Prototypingand manufacturing, RP﹠amp; M) technology of using in, more specifically say so about being used for hot optical three-dimensional molded object (Thermal Stereolithograpty, TSL) system, long-pending moulding (the Fuesd Deposition Modeliug of molten retrogradation, FDM) system or its local deposits moulding (Selective Deposition Modeling, SDM) used formation and method for supporting and equipment in the system.

Background information

Can adopt various different measure to realize that automatic or semi-automatic three-dimensional body produces, is fast rapid-result prototype and processing (RP﹠amp in recent years; M), its characteristics are that each all a plurality of formation sets about carrying out the foundation of 3D object with thin layer that adhere to describe with the 3D computer data of the morphogenetic object of layered laminate.These thin layers be referred to as sometimes section, the structure of object layer, object layer, object layer or be called layer (if context clearlys show that it is like this that the consolidated structure of suitable shape shows) simply.Each thin layer is represented section of this three-dimensional body.Usually thin layer is formed and is bonded to a folded previous thin layer that forms and bond.At some RP﹠amp; In the M technology, the technology that has proposed is different from the strict process of setting up layer by layer but only part formation of an initial thin layer, and at least one follow-up thin layer is formed at least in part before the remainder of this initial thin layer.

According to such measure, the foundation of three-dimensional body is to use consecutive layer that do not condense, negotiable material to be added to working surface, then with desirable pattern with the local synergism excitation that these layers stand, the object thin layer of the object thin layer that makes these layers be frozen into partly to bond to previous formation.In this measure, material is formed on the interval both sides that will can not become the interval of object coating portion on the working surface and will become the part of object thin layer.The representative of this measure is optical three-dimensional molded object (SL), as U.S. patent No.4, described in 575,330 (Hull).According to an embodiment of optical three-dimensional molded object, this synergism excitation is from the ray of UV laser, and material is a photopolymer.Another example of this measure is that local laser sintered (Selective Laser Sintering, SLS), as U.S patent N0.4, described in 863,538 (Deckard), wherein synergism is actuated to from CO ₂The IR ray of laser instrument, material are sintered powder.This first measure can be called light base optical three-dimensional molded object.The 3rd example is three dimensional printing (Three Dimensional Printing, 3DP) form casting (Direct Shell Production Casting with direct housing, DSPC), as U.S. patent No.5,340,656 and 5,204, explanation among 055 (Sachs etc.), wherein the synergism excitation is Chemical Felter (as a kind of glue), and material is to apply the powder that particle that chemical adhesive is bonded together constitutes by the part.

According to second such measure, but the foundation of object be one by one cut the erosion have the object section of desirable shape, and make the size sheet material form the object thin layer.Usually in practice, cardboard was stacked and bonds to the cardboard of previous cutting before they are cut, but also can pile up and bonding between cut.The representative of this measure be layering object processing (Laminated Object Manufacturing, LOM), as U.S. patent No.4, described in 752,352 (Feygin), wherein material is a paper, the means that cardboard cut into desired shape and size are CO ₂Laser.U.S. patent No.5,015,312 (Kinzi) discuss with the LOM technology to constitute object.

According to the 3rd this measure, the formation of object thin layer is can wish that pattern is selectively attached to the interval that will become the part of object thin layer on the working surface with not solidified flowable material.Selectively between the setting stage or afterwards this is made local material cured of adhering to, to form the follow-up object thin layer on bonding agent front formation and the stacked object thin layer.Repeat these steps then to build up object layer by layer with connecting.This object forms technology and be referred to as local deposits moulding (SDM) on kind.The key distinction between this measure and first measure is material only will be become the object coating portion selectively attached to those interval.The representative of this measure is consolidation deposition modeling (FDM), as U.S. patent No.5,121, described in 329 and 5,340,433 (Crump), wherein, but but material be spread in flow state and be in the environment of flow temperature that temperature is lower than material, make it to cool off after-hardening again.U.S patent No.5260,009 (Penn) introduced second example of this technology.The 3rd example be shooting particle processing (Ballistic Particle Manufacturing, BPM), as U.S. patent No.4,665,492,5,134,569 and 5, illustrate among 216,616 (Masters) that wherein, particle is directed to the locality and forms the object section.The 4th example is U.S patent No.5, illustrated hot optical three-dimensional molded object (TSL) among 141,680 (Almguist etc.).

Using SDM (and other RP﹠amp; M constitutes technology) time, be used to generate the various distinct methods of practical object and the appropriateness of equipment and depend on several factors.Because it is desirable that these factors generally can not become simultaneously, depend on the compromise of specific needs and environment so select suitable process technology and associated method and apparatus to relate to.Some factors that should consider include: 1) equipment cost, 2) operating cost, 3) speed of production, the 4) degree of accuracy of object, 5) body surface smooth finish, 6) form the material character of object, 7) application of the expection of object, 8) make the possibility of secondary treating for obtaining different material characters, 9) simplification of Ying Yonging and operating personnel restriction, 10) required or desirable running environment, 11) security and 12) aftertreatment time and strength.

In this respect for more effectively constituting three-dimensional body, have for a long time and necessaryly can optimize these parameters simultaneously as much as possible.As first example, when utilizing the 3rd measure SDM such as above-mentioned (for example hot optical three-dimensional molded object), be necessary to increase the generation speed of object and keep simultaneously or reduce equipment cost.As second example, exist the low-cost RP﹠amp that need be able to be applied in the office environment for a long time; The M system.

At SDM and other RP﹠amp; In the M measure, require the location working surface that forms exactly usually so that can accurately form and arrange section district, outside.Two measures at first provide the working surface that can locate material layer subsequently in the above and form thin layer naturally.But because the 3rd measure SDM not necessarily provides working surface, and be faced with the sharp-pointed especially problem that forms exactly and locate thin layer subsequently, in aspect these thin layers contain the material that for example is included in previous spreading towards such zone on outer surface not exclusively by the zone that material supported of previous spreading.During this typical formation on follow-up thin layer is placed in the thin layer of previous formation was handled, this especially became problem for the prone surface (part that faces down of thin layer) of object.This point can by consider the 3rd measure in theory only attachment material in those will become the zone of working surface of part of corresponding object thin layer, understand.Therefore without any supporting the working surface that appears at the arbitrary surface that faces down on the follow-up section.As relevant optical three-dimensional molded object based on light but also can be applied to other RP﹠amp; The M technology comprises the zone that faces down of SDM, and towards last and continuous section zone, in U.S. patent No.5345391 (Hull) and No.5321633 (Snead etc.) detailed introduction is arranged respectively.In the zone that faces down, do not have previous thin layer, thereby can not form desired support function.Equally, not solidified material can not be realized support function, because according to definition, material is not placed usually into and will can become in the zone of object section part like this in this 3rd measure.The problem that causes because of this situation can be referred to as the problem of " lacking working surface ".

This problem that " lacks working surface " is described among Fig. 1, its describe adopt that three-dimensionally shaped method and apparatus constitutes with digital 1 and 2 two thin layers that indicate.As shown, place the thin layers 1 above the thin layer 2 to have two prone surfaces, represent and indicate with several 3 and 4 with cross-hauling.Adopt above-mentioned SDM measure, not solidified material can not be placed into several 5 and 6 indicate be located immediately in the volume under the prone surface.Like this, utilize the working surface that the SDM measure just can this two prone surface of useful support.

Propose several organization plans for addressing this problem, but do not have any to be entirely satisfactory so far.U.S patent No.4,247,508 (Housholder), No.4,961,154,5,031,120,5,263,130 and 5,386,500 (Pomerantz etc.), No.5,136,515 (Helinski), No.5,141,680 (Almquist etc.), No.5,260,009 (Penn), No.5,287,435 (Cohen etc.), No.5,362,427 (Mitchell), No.5,398,193 (dunghills), No.5,286,573 and 5,301,415 (prinz etc.) advise or illustrate a kind of such organization plan relate to utilize a kind of with constitute used for object different and can suppose and can be easy to be full of volumetric spaces under the prone surface by its propping material that separates (for example saying) by having than low melting point.For example aspect Fig. 1, will be marked with several 5 and 6 volume before by spreading and fill being used for forming prone surperficial 3 and 4 material with propping material.

Utilize the problem of the measure of two kinds of materials (being constituent material and different propping materials) to be because efficient is low, the requirement of heat rejection and with handle and provide support, that is second kind of relevant expense of material and the high and trouble of cost that causes.For example must be provided for the independently material processed and the configuration of propping material.In addition, also may must have work in coordination with the processing of these two kinds of materials and the means of sending by an individual system.

U.S. patent No.4,999,143 (Hull etc.), No.5,216,616 (Masters), and No.5, the measure that 386,500 (Pomerantz etc.) introduce be by with constitute the same material of used for object material and totally set up the supporting construction of separation.This measure has produced numerous problems.At first a problem is exactly that the supporting construction that can not make arbitrary height guarantees that again it can easily be separated by object simultaneously.Next problem that runs into is to realize being easy to separation property and being kept for constituting effective working surface with the outside surface of supporting surface at the same time between object and the supporting construction.The 3rd problem is to go up gathering supporting construction (tissue) in the direction (as vertical direction) perpendicular to cross sectional plane near assembling identical speed with object.The 4th problem is to guarantee separability easily and minimum the surface that makes progress that must support (knot knot) placed on it as the prone surface of the part of succeeding layer for supporting in the above of endangering.The 5th then is to wish to increase system productivity.

Illustrate, realize the task of being easy to separate just require the surface go up each supporting construction contact with object the zone of process keep very little as much as possible.On the other hand, the section zone that the target that supports with the speed that approaches the object gathering in the Z direction then requires each to support obtains big area-periphery ratio as far as possible greatly, the any true property of coming to make to have big target area to remedy in the deposition process is not thus done vertical accumulation and the possibility of transverse dispersion with limiting material, thereby can make the loss of the material that accumulates on the Z direction owing to caused confessions such as overflowing, spread, miss the target drop to minimum.

Be reach the target of harm minimum to the surface that faces down between then requiring to support to separate maintenance big as far as possible so that can make contact area minimum between support and the object.On the other hand, then require partition distance as far as possible little for the task of obtaining being used to setting up effective working surface on prone surface.Obviously, realize that simultaneously these targets have conflict.

This problem describes in Fig. 2, and wherein identical with Fig. 1 parts are marked by same numbers.As shown, prone surperficial 3 support by columnar stays 7a, 7b and 7c, and prone surperficial 4 support by columnar stays 8a, 8b, 8c and 8d.Columnar stays 7a, 7b, 7c are spaced from each other very wide so that reduce prone surperficial 3 harm.And they also are constituted as separately by relatively little surperficial surface of contact and increase isolation to lower surface.On the other hand, because their very little section surface areas, they might gathering in vertical direction enough catch up with the throughput rate of object soon.And because their isolation are very wide, their possibly can't be provided as sets up and supports effective workplace of prone surperficial 3.

On the contrary, cylindricality support 8a, 8b, 8c and 8d are approaching mutually so that can be provided for setting up and supporting prone surperficial 4 effective workplace.And each is configured with bigger surface area so that they can be to be similar to the throughput rate volume increase of object.Unfortunately, because their more approaching distances and bigger cross-sectional area, these are supported on when they are removed and will cause the bigger harm in downward surface.

All patents of above-mentioned application all are used as reference in this joint of this instructions as being elaborated.

Here listed appendix A provides the details of the preferred hot optical three-dimensional molded object of using in some preferred embodiment of the present invention.

Below combination is as a reference as describing in detail at this in application.

Date of application	Application number	Exercise question	State
				????95.9.27	????08/534,813	For forming the local deposits forming method and the equipment of three-dimensional body and support	Unsettled
????95.9.27	????08/534,447	Make the method and apparatus of data operation and system's control in the local deposits formation system	Unsettled
				????95.9.27	????08/535,772	Local deposits moulding material and method	Unsettled
????95.9.27	????08/534,477	Local deposits forming method and system	Unsettled

Present assignee, 3 D Systems Inc. submits the application simultaneously with following related application (combining with the reference in elaborating at this):

Outline number	The applying date	Application number	Exercise question	State
					??U.S.A.143	With its while	Do not specify	Make the method and apparatus of data operation and system's control in the local deposits formation system	Unsettled

According to hot optical three-dimensional molded object and the long-pending forming technique of some retrogradation, three-dimensional body is by being constituted layer by layer by heat to the material that then spreads with the dispenser branch that can flow.This material can be used as semi-continuous material stream and spreads or also can be used as single drop by the dispenser branch and divided and spread.Be used as at material and be appreciated that in the situation that semicontinuous fluid branch spreads and can allow more undemanding working surface standard, U.S. patent No.5 has introduced previous hot lithographic embodiment in 141,680, is used as reference here.Hot lithography is specially adapted in the environment of office because of it can not adopt material reflection, nontoxic especially.And, the processing that utilizes these materials to form object need not to relate to uses ray (as the UV ray, the IR ray, visible light and/or laser beam), with material be heated to inflammable temperature (as in some LOM technology along the cross section incendiary material), activating chemical (as single polymers, photopolymer) or poisonous chemicals (as solvent), duplicate cut the factor that erosion machinery or the like may produce noise or cause serious harm when the maloperation.Only material is heated to flowable temperature particulate-material and make it cooling and form object partly again and can replace.

U.S. patented claim No.08/534, the 447th, support and the data conversion technology of object data at use in preferred local deposits (SDM) system according to the SDM/TSL principle the 3D object data is for conversion into.This application reference is still at various data processing, Data Control and the system's control technology for the preferred SDM/TSL of control system described later.Also illustrated and be used for the SDM system and be used for other RP﹠amp; Some alternate data operative technique and control technology of M system.

U.S patented claim No.08/535 cited above, the 772nd, at the adoptable preferred material of preferred SDM/TSL system described here.

U.S patented claim No.08/534, the 477th, at preferred SDM/TSL system and some details.Also speak of some and replace structure.

The application's assignee, 3 D Systems Inc. also is RP﹠amp; The M field is many other U.S. patented claims in the light base optical three-dimensional molded object part in this field and the owner of U.S. patent particularly.These patent disclosures can combine with teachings herein and improve SDM object formation technology.Combination is as a reference as describing in detail at this for following U.S. patented claim of owning together and U.S. patent:

Application number	Theme	The state or the patent No.
			08/484582	Indicate the basic composition of optical three-dimensional molded object	Unsettled
08/475715	The various recording techniques of using among the SL are described, comprise the material dispenser that to make local deposits by many orifices	Unsettled
			08/479,875	Various LOM type formation technology are described	Unsettled
08/486,098	The technology of buckling deformation and various these distortion of minimizing is described	Unsettled
			08/475,730	Be illustrated as the 3D data fragmentation technology that obtains profile data and utilize boolean's layer relatively to define downwards, make progress and continuum, also introduced the technology that initial CAD design is corrected wide compensation and produced various object configurations.	Unsettled
08/480,670	Illustrate that a previous SL divides chip technology, comprise the vector compensation and correct width compensation	Unsettled
			08/428,950	Illustrate and use various formation technology among the SL, be included as the oscillation sorting that formation semisolid and solid body relate to, the various formation patterns of vectorial alternation sum vector offset	Unsettled
08/428,951	Indicate the multilayer that is used for SL and correct technology simultaneously, comprise and do relatively vertical and because error correction, horizontal comparison techniques and the horizontal etch program of the overcorrection of Z direction.	Unsettled
			08/405,812	The SL recoat coating technique that utilizes energy of vibration is described	Unsettled
08/402,553	The SL recoat recovering technology that utilizes scraping blade and liquid water surface control technology is described	Unsettled
			08/382,268	Several SL recoat coating techniques are described, are included as and form the not gel material technology of utilizing ink-jet to come spreading material partly to relate to of one deck down	Unsettled
07/182,801	The support structure that SL uses is described	4,999,143
			08/148,544	The primary element of hot stereolithography art is described	5,501,824
07/183,015	It is empty in the object configuration to be illustrated as the stress that reduces in the SL object	5,015,143
			07/365,444	Illustrate that the SL that concentrates constitutes, purifies and back correction technology	5,143,663
07/824,819	The various characteristics of large-scale SL equipment are described	5,182,715
			07/605,979	Be illustrated as the technology that strengthens SL body surface smooth finish, comprise and adopting with level and smooth than the thin packed layer and the falcate of the combination of thick structure layer	5,209,878
07/929,463	Illustrate that powder coated is to strengthen surface smoothness	5,234,636
			07/939,549	The formation technology that relies on equilibrium stress and shrinkage district to reduce the buckling deformation among the SL is described	5,238,639

Summary of the invention

The present invention realize can be individually or combinedly be used for determining a plurality of with constitute and support the multiple technologies (method and apparatus) of utilizing the object that the local deposits forming technique forms.Though mainly be at the SDM technology, the technology of discussing later also can be by different way (be familiar with the personage to the present technique field of reading this explanation will be obviously) is applied to above-mentioned other RP﹠amp; The M technology is to improve object accuracy, surface smoothness, Time Created and/or subsequent treatment strength and time.And, here Shuo Ming technology also can be applied to the local deposits formation system that adopts one or more formations and/or propping material, wherein one or more makes local spreading and some other non local spreading, and wherein can or not adopt the temperature of rising to assist the deposition of the material of all or part.

This technology can be applied to the SDM system, wherein constituent material (for example coating or ink) adds solvent (being suitable for the solvent of specific formation as water, alcohol, acetone, coating dilution or other) for carrying out spreading, and wherein material is solidified (for example with the material of heating spreading, the material spreading is advanced part be evacuated the indoor or chien shih solvent evaporations when enough simply of the formation of (being vacuum)) to remove solvent during spreading or afterwards.Replace and/or additionally, constituent material (as coating) can be thixotroping in nature, at this, the increase of the shear force on the material can be used to assist its spreading, and perhaps this thixotropy can be used for aid in material simply and keep its shape after by spreading.Replace or additionally, material can be reactive (photopolymer for example in nature, thermopolymer, one or two part epoxy materials, such as one of previous materials and wax or the combined combined material of thermoplastic) or coagulable when other materials (as plaster of paris and water) makes up at least, wherein, material by the excitation of application specifies rightly (for example behind spreading, heat, EM ray (visible light, IR, UV, X ray etc.), the reactive chemistry goods, the second portion of two epoxies, second or a plurality of part of one combination) react, at this, constituent material and/or combination of materials become and solidify.Certainly, hot stereolithography material and spreading technology can be utilized individually or with above-mentioned substitute combination.And, can adopt various different spreading technology, for example comprise hot melt ink jet, foam jet etc., and the single or multiple holes extruding jet nozzle or the shower nozzle of continuous or semicontinuous stream are made spreading by single or multiple ink discharge devices.

Thereby first purpose of the present invention provides the method and apparatus that more high-precision object generates.

Second purpose of the present invention provides by the thermal environment during the formation of control object and reduces the method and apparatus that distortion ground generates object.

The 3rd purpose of the present invention provides how spreading reduces the method and apparatus that distortion ground generates object by control material.

The 4th purpose of the present invention provides the method and apparatus that increases the object formation speed.

The 5th purpose of the present invention provides the supporting construction method and apparatus of the object support that can form arbitrary height.

The 6th purpose of the present invention provides the supporting construction method and apparatus that can obtain the works fine surface.

The 7th purpose of the present invention provides and forms the method and apparatus be easy to by the supporting construction of the prone surface removal of object.

The 8th purpose of the present invention provides the supporting construction method and apparatus that it is produced minimum harm by the prone surface removal of object the time.

The 9th purpose of the present invention provides by object and removes the method and apparatus that supports.

The tenth purpose of the present invention provides the heavy supporting construction method and apparatus of support of directly setting up of speed of directly setting up speed with the weight that approaches object.

The 11 purpose of the present invention provides the method and apparatus that forms the supporting construction be easy to the surface removal that made progress by object plane.

The 12 purpose of the present invention provide by towards on surface removal the time to the minimum supporting construction method and apparatus of its harm.

The 13 purpose of the present invention provides the method and apparatus of the support that generation separates with vertical body surface.

The 14 purpose of the present invention provide into the reinforce body form can with other RP﹠amp; The supporting construction that the M technology combines.

Desired is but that each free different aspect of the present invention of above-mentioned purpose is realized, other purpose of the present invention is that above-mentioned independently purpose is done multiple combination so that the income that can be obtained making up by combination technique.

Other purposes of the present invention instructions thus will be seen that.

To brief description of drawings:

Fig. 1 shows the prone surface of object;

Fig. 2 shows two kinds of supporting constructions on the prone surface of supporting Fig. 1;

Fig. 3 is the function of tonic chord component diagram of preferred local deposits moulding/hot optical three-dimensional molded object system;

Fig. 4 a represents the different directed upward orifice plates of the printhead of Fig. 3 of relative scanning direction with 4b;

Fig. 5 is the plane detailed icon of Fig. 3;

Fig. 6 illustrates that adjacent nozzle on the orifice plate and adjacent light delete space in the ranks;

Fig. 7 illustrates the pixel grid of define system data resolution;

Fig. 8 illustrates two vertical examples of the capable orientation of grating;

Fig. 9 shows two examples that the deposition in the sub scanning direction is propagated;

Figure 10 a and 10b show two examples that the deposition of main scanning direction is propagated;

Figure 11 a and 11b show the scan line example of interlocking;

Figure 12 a and 12b show along the example of the dropping liquid ground dot interlace of number scan line;

Figure 13 a and 13b show along another example of the dropping liquid ground dot interlace of number scan line;

Figure 14 shows single pixel checkerboard sedimentation model;

Figure 15 shows that 3 * 3 posts that form a preferred support structure support pixel mode;

Figure 16 a shows several over print schemes to 16d;

Figure 17 a and 17b show contingent mistake registration problem when utilizing the over print technology;

Figure 18 shows resulting sedimentary province when the pixel of Figure 15 utilizes the over print mode to expose;

Figure 19 shows the alternately pixel mode that post supports;

Figure 20 shows the mixing supporting construction;

Figure 21 a and 21b show that the arch formula supports;

The staggered embodiment of deposition materials during Figure 22 a～d explanation formation object;

The formation embodiment of Figure 23 a～h explanation employing level and vertical pixel skew;

Figure 24 a～d explanation reduces the deposition embodiment that bridge joint danger is taken place by the interval of separated;

Figure 25 a～e explanation bonds to formation technology together then with object burst, independent formation;

Figure 26 shows preferred two step raster scanning and transposition patterns;

Figure 27 a～e shows the various combination of working surface and target location;

Figure 28 a represents that bifurcated supports the side view of embodiment;

Figure 28 b represents that bifurcated supports the side view of another embodiment;

Figure 29 a～e represents that bifurcated supports the top view of the bifurcated layer of example;

Figure 30 a～m represents that bifurcated supports the bifurcated layer top view of another embodiment;

Figure 31 a～c represents that bifurcated supports the top view of the bifurcated layer of another embodiment;

With

Figure 32 a～d represents that bifurcated supports the top view of the bifurcated layer of another embodiment.The explanation of preferred embodiment

As discussed earlier, this application is at being suitable for the support technology used in local deposits moulding (SDM) system and the technology of formation.Particularly, preferred SDM system is hot optical three-dimensional molded object (TSL) system.The explanation of this preferred embodiment will begin so that preferred TSL system specialization to be described.This optimum decision system, digit manipulation technology, system's control technology, material composition and characteristic, various replacements be described in more detail the visible U.S patented claim NO.08/534 that before quotes and combine of application meanwhile, 813,08/534,447,08/535,722 and 08/534,477, and 3D outline NO U.S.A.143.And alternative system also has been discussed in a plurality of fronts in conjunction with application of quoting and patent, particularly those are quoted as directly related, perhaps can be applicable to SDM, TSL's or consolidation deposition modeling (FDM).In this respect, supporting construction described later and constitute that style should be interpreted as can be applicable to multiple SDM, TSL and FDM system and system's example of being not limited to illustrate here.And as preceding indication, these supporting constructions and formation pattern have practicality in other RP § M technology.

Fig. 3 is illustrated as the preferred embodiment of the equipment of carrying out SDM/TSL.This equipment comprises spreading platform 18, spreading head 9 (for example porous ink jet head), and wherein spreading head 9 is placed on the spreading platform 18, and complanation device 11 and part constitute platform 15.Spreading platform 18 is the horizontal part of an energy supporting plane device 11 and spreading head 9.Spreading platform 18 is coupled to X frame 12 slidably by coupling unit 13.This X frame 12 is preferably by a control computer or microprocessor (not shown) control, and control spreading platform 18 can move forward and backward at directions X, i.e. main scanning direction.

And fan to be housed in platform 18 both sides, be used for air blast vertically downward and help cooling spreading material 14 and part to constitute platform 15 so that keep desirable formation temperature with nation.Other scheme and/or other cooling systems that are suitable for installing fan include, but is not limited to the promising atomising device that transpirable liquid (as water, alcohol or flux) is directed to body surface, fan is installed in the forced cooling device between complanation device 11 and the spreading head 9 and is installed in the forced cooling device of the fixing or mobile fan outside the spreading platform.Cooling system can include former or passive heat dissipation technology, they can be in conjunction with temperature sensing device by computer-controlled, with the material of keeping previous spreading within desirable formation temperature range.Other cooling provision includes, but is not limited to mix in material and spreads the impurity of black-body radiation device effect, particularly IR frequency, so that heat is easy to be penetrated by the object width of cloth in the formation process.Other measure also includes, but is not limited to every several layers material be increased conductive materials, to the material solubilizer, constitutes the part of band cooling duct or has the embedding substrate (row for example interweaves) of making cooling usefulness, is formed on glass plate or the polyester sheet.

For coolant or to other embodiment that major general's spreading material maintains suitable temperature can be to utilize the object upper surface guiding that forms in the part with adjustment gas (refrigerating gas as air), as discussed above, but they also can add with the control technology by the surface removal cooling air.This technology can be to adopt to advertise and aspirator and alternation blast pipe (gas enters pipe) and suction tube (air scavenge).These pipelines make the gas superheated and remove refrigerating gas before reducing effective cooldown rate.Being introduced in lip-deep gas can be made the state of cooling, made room temperature or be made some other preference temperature.As making group structure aptly, conduit is feasible to add the distortion that fast scan speed can be allowed the turbulent flow or the wind of the weak structure as supporting thereby these introducings that replace are removed.These conduits can must be provided to reduce with this with the airflow of the direction of printhead reverse movement and enter the clean wind speed that contacts with the object of part formation by the group structure.With individual no matter direction of motion that printhead is depended in the air blast that is associated or suction and can be reversed, open or turn-off.

Printhead 9 is the printhead of market supply, is sprayed the hot melt ink by being organized structure, and for example thermoplastic or wax-like materials is modified and is used for three-dimensionally shaped system, and wherein printhead stands to seesaw and quicken.The printhead modification comprises that the group structure stays any printhead on the energy device so that acceleration causes staying the least displacement of material in the energy device in airborne.One preferred embodiment comprises the commercially available printhead of one 96 nozzles (Model NO.HDS96i (spectra Corporation is on sale, Nashua, Hew Ham Shire)), includes to stay energy device modification.Printhead is by a U.S patented claim NO.08/534 who had before quoted, material package described in 477 and processing subsystem (not shown) but supply with the material of flow state.In this embodiment, whole 96 nozzles on the injector head begin to do localized ejection by orifice plate 10 when placing the spreading drop rightly on desirable position when each spray orifice (being nozzle) under computer control.In the practice, per second sends near 12000 to 16000 and orders each nozzle, orders each nozzle ejection (spreading drop) selectively or does not spray (not spreading drop) according to nozzle location with for material deposits desirable place.In the practice, spray order and also be sent to all nozzles simultaneously.Because preferred printhead above-mentioned contains almost 100 nozzles, above-mentioned injection rate needing to cause per second to send near 1.2 to 1.6 * 10 ⁶Firing order is to printhead.Like this, printhead is made that by computer controlled making injection nozzle makes them launch the drop that dissolves material simultaneously by one or more hole in the orifice plate 10 selectively, certainly, can see in another preferred embodiment, can adopt printhead with varying number nozzle, different injection frequencies can be arranged and under suitable environment, may side by side not launch nozzle.

For constituting three-dimensional body most effectively, wish that at first all nozzles all correctly spray.For guaranteeing that all nozzles correctly spray or will making the nozzle quantity maximum of emission correctly at least, can adopt various technology.Such embodiment forms thin layer to check nozzle afterwards at every turn.This technology comprises step: 1) form skim; 2) check nozzle by all nozzle ejection with printing test pattern row on a piece of paper; 3) whether optical check (by bar code scan etc.) nozzle sprays by mistake; 4) remove the nozzle greasy dirt; 5) integral body (for example adopting preferred planar device described later to process) of the firm spreading layer of removal; With 6) utilize and to comprise that all nozzles of the nozzle that does not fill up reconstitute thin layer.

Second embodiment has following preferred steps: 1) form one deck; 2) optical check mistake injection nozzle; 3) rescanning should by the mistake injection nozzle forms layer on row; 4) in handling, remaining formation stops using the mistake injection nozzle; With 5) scan succeeding layer (promptly doing extra by to cover row) simultaneously remedying the mistake injection nozzle corresponding to the mistake injection nozzle with a main jet.Selectively, whether cyclic check mistake injection nozzle has begun function again.If this nozzle is a return.Another selection comprises, makes the mistake injection nozzle check by activating routine more whether it can play function.This can or carry out during system service during constituting processing.As another replacement scheme, can determine whether a nozzle correctly sprays by following the tracks of the electrical specification of pressure elements when taking place to spray.

The 3rd embodiment adopts compliant member to clear away superfluous material by the printhead bottom.This embodiment is with heated rubber (as VITON) scraper plate cleaning orifice plate after all nozzle ejection.Preferably this scraper plate is placed at its with orifice plate do relative motion mutually by the time can contact with orifice plate, produce thus to scrape on the operation cause orifice plate and remove excess material and help to recover the nozzle of any malfunction.Preferably orifice plate and scraper plate are disposed in addition have each other an angle make any once during they contact only the part of abacus contact with scraper plate, the power that makes scraper plate be added on the orifice plate thus becomes minimum.

Orifice plate 10 is installed in and makes on the spreading platform 18 that droplets of materials can be by the downside emission of spreading platform 18.This orifice plate 10 is as shown in Fig. 4 a and 4b.In a preferred embodiment, and as shown in Fig. 4 a, orifice plate 10 (being the row in hole) is installed into and approaches vertical main scanning direction (X-direction) and constitute (being marked with 10 (1), 10 (2), 10 (3) ... 10 (96)) by the hole that N=96 can control individually separately.Each hole is provided with a piezoelectric element, is making a pressure wave pass material when an electric starting impulse is added to this element.This pressure wave makes by material of emission in the hole.These 96 holes are controlled by control computer, are added to the speed and the timing of the starting impulse in each indivedual hole with control.Referring to Fig. 4 a, the distance ' ' d ' ' in this preferred embodiment between adjacent holes is about 8/300 inch (about 26.67mils or 0.677mm).Like this, adopt 96 holes, effective length " D " of orifice plate promptly is about (N * 8/300 inch)=(96 * 8/300 inches)=2.56 inches (65.62mm).

For accurately constituting an object, printhead must spray to such an extent that to make drop arrive specific " desirable drippage place " be the designated place that will arrive at of drop.Press this desirable drippage object is depicted as a series of regional data mappings of putting spaced apart from each other, is that pixel distributes to determine.For making drop arrive desirable drippage place, printhead must be by " desirable injection place " liquid droplets, that is one with printhead to desirable relative position, the speed of printhead and squeezed " the desired launch time " of the ballistic characteristics of penetrating the back plasmid.

In a preferred embodiment, adopt raster scanning that printhead 9 and hole are positioned at desirable place.The print processing of each layer is promptly sprayed between the place a series of relative motion by printhead 9 and desirable drippage and is finished.Usually print is to carry out in printhead 9 is done the relative motion of main scanning direction.Usually be to do a very little incremental motion but spreading does not take place on one second (pair) direction of scanning subsequently, the back is then made retrace scanning at main scanning direction and is carried out spreading simultaneously again.The alternation procedure of this main sweep and subscan repeats to be deposited fully until thin layer.

The preferred embodiment that substitutes can be done little subscan campaign during main sweep is carried out.Because usually along between the clean sweep velocity of the auxiliary direction of advocating peace, have very big difference, this replacement scheme will still obtain along near with the deposition of the parallel and vertical scanning of main scanning direction with sub scanning direction.The alternative preferred embodiment that has again can adopt vector scan technology or vector scan and raster scan art to combine.

Find that and then drop is being compared the shape with an elongation after by the nozzle bore spreading with its width.This drop length and wide ratio can be defined as the form ratio of drop.That the form of also seeing these drops becomes than when being sent by nozzle bore is less (they be in shape dome shape).

Should be understood that the distance between the orifice plate 10 and working surface is preferably enough big so that the drop of She Chuing shape when they bump against working surface has become semicircular thus in certain embodiments.Should also be understood that on the other hand this distance (determining the distance that drop is advanced during the print procedure before collision), should be minimum for avoiding contingent accuracy problem when traveling time increases.Find in the practice, when at least 90% drop by the orifice plate emission has reached best less than about 1.3, better less than about 1.2, these two bars all can satisfy satisfactorily when preferably the form between about 1.05 and 1.1 was than (that is wide by its long ratio that removes gained by drop).

In substituting excellent embodiment far away, printhead 9 can be installed on the non-perpendicular angle to main scanning direction.This situation is as shown in Fig. 4 b, and wherein printhead 9 is installed in main scanning direction (as " X " direction) and is " α " angle.In this replacement state, the distance between the hole drops to d ' (=dsin α) by d, and the effective length of printhead 9 is reduced to D '=(Dxsin α).When spacing d ' equaled desirable print resolution on the sub scanning direction (near perpendicular to the direction of main scanning direction), this angle [alpha] promptly was regarded as " instructing the angle ".

If the unwished-for secondary print resolution of spacing d or d ' (being that printhead is not instructing on the angle) then in order to optimize the efficient of printing one deck, must select desirable resolution to make d or d ' become the integral multiple of desired resolution, equally, when printing with α=90 °, the spacing between nozzle promptly is present in main scanning direction and the width of cloth is penetrated on the direction of scanning.This gap is defined as d "=d * cos α.This thus also require desirable main scanning direction print resolution is chosen as d " integral multiple optimize printing effect (this be supposition spray the place be located in the shape grid).The another kind of method that shows this situation is, angle [alpha] is selected as to make α ' and/or d " produces desirable major and minor scanning resolution when being removed by suitable integer M and P.Adopt the advantage of this preferred printhead orientation (α=90 °) to be, it all still can maintain best efficient when making on main scanning direction any desirable print resolution.

In other preferred embodiment, can adopt end-to-end arrangement (extending) and/or lean against privately the multiple printhead that piles up (piling up) at main scanning direction at sub scanning direction.When piling up back-to-back, printhead can be aimed at main scanning direction and arrange spray orifice so that they are printed by same row, perhaps their mutual displacements is come along different main scanning line spreading materials.Particularly, can make back-to-back printhead do the displacement of desirable grating between-line spacing mutually so that the main sweep process number of times minimum that must carry out at sub scanning direction.In other preferred embodiment, the data of regulation deposition position can can't help group structure in the rectangular grid the pixel location but replace that the group structure is the pixel location in certain other patterns (as displacement or staggered pattern).More specifically, deposition position can change between layer and layer whole or in part, so that can carry out the displacement of local pixel dropping liquid location to the entire portion of whole layer or one deck according to the details of desiring between inlet zone.

The deposition resolution that this preferred printing technology has is per inch 300,600 and 1200 dropping liquids and is 300 of per inchs at sub scanning direction at main scanning direction.

Referring to Fig. 3 and 5, complanation device 11 comprises heated rotation (as 2000rpm) the roller 18a on band texture shape (as by an annular knurl) surface.Its function is the material layer (thin layer) of fusion, transfer and removal front spreading so that make it smooth, set the last desirable thickness of layer that forms and last cambial upper surface is set to the level that requires.The material layer that digital 19 indication printheads have just deposited.Swivelling idler 18a is installed in the spreading platform so that it can be by enough big or small so that the material 19 of contact on desired level on the outstanding Z direction in the below of platform.The more important thing is this swivelling idler 18a be mounted can be printed head or orifice plate below desirable distance under the plane of removing.In orifice plate oneself is given prominence to situation under spreading platform 18, execute tumbler post 18a and will give prominence to more following at spreading platform 18.In this preferred embodiment, the outstanding scope that is positioned at 0.5mm to 1.0mm below Z direction orifice plate.The scope that roller reaches under the spreading platform 18 is the determinative of the spacing between orifice plate 10 and the working surface.Thereby, in some preferred embodiment, the scope that best complanation device 11 reaches under the orifice plate 10 is not inconsistent with previously described condition about the droplet morphology ratio, wherein after collision 90% drop reached form than best less than about 1.3, be more preferably less than 1.2 and it would be desirable between about 1.05～1.1.

The material of the layer of the firm deposition that indicates with label 21 among the figure is cleared away in the rotation of roller, the left smooth surface 20 of its tail down.Material 21 bonds to the textured surface of roller and is touched remover 22 by displacement up to it.As shown, remover 22 is configured to " strike off " material 21 effectively by roller surface.Remover preferably is made of VITON, though other materials for example can also be suitable for by the TEFLON  that roller surface is removed material.Preferably this scaler material is not is not worn and torn with enough contacting swivelling idler 18a enduringly to the constituent material right and wrong of liquefaction are infiltrating too soon.The material that is eliminated is scavenged into defective material case (not shown) by heated temporary pipeline under suction, here it or be excluded or recycle.Complanation device defective material case remains on vacuum consistently so that constantly remove material by complanation device roller.System's auto-reverse vacuum several seconds blows down to obsolete material and enters bigger defective material groove through non-return valve when this defective material tank is filled.In case promptly recover vacuum and continuation after the headroom by complanation device inspiration defective material.In the practice, observed removing by the spreading material near 10～15% flattened devices.Though most of preferred embodiment adopts rotation, fusion and strikes off combination and carry out complanation, can believe that other embodiment can utilize any or two the combination in any in them in three.

In the present embodiment, roller 18a makes unilaterally to rotate when each direction moves forward and backward (for example with about 2000rpm) at printhead.In alternate embodiment, roller 18a can rotate according to making in relative direction when platform 18 is to front or rear cleaning between moving period at main scanning direction.Some embodiment can comprise that the turning axle of roller 18a is for from axle with respect to the orientation axes of printhead.Also may adopt roller 18a in other embodiments more than one.For example,, each is rotated with different directions, also may make perpendicular positioning so that can during arbitrary given cleaning, select one to participate in complanation if adopt two rollers.

When adopting single printhead 10 and roller 18a, though each time by all take place deposition only printhead per second time by the once effective complanation (being that complanation always occurs in same direction) of generation.In these cases, point to one when the cleaning direction complanation takes place when pointing to the same direction of printhead with arrow by roller.In other words, after following printhead complanation takes place at parts roller when main scanning direction passes through this layer for making when cleaning direction.

Other preferred embodiments can utilize single roller, but utilize one or more printhead be positioned at roller two row, so that produce effective complanation during cleaning on two directions.Other alternative embodiments may be eliminated the relation between printhead and the motion of complanation roller.This isolation may make complanation and spreading operation independently carry out.It is different with roller cleaning direction (as the Y direction) that such isolation may relate to printhead cleaning direction (as directions X).This isolation also may make and can form multilayer or deposit single layer multirow between planarization steps.

Referring to Fig. 3 a, show that also part constitutes platform 15.Three-dimensional body or part with label 14 appointments among the figure constitute on platform 15.Platform 15 is coupled under computer control the may command platform slidably at reciprocating Y framework 16a of Y direction (direction of index or sub scanning direction) and 16b.Platform 15 also is coupled to can control move up and down in the Z direction Z framework 17 of (downward gradually during constituting usually) of platform under computer control.

Be to constitute a section, thin layer or the layer of a part, the Z framework as making part constitute that 15 pairs of printheads 9 of platform are done relative motion so that the last formation section of part 14 is positioned at appropriate location under the orifice plate 10 of printhead 9.Then printhead 9 combines with Y framework 16a, 16b to facilitate XY is constituted zone cleaning one or repeatedly (printhead before and after directions X cleaning and Y framework 16a, 16b at the object of Y direction translator unit ground formation).The combination of the section of Xing Chenging, thin layer (being the layer of object) and associated any support at last is defined as depositing down the working surface of skim and relative any support.During the XY direction transmitted, the nozzle bore of printhead 9 sprayed by desired pattern and sequential aggradation material to constitute the following skim of object with the layer of the previous relatively spreading of pattern register.In handling, removed by mode discussed above by complanation device 11 spreading by the spreading material.Repeat X, Y and Z motion, spreading and complanation to constitute object by a plurality of local spreadings and tack coat.And platform 15 is in the direction when spreading platform 18 can be in Y or the transposition of Z direction in the anti-phase process time after finishing one scan.

In a preferred embodiment, the material that deposits during the formation skim has the thickness that is equal to or slightly greater than desirable layer thickness.As above-mentioned, the operation of the flattened device of excess material of deposition is removed.In these situations, the actual formation thickness of interlayer be can't help that every layer of quantity of material that is deposited determined but is determined by the downward vertical increment that platform after every layer of deposition is done.If the quantity of material minimum that requires to optimize formation speed and/or make waste then wishes to reject in the deposition process the least possible material.The rejecting of material is few more, and the thick more and object of each thin layer constitutes fast more.If make bed thickness that is Z increment too big on the other hand, then desired horizontal will be begun to lag behind with the formation amount of some dropping liquid ground spot correlation at least.This hysteresis will cause the actual physical working surface to be in different position with desired working surface, and may cause forming irregular working surface.Locational difference may cause being longer than because of the time of splashing the XY dislocation that causes drop of expection, and and then may cause the vertical dislocation of object profile, the beginning or the end of layer when this occurs in the dislocation on real work surface.Therefore in some example, wish to optimize the increment on vertical direction upper strata.

Be to determine desirable Z axle increment, can adopt the diagnosis part that adds up.This technology preferably constitutes the layer of one or more part of detecting that progressively increases the Z increment, measure the height of formed profile, and determine that what kind of Z increment obtains formation height (promptly vertically adding up) and what kind of Z increment of correct number and make formation highly lag behind desirable amount.Can expect that layer increment (being the Z increment) reaches the level that product that a certain value (being maximum receivable value) will produce each number of plies such as level of formation object and each bed thickness is scheduled to.After increment surpassed this maximum receivable value, the formation level of object will not reach the long-pending value of being estimated of the number of plies and each bed thickness.In other words, the complanation of the upper surface of diagnosis part may lose (show some dropping liquid place may receive enough materials other then deny).Check this diagnosis part, just can test and determine maximum acceptable Z increment size.Can select this best Z increment size as this maximum receivable value then, perhaps it can be chosen as and be lower than this peaked certain thickness slightly.Because knowing different formations accumulates with different speed in vertical direction with the support pattern, can constitute pattern at each and carry out above-mentioned test with the support pattern, can select best Z increment therefrom, make it not be thicker than arbitrary maximal value that various patterns are individually determined the combination of different patterns.

And the spreading head is when following the tracks of a given scan line, keeps substantially invariable speed in the time of can be only on by the part of this scan line.At the remainder of scanning, printhead 9 can quicken or slow down.According to injection how to control mouth, this might or can not cause in the acceleration of motion and the excessive problem that constitutes of decelerating phase.May cause under the situation of the problem on the cumulative speed in the speed change, can with this part or support to constitute being defined in the part that printhead has the scan line of substantially constant speed.In other words, discuss in the US patented claim of submitting as corresponding to 3D outline NO.USA143 the time, can adopt one to spray controlling schemes and make and to deposit exactly at the acceleration or the deceleration part of scan line.

As noted, in some preferred embodiment, printhead 9 is guided to follow the tracks of a grating mode.Show the one example among Fig. 6.As shown, this grating mode is by system's grating capable (or scan line) R (1), R (2) ... R (N) forms, and at directions X, promptly main scanning direction moves and arranges (promptly separating) along Y direction (being direction of index or sub scanning direction).Grating is capable to be spaced from each other apart from d, is 1/300 inch (about 3.3mils or 83.8 μ m) in a preferred embodiment.Because the hole standoff distance d of printhead 9, its preferably about 26.67mils as discussed above (0.6774 μ m), and because desirable grating line number can be extended a distance greater than orifice plate 10 length in direction of index, about 2.56 inches (65.02mm), printhead 9 must be on working surface by capable so that can follow all desirable gratings by the cleaning of several process.

This preferably finishes with two following step process.The first step, printhead main scanning direction on working surface by 8 times, this moment Y framework 16a, 16b on each main scanning direction by i.e. transposition d on sub scanning direction after once.In second step, Y framework 16a, 16b transposition equal the distance (2.5600 inches+d (0.0267) inch)=2.5867 inches (65.70mm) of the length of orifice plate 10.Repeat then this two step process up to all desirable gratings draw all tracked inswept till.

For example say that when passing through for the first time, printhead 9 may be directed to follows the tracks of the capable R of grating (1) (via the hole among Fig. 4 10 (1)), R (9) (via hole 10 (2)), R (7) (via hole 10 (3)) or the like.Y framework 16a, 16b will be guided to move on direction of index to constitute platform 18 apart from dr (grating is capable) then.Next time by the time, printhead 9 can be directed to follow the tracks of R (2) (via 10 (1), R (10) (via 10 (2)), R (7) (via 10 (3)) etc.At every turn by after Y framework 16a, 16b transposition carry out 6 times again by passing through for 8 times altogether until carrying out apart from dr.

Carry out after the first step (by 8 times by constituting), promptly carried out for second step as also having capable need the tracking of grating.Second step comprised that the Y framework is moved constituted the total length 10+dr that platform equals orifice plate, 2.5867 inches (65.70mm).As needs, comprise that another group of first step is passed through for 8 times to carry out after another second step.Repeating above-mentioned two step process has then been swept until all gratings are capable.

Figure 26 shows the example of this two step process, and wherein printhead is made of two nozzles, and this two nozzle is separated 8 grating line spaces mutually.Being placed in position 201 and second nozzle with first nozzle is placed in the position 301 and begins profile scanning.The first step of scan process begin with respectively by first and second nozzles at designated scanning direction grating capable 211 and 311.As the part of first step, grating capable 211 and 311 preliminary sweep heel are with the transposition increment of the grating line width that indicates as element 221 and 321.Continuation is as the part of first step, initial raster scanning and transposition increment heel be spaced with a grating line width transposition increment more than 6 (be indicated as element to 222 and 322,223 and 323,224 and 324,225 and 325,226 and 326, and 227 and 327) 7 raster scannings again (be indicated as capable to 212 and 312,213 and 313,214 and 314,215 and 315,216 and 316,217 and 317, reach 218 and 318).Be right after the raster row and after 218 and 318, carry out second step process, do the transposition of Y direction according to the direction and the length printhead of grating capable 228 and 229.This transposition length equals to print the head breadth (promptly being 8 grating line width) and adds capable wide of grating again in this example.After this big increment, repeat the scanning that the first step and required number of times of second step are finished this specific section that is forming.To person skilled in the art will be very obvious, and this two steps scanning technique also can otherwise be finished in alternate embodiment.For example, second step can be not forming, but by forming (i.e. 1 grating line width is gone in 3 printhead reductions) as the big negative increment among the specified Y of element 330 by the positive transposition increment among element 228 and the 328 specified Y.

This preferred embodiment can be summarized the following characteristics that comprise: 1) being spaced apart near the integer (N) at the deposited adjacent desirable interval (dr) in the ranks of extending in the Print direction perpendicular to direction of index doubly between adjacent nozzle on the direction of index; 2) first step comprise carry out in the Print direction repeatedly by (N), wherein each time by in the desirable in the ranks gap of direction of index top offset deposited adjacent (dr); 3) second step is included in that direction of index makes printhead 9 skew one very big amounts so that nozzle can be at the other middle deposition materials that pass through, wherein in succession pass through after this will be made another big transposition increment when needed by the capable transposition increment separation of a grating.In most of excellent embodiment, the interval that the transposition amount of second step will equal first nozzle and last nozzle adds desired interval sum between the deposited adjacent row (be N * J+dr, wherein J is the nozzle number on the printhead 9).

As above example is pointed out, other the second step transposition amount also is possible.For example, the negative second step increment reverse direction of used transposition increment (and in the first step) equals to print the head breadth and adds in succession wide between nozzle two times long-pending and subtract the wide of a grating between-line spacing.In a further embodiment, may utilize second step transposition amount change or that between positive and negative value, back and forth replace.The second step increment size has common trait in these embodiments, greater than indivedual transposition amounts used in the first step.

In other preferred embodiments, can adopt other single or multiple step transposition patterns.The direction of index increment can generally make to comprise has on the Y-axis increments negative and positive mobile both sides.This can be by scanning capable the finishing of grating of being jumped at first.This will further discuss in relating to the technology that is called as " staggered scanning ".

In some preferred embodiment, the injection of ink spray is by remaining on rectangular bitmap in control computer or other memory storages, being that pixel location is controlled.Bitmap comprises the memory cell grid, and wherein each memory cell is corresponding to a pixel of working surface, and wherein the row of this grid extends and the sub scanning direction (Y direction) that is listed in of grid extends at main scanning direction (directions X).Wide (line space from) of row (along the interval of Y direction) may with row (along the interval of directions X) wide (length or between distance) different, may there be the pixel of inhomogeneous size in requirement between X and Y direction or layer, wherein pixel one of wide or long or both change with pixel location.Pixel pattern of rows and columns other in other preferred embodiments more also may.For example the part value at the interval of the pixel on the adjacent lines between main scanning direction displacement pixel so that their central point do not aim at the central point of pixel in the adjacent lines.This part value can be 1/2 so that their central point aim at the pixel border of adjacent lines.It 1/3,1/4 or some other value so that can pixel mode once more on succeeding layer permutatation two or more middle layer are arranged before this.Substituting of having again, pixel arranges and can be depending on by the geometric configuration of the object of spreading or support.For example, may wish the arrangement of displacement pixel when the part of the support modes that is considered to the gap between the bridge joint support column in formation one or in the timesharing that faces toward of working as formation one object.These and other replace pixel arrangement schemes can be by revising group of pixels structure or definition high-resolution configuration of pixels (in X and/or Y) and utilizing not spray in each pixel place but spray in the selecteed pixel place that separates that may change according to desirable at random, predetermined or object offset mode and realize.

The data resolution of main scanning direction can be by principal direction pixel (Main DirectionPixels, MDP) definition.MDP can describe by pixel length or by the long pixel number of per unit.In some preferred embodiments, MDP=300 pixel/inch (26.67mils/ pixel or 677. μ m/ pixels).In other preferred embodiments, MDP=1200 pixel/inch.Certainly, can adopt any other MDP value according to hope.Equally, the data resolution in the sub scanning direction can be by auxiliary direction pixel (Secondary Direction Pixels, SDP) definition.And SDP is can be by pixel wide or described by the per unit length pixel number.SDP=MDP=300 pixel/inch in some preferred embodiment (26.67mils/ pixel or 67.74 μ m/ pixels).SDP can equal or be not equal to grating spacing in the ranks, and MDP may equal or be not equal to along the interval between the capable place of dropping liquid in succession of each grating.Grating interval in the ranks can be defined as secondary dropping liquid place (Secondary Drop Location SDL), and may be defined as main dropping liquid place (MDL) along the distance between the capable place of dropping liquid in succession of each grating in succession.Similar with MDP to SDP, SDL and MDL can define at interval by per unit long dropping liquid or dropping liquid.

If SDP=SPL, along the relation that the data and the dropping liquid intersite of sub scanning direction exists man-to-man correspondence, pixel pitch equals the grating line space.As MDP=MPL, there is man-to-man corresponding relation along the data and the dropping liquid intersite of main scanning direction.

If SDL and/or MDL are separately greater than SDP and/or MDP then need to spray the more dropping liquid that has needs than data, thereby the spray that each pixel must be used to control more than a dropping liquid is dripped.The spreading of these extra drops can or directly carry out in pixel central top (being direct dropping liquid " DD ") by the intermediate point spreading drop between the center of pixel in succession (dropping liquid " ID " promptly).This technology is referred to as " over print " under these two kinds of situations, and causes material faster to constitute and relax the restriction of the Machine Design that relates to maximum sweep rate and acceleration, constitutes because can carry out same Z when mobile print head and/or object more slowly.Figure 16 a～d shows that ID over print and non-over print are the difference in the DD over print.Figure 16 a shows that single dropping liquid 60 is deposited and corresponding solidification zone 62 around it when printhead moves on direction 64.On the other hand, but Figure 16 b shows the processed employing ID over print technology in same district when printhead moves on direction 64, deposit two dropping liquids 60 and 66 relatively at this and individual data point.The sedimentary province that is full of of two dropping liquids is expressed as district 68 for this reason.Figure 16 c represents the similar situation to 4 dropping liquid ID over print schemes, and wherein dropping liquid is marked by number 60,70,66 and 72, and sedimentary province is indicated as being 76, and wherein the direction of scanning still is indicated as 64.Figure 16 d shows the analogue to delegation's pixel 78,80,82,84,86 and 88, and wherein number 90 shows the length of the sedimentary province of no over print, and digital 92 show the sedimentary province length when adopting 4 dropping liquid ID over print technology.Can say blanketly that more than the ID over print is added to any zone of adopting it with about 1/2 to the additional pixels length below 1.Certainly, the over print dropping liquid of employing is many more, and the vertical generation of pixel region is just many more.

If SDL and/or MDL are less than SDP and/or MDP separately, dropping liquid will be being less than the place injection that has data, at least for printing first given passing through.This data cases can be used to realize the above-mentioned skew pixel and/or the pixel technology of non-homogeneous size.

Fig. 7 shows the grid of the capable M of taking advantage of of N row, and as shown, the rower in the grid is with R (1), R (2) ... R (N), and the row in the grid be marked by C (1), C (2) ... C (M).And this grid of forming by pixel of expression.They are marked with P (1,1), P (1,2) ... and P (M, N).

For constituting the transversal section, at first to represent the Data Loading bitmap of desired section (and any support of wishing formation).Suppose as some preferred embodiment, adopt single formation and propping material.If wish deposition materials in a given pixel place, then corresponding to the memory cell in this place suitably in addition mark (for example being marked with binary one) and if do not have material and will deposit and promptly adopt opposite sign (for example binary zero).As adopt multiple, corresponding to the unit of deposition side by the material type of mark in addition suitably to indicate dropping liquid place side not only but also will deposit.For ease of being for data processing, packed data of definition object or Support (the US patented claim NO corresponding to the general NO.USA.143 of 3D system that submits to simultaneously for example---definition of middle explanation is along capable logical of each grating---the RLE data of disconnected location point) and the fill pattern explanation (for example resembling the style fileinfo that illustrates among the Docket USA143) of desiring to be used to given zone can be carried out logical operation is used to make the spreading nozzle ejection with deduction final bitmap expression formula.The working control of nozzle can be by the bitmap management that is corrected subsequently, this figure contain make time lag or be modified so that the data that can more effectively transfer data to jet control system.These contents are further specified in the U.S patented claim based on the general USA143 of 3D system.The capable distributions with previous discussion of grating that then constitutes grid arrives a plurality of holes.It is that pixel location sprays or do not spray (depending on how corresponding unit is carried out mark in the bitmap) that specific hole is specified in corresponding to desired dropping liquid place.

As discussed above, printhead 9 can be with many different resolution deposition drops.In some preferred embodiment of the present invention, SDP=SDL=300 pixel and dropping liquid/inch.Can also when being maintained fixed, MDP make MDL can obtain three different values in some preferred embodiments: 1) MDL=300 dropping liquid/inch and MDP=300 pixel/inch; 2) MDL=600 dropping liquid/inch and MDP=300 pixel/inch; Or 3) MDL=1200 dropping liquid/inch and MDP=300 pixel/inch.When the ratio of MDL and MDP greater than 1 the time, the extra dropping liquid (ID over print) of each pixel is carried out in the centre position between the center of pixel.With current preferred printhead and material, the volume of each dropping liquid is about 80 to 100 picoliters, and this roughly generates the dropping liquid of (the 50.8 μ m) diameter that has 2mil.With current preferred printhead, the maximum frequency of injection is approximately 20KHz.By comparing, the injection rate 1200dpi during 13ips relates to the injection frequency of about 16KHz, in the tolerance limit scope.

In some preferred embodiment, constitute pattern respectively by the object data definition, for being easy to data management, transmission and memory loads.In this respect, as noted above, describe the data of object make logical process one by one to (as the ground that intersects) pixel, explain to the sedimentation model of pixel with the pixel that generates any given place with describing the information that constitutes pattern.For example, if a complete fixed mode will be at secondary by middle spreading (for example two step formulas), object data will be at first made first the constituting pattern mode and make logical process (as intersecting) (perhaps for ease of the term explanation, can be called " exposure " similarly with used local solidification in the light base stereolithography) of pixel parts of dropping liquid deposition with the expression desire.The correction pixel data of this gained can be used to control nozzle ejection then.Then object data constitutes pattern mode and carries out logical process (as intersecting) with mending mutually, is used to control the correction pixel data of second injection of nozzle with generation.In other preferred embodiment, object data and support data can directly be corrected to the formation pattern data according to its deflection.Constituting style information in other preferred embodiment also may comprise pixel displacement information, pixel size information, over print information, be the direction of scanning benchmark at many pixels ground spot deposition, complanation direction and rotation benchmark etc.Formation pattern enhanced system performance described here be by: 1) increase formation speed; 2) accuracy of the increase object that forms; 3) increase surface smoothness; 4) reduce distortion in the object and/or object; Or 5) combination one or more in these time.

A significant problem of local deposits formation system is the reliability that guarantees the material deposition, particularly realizes the uniform thickness of deposition section.Another problem is to realize that all constitute the uniform thickness of pattern.In the ink nozzle system, this integrity problem may take mistake to spray or do not have the form of injection nozzle.In a multi-nozzle desorption system, be problematic in that on the heterogeneity of heterogeneity, the spreading amount between nozzle of nozzle spray direction and the less degree spreading amount heterogeneity in time by a single-nozzle.

The heterogeneity problem of section thickness also may be caused by other phenomenons.As an example, when a drop leaves a nozzle, before this drop reaches working face, there is one and falls the time.When leaving nozzle, dropping liquid sprays with an initial speed component downwards and leaves nozzle, but because nozzle moves on main scanning direction, this drop also has a horizontal velocity component.It just stands various outsides and inner power in case drop leaves nozzle, comprises gravity, viscous drag and surface tension.The result that these starting condition and power will cause is, drop may be not, and directly do not drop on probably on the working surface below just of position that it is launched.But this drop will land the common direction of introducing at printhead in the somewhere of departing from this theoretical dropping liquid point slightly.In other words, spray the place and will not have identical XY coordinate, but displacement is arranged each other with bump (drippage) place.The displacement of the horizontal range that is taken place is depended on above-mentioned factor but is also depended on distance (as X and/or Y position) between the upright position (for example " Z " position) at each horizontal place orifice plate 10 and working surface.Point out that as top the variation of upright position may produce because of a plurality of reasons.For example, change and to produce (many or few material is sent the size that causes deposit thickness forth) because of the difference on geometric configuration between the different piece of a section.Another example is, changes to cause (material possibility limiting material the disseminating on this direction that had before deposited in an adjacent image point place) because of the temporary transient ordering to the deposition of a spatial model.

As noted, realize that the section that optimum decision system of the present invention utilizes complanation that each is deposited reaches even height, wherein the thick complanation level by two successive layerss in the Z direction of net layer obtains.Thereby, forming a level and smooth and smooth equably fully layer if wish planarization steps, the Z increment between the complanation is necessary for or is lower than the upward minimal deposition/formation thickness of every bit of whole layer.If constituting, a nozzle ejection very weak (or not spraying), minimum thickness may cause net layer thickness much smaller than (promptly near zero or be zero) desired value, and so than the desired much longer formation time.Other preferred embodiments can be that interrupted layer rather than each layer are done complanation.For example can do complanation to per two, the layer at three or more intervals.In addition, can come the part of true which layer or layer to do complanation according to the geometric configuration that thing is stopped.The correction of time falls

Indicate as top, guarantee that drop reaches that a difficulty of desired position is the time (be the falling time of drop) of drop in falling on the working surface.Just can there be the matter of time that falls if the direction of always identical and skew is always identical with amount if this falls, because have only the displacement between injection coordinate and deposition coordinate to work.But, when forming three-dimensional body, wish printhead equal blasting materials (comprising the definition of the sub scanning direction of for example alternately advocating peace) when positive and negative main scanning direction two directions are advanced usually with other.This causes owing to the variation (reversing as the offset direction) in the offset direction of going up at different directions (as reverse direction) between the scanning that caused by relative motion takes place.This problem can be easily by making that directly before point above the desired location place injection signal taking place in the actual arrival of printhead solves.This correction to injecting time is referred to as " correction of the time that falls ".The time of falling can utilize one to be applied at the multi-direction correction factor of scanning respectively and to proofread and correct, and perhaps can adopt a single correction factor to make deposition by the one scan direction enter registration with the not correct scan of doing in the other direction.Falling time adjustment can be by accomplished in many ways.A kind of approach for example is that this initial injection place will be used to every other pixel capable along this grating is set the injection place in the capable definition initial injection place (X position) of starting of each grating.

Figure 27 a～e shows the relation between the time of spraying place, dropping liquid place and falling, and wherein same parts are marked with identical number.Figure 27 a show eject position 404a and 404b all with the situation of desirable drip position 402 consistent (promptly not utilizing factor correction time that falls).Parts 404a be illustrated in printhead positive directions X with parts 406a represent by the time the injection place, parts 404b be illustrated in printhead negative directions X with parts 406b represent by the time the injection place, parts 408a and 408b represent that respectively heel is to leave the nominal path that sprays the drop behind place 404a and the 404b.This nominal path 408a and 408b guide drop to actual dropping liquid place 410a and 410b, form the drop 412a and the 412b of bump at this drop impact surface.Launch drop intersection point (being focus) when twocouese scans, be indicated as number 414.The defined plane of intersection point by whole layer can be referred to as the focal plane.Parts 416a and 416b are illustrated in the used time factor that falls of X sense of displacement of spraying between place and the desirable dropping liquid place.Whether actual dropping liquid place is consistent with desirable dropping liquid place and determines the well-formedness of correction factor.Can see among Figure 27 a, not overlapping thereby drop moves the bump drop in the direction that departs from working surface, cause formation and the inaccurate XY displacement of material in Z direction minimum.Figure 27 b represents to adopt the situation of very little fall time adjustment factor 416a and 416b, causes focus to be positioned on the desired working surface and causes and comparing bump drop 412a and 412b at a distance of more approaching shown in Figure 27 a.Time adjustment is bigger if fall, then because bump drop 412a and 412b is overlapping or stack Z constitutes and will increase.The situation that Figure 27 c represents is that the time adjustment factor that falls of employing causes being clashed into the displacement the most accurately (suppose that the thickness of comparing bump drop 412a with dropping liquid distance 418 is less, and inconsistent angle being not too big) of drop 412a and 412b.If the best time adjustment that falls is based on maximum Z accumulation, then Figure 27 c promptly shows this optimal cases.The situation that Figure 27 d represents is that fall time adjustment factor 416a and 416b are a bit larger tham those that are adopted among Figure 27 c, but still cause the overlapping Z accumulation based on two drops.The directions X displacement of drop is still quite accurate, and the focus 414 of spreading is lower than desirable working surface (with the real work surface).The situation that Figure 27 e represents is adopt the bigger time adjustment factor that falls to make the Z accumulation can be reduced to a minimum, and this moment, focus more to be lower than desirable working surface.

If ignore drag force and gravity to the effect of the time of falling, the time adjustment value that falls (time) will equal the downward speed (length/time) of the partition distance (length) of pitch-row working surface divided by the drop spreading.But think that drag force is a key factor.For example, the printhead sweep velocity to approximate 0.020 inch of the distance of working surface, and thinks that initial vertical jet velocity is in the scope of 200～360 inch per seconds by orifice plate near 13 inch per seconds in some preferred embodiment.If ignore drag force or other friction force, under such starting condition, the displacement of estimate spraying between place and the dropping liquid place will be for 0.8 to 1.3mils.But under these conditions, in fact observed injection place and the displacement of drag force intersite on main scanning direction are about 2mils.

Manage to carry out this test with repetition with different corrected values at single X place deposition drop when twocouese scans and land in same point until two dropping liquids, this just can easily test and determine suitable corrected value.As noted above, in some preferred embodiment, the optimum time of the corrected value that falls is that drop hits same position.According to last example, as ignoring drag force, the time adjustment factor of estimating to fall is close to 60～100 μ s.Finding in the practice that correction factor approaches 150～200 μ s will be more suitable.

In other preferred embodiment, the best time adjustment factor that falls is not the value (being that focus is not on the working surface) that is set as generation hit the most accurately but replaces and be set to generation and most accurately hit a certain distance under the real work surface (being that focus is positioned under the working surface).These embodiment are referred to as " surface is outer hits " embodiment.On this meaning, say, hit the most accurately and be considered to occur in vertical cumulative speed when maximum and be when the most accurately being clashed into mostly in the X position.Figure 27 a illustrates the outer example of hitting of hitting embodiment in these surfaces.These surfaces are outer hits embodiment and is considered to extra when producing formation for the parts that will desirable and actual workplace remain on same level particularly useful (for example do not have the complanation device or do not have the optional feature that resembles surfacing pick-up unit and adjusting mechanism or configuration etc.) to not adopting.

The outer characteristics of hitting embodiment in these surfaces are that the Z accumulation is self-correction, and are promptly self-compensating.As long as the Z increment between the deposition of successive layer is in a suitable scope, and sedimentation model make can be not only vertically tired and can also do the horizontal proliferation of spreading material.Then the accumulation of the excessive Z on one deck will make one or many succeeding layers on the Z accumulation reduce, and make clean accumulation that focus is remained on somewhere under the real work surface.On the other hand, also if the increment between the deposition of successive layers within a proper range and sedimentation model make the horizontal proliferation that can only vertically accumulate and can do the spreading material, then accumulate the Z cumulative rises that cause on one or more succeeding layer, make clean accumulation that focus is remained on somewhere under the real work surface thus at Z very little on one deck.This preferred Z incremental range is further discussed below.

This self-correcting characteristic can and compare 27c, 27d by research, 27e obtains understanding.(as on platform) selection falls the time adjustment factor so that focus is lower than somewhere, real work plane when beginning to deposit, as shown in Figure 27 d (that is, should must be in an appropriate location so that situation can not take place shown in Figure 27 c and Figure 27 e) with focal point settings.Too little as material when forming ground floor to the given Z increment deposition that adopted, then real surface will be lower than this focal plane that is changed the position (but as long as the Z increment not too senior general still can be higher than it).Better focusing deposition when this causes forming down one deck, this causes the increase on the deposit thickness as shown in Figure 27 c again.If by the clean Z stack still too low (comparing) that gets of the deposition second layer, then descend one deck when being deposited, will have real surface than the more approaching desirable focal plane of initial surface with the two Z increments of being done.The method of this more approaching optimization location causes changing to the required direction of Z increment ordering about the thickness that adds up only once more.On the other hand, if by the clean accumulation that gets of the deposition second layer greater than by two Z increments represented the time, the focal plane will be further left on the real work surface, less Z will take place behind one deck under forming accumulate, and order about clean accumulation thus to the desired quantitative changeization of Z increment.This is the situation that shows among Figure 27 e.

When the focal plane suitably is lower than the real work plane, when the Z increment size is suitably chosen the suitably rate of sedimentation of coupling, when object/support was formed (not being that whole pixel locations are all directly deposited) with non-solid state, stabilized and support of system and object all can form and not have and need a complanation device clearly with vertical dimension accurately.Certainly when wishing, still can utilize the complanation device.For carrying out these embodiment best, the average magnitude (between Figure 27 e) of every layer of average magnitude of being accumulated (as Figure 27 c) and accumulation when not overlapping during preferably this Z increment should be selected at the best and hits.And preferably the thickness of layer will be significantly less than the separation distance of best focus plane (as Figure 27 c) apart from the plane (as Figure 27 d) at the place that no longer overlaps.

As noted above, in certain embodiments, object can be formed make material sections can according to hit good level not only vertically accumulation also make horizontal extension, make thus and can do Z accumulation self-correcting.Such embodiment forms the combination that integral layer and checkerboard layer replace with object.This enforcement in addition can be to form whole other hatch frames in outside surface and checkerboard, skew grid or internal objects interval.Other suitable formation pattern can be determined by constituting with analytical test part experience.

Hit among the embodiment on some this skew surface, most of preferred initial target surface/focal plane position are chosen to approach the central authorities of situation about showing among Figure 27 c and the 27e.A kind of method that realizes this point is to ignore the focus of imagination and concentrate on the time that falls.The time adjustment value that falls can select make they greater than the time adjustment value (as discussed above) and being lower than of falling generate adjacency immediately but the time adjustment value that falls of not overlapping (not stacked) impingement region.Preferably this selecteed time value that falls is got the mean value of this two ultimate value.

Some skew surface is hit embodiment and is used to form different object parts simultaneously and/or support, and has a mind to become different high levels so that form their upper surface of back at arbitrary given layer.These differing heights embodiment may have benefited from adopting and resemble the such data management technique of SMLC technology, as the US patented claim NO.08/428 that had before quoted, 951 and some other US patent of before having quoted and application in discuss.

Except that the time that falls of pointing out above, also cause the other problem that the time adjustment factor that falls that utilize to revise is proofreaied and correct.This CONSTRUCTED SPECIFICATION for example, when utilizing ID over print technology to impel more formations, will lose collimation, because will extended and extend to other directions in the delegation to a direction on another row in the CONSTRUCTED SPECIFICATION of being done on the scan line of scanning in the other direction.This situation is shown in Figure 17 a and Figure 17 b.Figure 17 a explanation belongs to 2: 60 and 100 of the scan line of advancing separately on direction 64 and 104.Zone 62 and 102 shows the scope of the deposition materials relevant with point 60 and 100 respectively.Figure 17 b shows the identical point 60 and 100 that utilizes 4 over prints (being 4 drop depositions of every pixel) that injection place takes place.The scope of deposition is respectively with digital 76 and 106 expressions.Can see, because the over print of different directions, and lose aligning between the physical details on two row.Above-mentioned misalignment can by experimental field or may the time the additional time adjustment factor that falls determined theoretically corrected, thereby make the CONSTRUCTED SPECIFICATION on different scanning is capable obtain realignment.Certainly, this correction form is not taken into account along scan line and is added to any extra length on the object details.

The suggested difference correction form that can avoid these two problems is to confirm that given pixel beyond on the direction of scanning comes adjacent with the adjacent image point that also requires to make the material deposition.So non-adjacent pixel is not adopted over print according to this affirmation.Substitute as another, extra line length can adopt the wide compensating form of a kind of dropping liquid that is similar to line width compensation used in the light base optical three-dimensional molded object to be compensated.As the US patented claim NO.08/475 that preceding quotes, described in 730 and 08/480,670, but only be applied to along the point of representing to be converted to each scan line that does not deposit by deposition.As a suitable correction, these " end point " will only be deleted it in being used the scope that ID over print that the next-door neighbour connects pixel checks fully the time 1/2 at them by sedimentation model.Another kind of variant is to utilize the displacement time adjustment data that fall to realize the subpixel deposition.

The time adjustment factor that falls also can be used for certain opposite purpose with the above with variant.In these embodiments, fall the time adjustment factor be used in the middle of pixel (being subpixel) place deposition materials formation technology to realize strengthening.The vertical material that the formation technology of these enhancings can include the formation of formation, support on the surface that faces down and layout, enhancing constitute, improve resolution, etc.In a preferred embodiment, the object of enhancing form can single by or repeatedly in realizing, reach.The drop width compensation

May wish to revise object data in some cases to carry out the wide compensation of drop (promptly depositing wide compensation).Compensation (inwardly rely on one of integral body or how completely pixel is wide be offset) can be used to reach the accuracy of improvement, if dropping liquid is wide wide and/or grow greater than pixel at least to a certain extent.The application that can combine with above-mentioned arbitrary embodiment or arbitrary embodiment described later of this technology.Dropping liquid wide near or when surpassing two times of pixel wide (and/or long), the accuracy that can obtain becoming better and better by single or multiple pixels skews.The wide compensation of drop can be according to US patented claim NO.08/475, those technology that disclose in 730 and 08/480,670.Perhaps they can be based on the corrosion routine of pixel.In certain embodiments, can be repeatedly by a bitmap based on the corrosion of pixel, " solid " pixel that wherein satisfies certain standard will be transformed into " hollow " pixel.

Some embodiment can comprise the steps that wherein each limit of bitmap is: 1) all are transformed " hollow " pixel on the right side with " hollow " pixel adjacent " solid " pixel for the first time by this bitmap the time; 2) in passing through for the second time, all " solid " pixels in left side and " hollow " pixel adjacency all are transformed " hollow " pixel; 3) in passing through for the third time, all thereon " solid " pixel of side and " hollow " pixel adjacency all be transformed " hollow " pixel; With 4) in the 4th time was passed through, all " solid " pixels in its downside and " hollow " pixel adjacency all were transformed into " hollow " pixel.Other embodiment may change step 1) to 4) repeatedly until reaching correct reduction amount.These embodiment can carry out the wide compensation of rational drop, but their shortcoming is that pixel (angle of object or object edge are not parallel to X or Y-axis) in the solid angular region is by with than showing that the marginarium is parallel to the fast speed of the pixel of X or Y-axis and removes.

Other the embodiment for handling these difference in the corrosion rate can comprise the following steps: 1) when passing through bitmap for the first time, all " solid " pixels in its right side and " hollow " pixel adjacency all are transformed to " hollow " pixel; 2) for the second time by the time all " solid " pixels in its left side and " hollow " pixel adjacency all be transformed to " hollow " pixel; 3) for the third time by the time all at least thereon " solid " pixel of side and " hollow " pixel adjacency all be transformed into " hollow " " pixel "; With 4) the 4th time by the time all at least its downside with " hollow " adjacent " solid " pixel of pixel all is transformed into " hollow " pixel.Other embodiment may change step 1) to 4) order or will be as the condition of conversion basis.Do pixel corrosion if desired not only one, but repeating step 1) to 4) repeatedly up to realizing correct reduction.These embodiment can drop to minimum with minimizing undue in the angular region effectively.

Other embodiment can be according to a pixel whether be two, three or four limits with " hollow " pixel in abutting connection with setting etching condition.Other embodiment can change etching condition according to the number of times by bitmap.Additional embodiments can be utilized the combination of corrosion and relatively deduce to such an extent that the final bitmap of pixel of desire exposure is represented with the logic of the bitmap of original section or other parts compensation.For focusing on that multiple other embodiment and the algorithm that reduce or keep the corrosion pixel of certain object structures details will be obvious for the personnel that know in the present technique field.

Under the visibly different situation of size of X and Y pixel, only need to carry out the wide compensation of drop along an axle rather than two axles.In these cases, being similar to above-mentioned these embodiment can be used, and wherein each corrodes only operating part step.Can predict, the deposition that has an indemnifying measure also can utilize one of X and Y size subpixel side-play amount among both to be applied.Randomization

Can utilize one to be called as randomized technology (method and apparatus) in the formation process.The use that can combine with arbitrary embodiment above-mentioned or that describe later of this technology.According to this technology, continue the mode of spreading material in each place of section with difference to two.This can reach at one deck (thin layer) goes up work formation more uniformly, thereby making to utilize potentially than thick-layer improves the formation time.This technology also makes from the minimum that influences of the single or multiple nozzles of the undesired injection of possibility.Can there be several means to change deposition.For example the generation of modification can by: 1) nozzle with respect to deposition materials on the counterpart of tight front changes the nozzle to the deposition materials on the certain portions on one deck; 2) with respect to any other part of one deck change this layer any to certain portions on the temporary transient order or the space sequence of spreading; With 3) their combination, for example change main sweep orientation (direction) and/or change subscan orientation (or direction).The variation of layer to layer deposition can be that completely random ground takes place, and perhaps takes place periodically or with arranged state.Adopted similar techniques in the light base optical three-dimensional molded object, though be for diverse purpose (the US patented claim NO.08/473 that the face of seing before is quoted, the alternating sequence in 834).

Explanation now changes the specific embodiment of deposition.Current preferred randomized technique keep advocating peace sub scanning direction orientation but adopt the corresponding scan line deposition of different dispenser (as nozzle) along two interlayers.In other words, first dispenser is used for scanning the specific main scanning line on the ground floor, and second dispenser can be used to scan the specific main scanning line (near the delegation of specific scan line on the ground floor) on the subsequent layer.In some preferred embodiment, a specific scan line utilize different nozzles expose line by line (i.e. deposition) until 96 layers all be deposited with each of 96 nozzles all till deposition on this specific scan line, after this deposition repeats.These embodiment are " full head " randomized examples.In other preferred embodiments, with " half a head " randomization as preferred.The half a head randomization can reduce must be at the enterprising number of times that worked of arbitrary section according to geometry of objects.According to a formation randomization of adopting current preferred 96 shower nozzles is by the scanning of the randomization spreading that produces from nozzle 1 to 48 or nozzle 49 to 96 by arbitrary given place.

For being explained in more detail complete randomization embodiment, referring to Fig. 4 a and 6.To a certain layer, the available pores capable R of 10 (1) spotting scamings (1)～R (8); Hole 10 (2)---row R (9)～R (16); Hole 10 (3)---row R (17)～R (25); Hole 10 (4)---row R (26)～R (33) etc.But at following one deck, these configurations are changed the same scan row that makes a given hole not follow the tracks of down one deck.For example can do following new arrangement; Hole 10 (1)---row R (257)～R (264); Hole 10 (2)---row R (256)～R (272); Hole 10 (3)---row R (273)～R (280) etc.

Additional embodiments is object and/or certain size of printhead (as 30 °, 60 °, 90 °) that rotating part forms between two layers deposition, so that major and minor scan orientation is from the directed change of its front.This causes being occurred in basically on the material that is deposited by other nozzles on the previous layer in the deposition of the material on anterior layer (being thin layer) by arbitrary nozzle.This as shown in Figure 8, wherein relevant with ground floor scan line is marked as capable R ₁(1), R ₁(2), R ₁(3), R ₁(4) ... R ₁(N-3), R ₁(N-2), R ₁(N-1), R ₁And the scan line relevant with succeeding layer is indicated as R (N), ₂(1), R ₂(2), R ₂(3) ... R ₂(N-2), R ₂(N-1), R ₂(N), they are done 90 ° of rotations by the scan line with respect to ground floor.Rotation amount can change between succeeding layer or be a steady state value.Angle can be selected like this, if promptly to enough layer rotations continuously of big quantity, equal nozzle layer is in front gone up deposition materials on the same scan row that deposition takes place.Perhaps, angle also can be selected to such an extent that unlikely generation same nozzle is made the resedimentation scan line.

Additional embodiments can be to change the order (at sub scanning direction) that is advanced to another row by the one scan row.This illustrates in Fig. 9, wherein to the material deposition order on the ground floor main scanning line with at the capable R of maximum scan ₃(1) beginning advances to scan line R ₃(2), R ₃(3) ... R ₃(N-2), R ₃(N-1) with minimum scan line R ₃(N) finish.The order that scan line advances is with arrow R _3PExpression.Material on the subsequent layer scan line is deposited with minimum scan line R ₄(2), R ₄(3) ... R ₄(N-2), R ₄(N-1) with the capable R of maximum scan ₄(N) finish.The order that advances that advance order and the ground floor of scan line is up on this succeeding layer is in the other direction, with front R _4PShow.

Show additional embodiments among Figure 10 a, the 10b, wherein the direction of scanning along corresponding scan line is reversed between 2 successive layer.Figure 10 a shows the direction of scanning of the scanning of scan line on the ground floor, wherein scan line R ₅(1) and R ₅(3) scanned scan line R from left to right ₅(2) scanned to a left side by the right side.Figure 10 b shows that the direction of scanning is inverted on a succeeding layer, wherein scan line R ₅(1), R ₅(2) and R ₅(3) R that superposes respectively ₅(1), R ₅(2) and R ₅(3), scan line R wherein ₆(1) and R ₆(3) scanned and scan line R from right to left ₆(2) scanned from left to right.

Many other randomization patterns are possibility also, comprises the combination of above-mentioned technology.Depend on selected randomized technique, randomisation process can cause comprehensive increase of layer sedimentation time, because it may cause the main sweep process that need add.But this possible shortcoming be considered to by conforming layer constitute enhancing overcame.In addition because the dissipation of heat is a significant problem when utilize improving spreading temperature (as being used to make material can circulate), these are extra pass through to be used for effectively making can work adds before the deposition subsequent layer cooling.The skew of dropping liquid place

As noted above, some formation technology is can be by shifted scanning capable and/or increase along the skew in the dropping liquid place of scan line.The application that can combine with randomized technique above-mentioned of these migration technologies can be offset mutually though should be understood that corresponding row and dropping liquid place on the successive layer.These technology also can with before this or later other embodiment that disclose combine application.In other preferred embodiments, this skew can reach 1/2 between-line spacing or dropping liquid interval.An application of skew pixel is that the part deposition materials that faces down at a section is so that help gap between the bridge joint adjacent support member.In fact, prone district can be repeatedly by middle disposal, wherein in succession by between skew that advance or that replace be used to wide interval between the bridge joint support component.In these embodiments, the arbitrary non-part that faces down of section can utilize one or many deposition and skew or un-offset pixel to expose, and the deposition in any part that faces down can be produced by the partly overlapping repeatedly deposition of pixel region (i.e. exposure).Whole height of deposition can be trimmed to proper level to realize unanimity by faceization not in the preferred embodiment.

In certain embodiments, for strengthening skew that pixel may take place during supporting construction that arcuation support, bridge circuit or difference support the formation of (as dendroid) forms and thereby the skew in dropping liquid place.Among some embodiment, during the object of the formation of the object part after an outstanding limited amount enters the border of the object thin layer of tight front for enhancing forms the pixel skew may take place.Outstanding support and the unavailable skew pixel of object part form, but it is believed that the skew pixel can help few materials can be absorbed in by the formation of the such structure in interval under the layer level of spreading.

Embodiment may comprise that each layer gone up the skew of pixel or may be the only skew of pixel on layer at interval.In this last replacement scheme, material is according to the same pixel location deposition to multilayer.According to this replacement scheme, rely on expectation formation overhang subsequently and on initial overhang, constitute a plurality of layers before, may improve the stability in the district of dangling.

The skew of pixel for example for constituting the bifurcated support or being pointed outside object structures, causes the formation through the outwardly directed structure of space length.This degree of stretching out is restricted to that to be lower than every layer one drop wide.Stretch out the into border of the layer of its tight front no matter be every layer, still on the layer of another back, constitute a plurality of layers, always can be according to determining that by on average stretching out of multilayer one stretches out the angle with the border that puts in tight front layer with the cycle.Maximum stretch out angle part ground depend on material near and the speed of in extension, solidifying, this so depend near and in extension the quantity of material of institute's spreading in institute's extension.Can constitute layer at any angle, wherein material solidification enough can support layer of material down soon.In certain preferred embodiment, stretch out the angle and realized near 30 °.Believe that to stretch out corner connection near or even to surpass 45 ° be possible.

Because material cooled speed, the solid objects of preferably dangling part be formed on repeatedly by in reach.In a preferred embodiment, stretch out the district one or more initial by in be deposited, and whole Support one or more subsequently pass through middle exposure.This embodiment makes the material that stretches out in the district cool off and to solidify under the situation that does not have the possibility additional delay relevant with the material caloric receptivity from be spread in inner area.In another preferred embodiment, layer inside is exposed at first, and it is follow-up by middle exposure at one or more to stretch out the district.This embodiment make time of material cooled of inner area can be slightly before in the spreading district, reduce thus and stretch out the danger that material remains the negotiable long time.To given group formation parameter, can determine the available angle of stretching out by constituting partly to test with verification test.

Pixel skew can with repeatedly should be used for making that by combining of one deck can make material around given geometric configuration details with predetermined order and modes of deflection constitutes to certain portions.For example, can produce skew in a side of a structure and make pixel leave this side direction of this structure, and can utilize the feasible displacement that can on the opposite side of structure, obtain same part in the reverse direction of different skews simultaneously in the part of locational pixel displacement.

One alternative of skew pixel is directly to utilize high-resolution data and corresponding formation pattern, be that pattern constitutes, its generates and may be lower than that data provided originally, but still can generate the desirable dropping liquid density of the form of one-piece construction or other desired structures.Scan line is staggered

Staggered is the another kind of technology that can be used to strengthen the formation of object.As among the every other embodiment that is here disclosed, the embodiment of this section also can combine with other embodiment that disclosed here.As discussed earlier, do not instruct the angle if injector head is oriented to, the spacing between the nozzle is the capable desirable problem of grating with regard to being not equal to desirable resolution thereby being not equal to main sweep.This says according to its character, just must adopt the staggered form of a kind of main scanning line if really require along all main scanning line deposition materials.But, owing to interlocking that a plurality of reasons (for example enhancement Layer cooling and/or material constitute) can be added.

Can adopt multiple scan line interleaving mode, and no matter whether printhead is oriented to leading angle, no matter whether adopt preferred raster scan art, no matter whether utilize the vector scan technology, no matter whether utilize some other scanning techniques or combination technique.

In one embodiment, as described above, head is oriented to perpendicular to main scanning direction and adopts the resolution of per inch 300 scan lines.Continuous nozzle is separated by 8/300 inch in this group of structure.Head is made to and carries out 8 scanning, and 7 wherein initial heels are with the wide subscan that equals grating spacing (grating is wide) in the ranks, equals effective head breadth and adds the wide subscan of grating and its 8th heel is wide.Repeat above-mentioned scan pattern wide equaling or exceeding of increment in sub scanning direction and constitute the wide of district.

Alternative embodiment is restricted to the X scope of main sweep to be enough to effectively by following desired workspace: by object, the certain objects section that is scanned, be to make each section of the required object length of 8 closely isolated main sweeps or caused other schemes of minimizing sweep time by other.Equally, along the layout of subscan axle is limited to object, the section that is scanned equally, the particular portion of the section that is scanned is graded wide and position.In a preferred embodiment, randomized application may increase the transposition amount that must carry out, and makes suitable nozzle can follow the tracks of suitable main scanning line.Other embodiment can be restricted to main sweep the actual path that comprises effective dropping liquid place.

Preferably substitute interleaving technique as first, will keep not adding exposure by the non-adjacent scan line in back at least for the first time, then one or more follow-up pass through the centre be about to be exposed.In other preferred embodiment, wish that deposition materials makes the intermediate raster row before arbitrary adjacent gratings row or at deposition materials after adjacent lines.The example that shows this class embodiment among Figure 11 a, 11b and the 22a～22d.Figure 11 a, 11b show for the first time by the time situation about being jumped in every line.Figure 11 a has 4 scan lines, wherein 2 row first by will be by light (the dropping liquid place that promptly will adopt).Figure 11 b shows 4 identical scan lines, and wherein two row will be for the second time by middle exposure (the dropping liquid place that promptly will be employed) in addition.Also represent the interleaving mode example among Figure 22 a～22b.Among these figure, four-headed arrow 30 expression main scanning directions, dr represents grating spacing in the ranks in succession at interval, and starting point of for clarity sake going and terminal point are represented as skew, though in fact these are about to have same starting point and terminal point.Figure 22 a represents a series of capable at the grating that main scanning direction is scanned.Figure 22 b show according to the example of Figure 11 a and 11b will be at first grating capable 32 by exposure for the first time and will be at second grating capable 34 by formation for the second time.Figure 22 c show respectively will first, second, third and the 4th time by the time exposure grating capable 32,34,36 and 38.Figure 22 d show respectively will first, second, third and fourth, five and six gratings capable 32,34,36,38,40 and 42 by exposure.In the example of Figure 22 d, also can adopt other grating row order and still guarantee when the centre row is deposited them or be not contiguous to the capable either side of the grating of previous deposition or be contiguous to its both sides.For example, other available scanning sequences can be 32,34,38,36,40 and 42,32,36,34,40,38 and 42 etc.

In a preferred embodiment, for adopting minimum number of pass times to come fully to realize these embodiment in the mode of generalization, the grating that must have odd number between row that is scanned by a nozzle (for example first nozzle) and the row by adjacent nozzle (as second nozzle) scanning is capable.In other words, the quantity of the spacing dr between the adjacent nozzle is necessary for even number, thus requirement two adjacent nozzles must be distributed can raster row M and M+N, M and N are integer and N is an even number here.Under the situation of inappropriate (as not being even number) of the spacing between nozzle, always may in passing through for the first time, only scan suitable grating capable (for example with every relevant those of a nozzle), then one or repeatedly subsequently to pass through remaining grating of middle exposure capable.Wide may be wider than line space greatly the time in deposition, in addition preferred embodiment can be not according to for the first time by the time jump over but according to for the first time by directly not being in contact with one another then at any row that is jumped over of one or more post-exposure filling so that institute's deposition materials is capable every the one scan row for deposition (exposure) selection scan line.

Even this first replaces interleaving technique and is fitted into and also can fully or closely realize when desired scan line resolution ground is arranged (nozzle location and scan line resolution make have the grating of even number between the row that is scanned by the row of a nozzle scan and adjacent nozzle capable) at adjacent nozzle.This can be by at least three kinds by way of finishing: 1) each nozzle is used to do every a grating line scanning between the position of its initial position and the row that originally formed by adjacent nozzle, removes and leaves no choice but be kept not exposing by at least two adjacent gratings of each nozzle scan are capable before being about to be exposed by the residue grating at least for the second time; 2) each nozzle also scans the grating that is contiguous to by first row of adjacent nozzle scanning at it and is used to do every the capable scanning of a grating before capable, and remaining then unexposed being about to selectively exposed by middle for the second time; And/or 3) only be used in the scanning process, guarantee thus to exist the grating of odd number capable between any two adjacent nozzles every a nozzle.In the embodiment of these and front, be preferably in beginning for the second time by the row that exposure replaces to all layers before the row in the middle of exposing, even but might before other parts by layer for the first time, finish the exposure of all scan lines between the starting point of some or all adjacent nozzles.

Many other staggered embodiment will be very obvious to studying common skilled person in the art of the present invention.For example have staggered can being used to that comparatively high amts passes through in the ranks taking place interlocking of certain contact first time by middle exposure.Certainly also can adopt engaging of staggered and aforementioned randomized technique, the exposure of succeeding layer also can change the direction of scanning (for example reverse first, second with more the scanning sequence of Gao Zuxu) of the order and/or the row itself of the many group row of scanning.Embodiment finishes staggered exposure to ground floor forming during one or more contact layer between exposure region simultaneously.Dropping liquid ground dot interlace

As adopting scanning staggered, object forms and can utilize along the capable dropping liquid ground dot interlace of doing of individual scanning.In this case, each scan line will be by secondary be by exposure at least, and wherein first by many dropping liquids that will expose, and then in one or more follow-up passing through, all the other dropping liquid places are exposed.As two steps (promptly passing through) example, for the first time by passing through then to middle drip position exposure for the second time to exposing every a dropping liquid place.This situation is as shown in Figure 12 a and 12b.Figure 12 a shows 4 scan lines with 4 dropping liquid places, wherein for the first time by exposure every a dropping liquid place, and Figure 12 b shows with delegation and place but mending the dropping liquid place second by only exposing.As second two step example, be once passing through for the first time, and pass through for the second time that two centre positions between them are exposed every three positions exposures.As three step examples, pass through for the first time from one of initial per the 5th position exposure of primary importance, then passing through from one of the 3rd POS INT per the 5th position exposure for the second time, pass through from the second place initial once at last every position exposure for the third time.

As the every other embodiment that discloses here, the embodiment of this section also can combine with other embodiment that disclosed.

In these interleaving techniques, scan line in succession can adopt interleaving mode exposure different or that do displacement, so that can realize two-dimentional interleaving mode (also can adopt the skew pixel).For example, can adopt two step interleaving modes to each scan line, wherein the starting point of consecutive line is shifted and passes through pattern the first time that a pixel forms the dish form.Figure 13 a, 13b illustrate this example.Figure 13 a shows that then show in the second time mutually benefit checker board pattern by exposure by dish lattice pattern Figure 13 b the first time.

Staggered like that as scan line, dropping liquid ground dot interlace can be finished before the row subsequently in exposure single row is all passed through, though preferably passed through all row that exposes by each time before follow-up the passing through of starting to the row of exposure partly.And, finish and can before other parts starting exposures, realize what all of the part of single row were passed through these row.

The third interleaving technique is staggered to the CONSTRUCTED SPECIFICATION of sensitivity.The order that given drip position is exposed in this technology depends on geometric configuration or a plurality of section geometric that direct section is independent.The sensitive structure details is staggered can be scan line alternation sum dropping liquid ground dot interlace one or both of.For example, in an individual layer embodiment, can determine the frontier district of section and guarantee this frontier district for the first time by in be exposed.Some interior zone of section also can carry out one or more follow-up passing through by exposing or also the exposure of all inside can being deferred to for the first time.For example, inner area can be exposed by also adopting checkerboard type to interlock in the first time in combination by exposure with all frontier districts first.Then pass through the inner area of all the other sections is exposed for the second time.Also might be to the exposure very wide border width of definition passed through for the first time so that can carry out subsequently pass through will be arranged into greater than the border of a drip position before around the section.This broadside battery limit (BL) can utilize above-mentionedly to be realized about the such corrosion example program of the wide compensation of dropping liquid.Another alternative, concentrate on guarantee for the first time by the time only place, scan line border or place, border, dropping liquid place (along the border of sub scanning direction) are exposed.Another replacement scheme is that interior zone can integrally or partly expose before the spreading material of frontier district.Can be opposite, at first the spreading frontier district constitutes in the vertical direction and the frontier district of exposing at last can cause improving the horizontal accuracy of object.Another replacement scheme can be at first spreading near the frontier district, the outer section border itself of the darker inner area of spreading section and last spreading subsequently.

The example of multibreak sensitive structure details interleaving technique can be to expose at first that those form the part of current section but the border on the section of front or the place in entity internal objects district.Border on the section of front and entity inner area can comprise the frontier district and the entity inner area of supporting construction and object structures.In adopting this embodiment, the deposition in Guan Jian (being important) object areas that faces down does not occur in and passes through for the first time at least, and the zone (pillar is directly arranged for example) by the support actual support of some character unless these face down.Material is formed the unsupported CONSTRUCTED SPECIFICATION that faces down by spreading in one or many exposure subsequently.Because the wide pixel width of being wider than usually of deposition, mostly be to dropping on the contrary at the following section of expecting with continuous, by land on this section drop with the adjacent pixel place of the material of front spreading of spreading, this drop will hit and be hopeful to bond on the adjacent deposition materials.And since in a preferred embodiment supporting construction at a distance of being not more than a pixel usually, when the exposure in the unsupported zone that faces down takes place when, with be sandwiched between the material that is spread on the front layer on the contrary, will be embedded in mostly by the material of spreading and be spread between the material on the anterior layer.But because liquid-drop diameter is usually less than sedimentation diameter (also Zhuan Ji liquid-drop diameter) and may be wide less than pixel because of it, the material that is deposited on the adjacent image point place may be not enough to put in and guarantee touching and stopping of plasmid in the path of dripping drops.

In another preferred embodiment, the dropping liquid place spreading unsupported face down the zone and preferably during adjacent area along main and/or sub scanning direction (preferably both) with the part of displacement pixel width (preferably near a pixel wide 1/2), drop is supported by the material of front spreading at least in part rather than drop is fully deposited with aiming at mostly like this.The drop that is preferably in partly on the supporting zone not carries out spreading in the zone to supporting fully of spreading by those in passing through subsequently.Superimposed (not being spread in the bonding any additional benefit of material on the given section) but of the section of might be under the rational perpendicular displacement that guarantees drop in not supported zone partly only leading and front and do not relate to the front.In this embodiment at least can be by displacement when the Support (as post) of anterior layer.This just guarantees the registration of layer to layer.Better is, wide gap utilize on section repeatedly by by the gap by the support limit inwardly the place of operation deposition gradually (being multistage) come closed, thereby wherein at every turn by by tight front pass through partly be offset to guarantee the suitable overlapping material displacement that can limit any of drop above desired level.And adopt in a preferred embodiment as US patented claim NO.08/428, multilayer treatment technology in the time of described in 951 (Simutaneous Multiple Layer CuringTechniques) upwards be offset key face down data one or more layers will be assigned to correct level so that can after deposition, form towards the material of lower floor.

This level of 1/2 pixel horizontal-shift and 1 bed thickness vertical shift and giving an example of vertical shift embodiment are adopted in expression among Figure 23 a～23h.Figure 23 a shows the side view of the object 120 that desire forms.Figure 23 b shows and normally is being divided into layer 122,124,126,128 and 130 o'clock object 120.Figure 23 c will be divided into layer 122,124,126,128 ' and the object 120 in 130 ' time.Layer 128 ' be removed with 128 different parts that face down of this layer that are, as expected it utilizing a series of skew exposures continuously will being produced between deposition materials on following one deck.Layer 130 ' be similar to layer 130 can utilize outside the different sedimentation models in forming at it.Figure 23 d show once more layer 122,124,126 and 128 ', but be further illustrated in addition cambium layer 130 ' during can be deposited the deposition place of material, promptly pixel location 132～137.Figure 23 e is similar to Figure 23 d, except that replacing representation dropping liquid place 132～137, expresses dropping liquid place 140～146.As appreciable by the relative position in dropping liquid place, skew 1/2 pixel is wide mutually in place 132～137 and 140～146.Figure 23 f show cambium layer 130 ' in by sedimentation model first time of printhead by forming.Drop 150,151,152 and 153 is deposited over dropping liquid place 141,145,142 and 144 respectively.Can find out only tegillum 128 ' partly support of drop 152 and 153, the result can think that they will partly stretch into the district that (as shown) originally belonged to floor 128.Figure 23 g show cambium layer 130 ' by pass through for the first time sedimentation model, and at the additional materials by middle deposition for the second time.Zone 160 and 162, is expressed in Figure 23 g as district 150,152,151 and 153 by being deposited for the first time.Carry out the deposition passed through for the second time according to the configuration of pixels shown in Figure 23 d.Drop 155 and 156 is deposited over dropping liquid place 132 and 137.In the practice, drop 155 and 156 spreading will cause being applied to a part of excess material in zone 160 and 162 at first, but this surplus will be trimmed in planarization.Drop 157 and 158 is deposited over dropping liquid place 134 and 135 but because these places are not bonding fully from following and material that deposit previously, so think that the part of institute's spreading material will put in the zone of original part for layer 128 downwards.Spreading drop 152,153,157 and 158 skew cause forming by the part that faces down of the layer 128 that is disappeared by layer 128 ' go.The 3rd with pass through at last, drop 164 be deposited to complete layer 130 on the dropping liquid place 143 ' formation.

In other preferred embodiment, can change the various different aspects of going up in the example.For example, material put in down surface layer interval (supposition drop be that the dropping liquid place is only partly supported) but value is not above-mentioned 1 layer thickness elongation.This elongation can be less than 1 layer thickness or different with the integer bed thickness at least.Perhaps this elongation will be the integer (for example 2 to 5 bed thickness or more) of bed thickness.In this case, for doing to form the most accurately, make initial object statement be transformed into an expression of revising hope, described in US patented claim NO.08/428951 (before or after producing profile data), so that when material was revised the statement spreading by this, prone CONSTRUCTED SPECIFICATION can be located rightly.Other variant can be adopt repeatedly by in continue to use the deposition based on geometric configuration of different off-set values as 1/4 pixel (thereby 3/4 dropping liquid district is not for supported) or 3/4 pixel (thereby only 1/4 dropping liquid place is unstayed).These different side-play amounts can be brought the more controls to measuring in the layer region that extends into the front.Other variant can adopt different deposition order, different over print amount or even the different depositions of each drop.The variant that has again can not adopt the skew pixel and replace the higher resolution pixel of employing, also might combine with the sedimentation model that generates correct drop density.

Other interleaving technique combination: 1) CONSTRUCTED SPECIFICATION susceptibility; With 2) selection direction of scanning when exposure object details.In this embodiment, will be used to determine the direction of scanning that when the zones of different of section is exposed, should get from section geometric (as the section boundary information) and the possible section geometric of coming the self-tightening front layer (as the section boundary information) when anterior layer.For example, when the left half in exposure one section entity district, if wish drop not bridge joint or not partly any little gap of bridge joint make head (nozzle of the row that the desire that promptly is used to expose forms) from left to right scanning may be favourable.On the other hand, if wish to produce certain bridge joint, guarantee that then the scanning on the opposite direction may be favourable.Equally, when the right half in an entity district of exposure section then right-to-left (for bridge joint does not take place) or from left to right (for making bridge joint) to scan may be favourable.Direction of scanning during by control deposition frontier district can guarantee that the horizontal momentum of drop is unlikely to be added to bridge gap, perhaps strengthens the bridge joint in gap.

Figure 24 a～24d represents non-bridging technology example.Figure 24 a～d be formed and for make the side view of tangent plane on the XZ plane.The Z direction is perpendicular to the plane of section, and directions X is a main scanning direction.The section that label 108 fingers are formed, label 100,102,104 and 106 is meant the section that forms previously.Figure 24 a indicates with broken string and shows the not section 108 of generating material deposition.Figure 24 b indicate direction of scanning 110 to the right with drop 112 for the first time by in be deposited on Far Left of each row.Figure 24 c show direction of scanning 124 left with drop 114 for the second time by in be deposited on the right side of each row.Figure 24 d indicate scanning take place on the either direction 126 and drop 116,118,120 and 122 for the third time by in be deposited the formation of finishing section.Illustrated therewith three is opposite by embodiment, can adopt two by embodiment, wherein drop 116,118,120 and 122 when drop 112 and 114 has been deposited one or both sides first or second by in should be deposited to their places separately.

Can predict, object can be done relative directed again (as do the one or many rotation around Z-axis) at the relative scanning direction of printhead (being nozzle), can be exposed simultaneously on desirable direction the edge of any desirable section details relatively the mobile print head strengthens or reduce the closely spaced probability of bridge joint so that make.

Point out that as top if orifice plate is too little to the distance of working surface, drop will have the shape (big form ratio) of elongation when they hit working surface.In being elongated the formation situation of drop, can predicting and to produce and those opposite results that point out above the above-indicated direction of scanning that on the edge of whole details, deposits.Other interleaving technique can be adjacent gratings row or the capable bidirectional printing of non-adjacent grating.

Above-mentioned formation technology can be applied to form whole object or combine with other technologies and form partly hollow, the i.e. object of half entity.In the original design of an object, the part of object is assumed that solid (promptly being formed by the material that solidifies) and part are assumed to hollow (i.e. Kong Dong zone).In fact that these are had a mind to is hollow (hollow) that district is not counted as the part of object, as long as because have object just to think material by definition.In connotation of the present invention, non-solid, hollow or semi-solid object is according to the content of some preferred embodiment object that constitute or that desire to add formation, wherein just is removed for the part of whole object.Its exemplary can hollow out, and partly hollows out, or will originally make cellular for the solid construction of object.No matter these original entity structures are referred to as the object wall and sometimes their dimensional orientation.Some preferably constitutes pattern and forms complete solid body, and other formation patterns then form the solid surface district of object but hollow out or partly hollow out interior zone.For example, it is lattice, section line, hexagonal crystal, hollow or make that cellular (these and other constitute patterns is of great use at this that the interior zone of one object can be formed a dish, as realizing, as introducing in above-cited patent and the application) in the three-dimensional flat typography of light base.Above-mentioned non-solid sedimentation model can be counted as the internal objects supporting construction.Like this, here Shuo Ming other supporting constructions also can be used as the internal objects supporting construction.Non-solid body weight like this will be lighter than solid body, they will utilize less material, depend on the details of special formation parameter even can be formed comparatively fast, they may be less run into the formation of heat dissipation problem ground because the heating material much less that during their formation, is deposited.These objects can be used for doing the investment cast pattern, thereby the possibility that mold breaks reduces.Temperature control

It is the object that will partly form when forming object when maintaining it and being formed in such temperature desired scope that other object forms embodiment, is perhaps kept making the temperature difference (being thermograde) of passing part very little at least.If during object formed, the different piece of object was in different temperature, object is cooled to room temperature or will stands different amounts of contraction when being brought into its serviceability temperature (temperature in the time of will be dropped into application) at it.This difference in the contraction can cause interior of articles to produce stress and corresponding modification or even the breaking of object.Preferably temperature maintenance can effectively kept in the scope of object modification in reasonable limit.The temperature difference of passing object preferably maintains in 20 ℃ the scope, and is better in 10 ℃ scope, better again in 5 ℃ scope and be preferably in 3 ℃ the scope.Howsoever, can estimate temperature desired by changing contraction (or expansion) difference of considering the material coefficient of thermal expansion coefficient and when formed object being cooled off (or heating), will take place to uniform temperature.If when the difference in shrinking causes above the error outside the desirable allowed band, can adjust above said temperature range.

In object forms, the initial object data can be changed worry by calibration and be cooled to its temperature of solidification (when weak DSC energy transmits temperature and is about 56 ℃ about 50 ℃～80 ℃) at object by its injection temperation (in this preferred embodiment about 130 ℃) and constitute temperature (about 40 ℃～45 ℃) and minimum to the variation of its application of temperature (for example room temperature, about 25 ℃) with size in the object of generation to it.This scaling factor can be used to expand the initial object design to make it when its application of temperature by sizing suitably by a suitable thermal shrinkage compensation factor.Can reckon with that also one or more is with geometric configuration or fixed shrinkage factor can be used to during constituting at the critical area that is changed to small part compensation object in the object temperature of expection with axle at least.

The temperature of the thin layer that forms previously and just forming in the cooldown rate of thin layer be found to be distortion and particularly reduce warpage and distort and form the important parameter of object with attenuating.Current preferred material bears about 15% contraction by their temperature of solidification cool to room temperature the time.This contraction produces huge excitation force and causes the warpage distortion, constitute internal stress, and corresponding post-processed distortion (in above-mentioned patent of quoting and application these distortion are illustrated aspect light base optical three-dimensional molded object, wherein many formation technology that are illustrated are according to the practice that can be used for SDM and TSL effectively that proposes among the application).See that if if object constitutes the temperature of temperature and the particularly last layer that forms when being maintained at temperature more than the room temperature in the formation process, warpage distorts and will reduce.Preferably the temperature of the object that forms of entire portion ground is maintained on the room temperature, and especially, and its temperature remains in view of difference discussed above shrinks in the permissible range of strictness of reason.

For effectively forming object, the formation temperature of the object that partly forms must be kept the fusing point that is lower than material obviously.In addition, constitute temperature must keep be lower than the material that solidifies can be had have enough shearings and compression strenght and even the temperature (forming embodiment) of tensile strength if particularly adopt side direction or put upside down object (for example stand typically relevant power simultaneously so that object can be formed exactly with the formation process, the relevant internal force of acceleration that will stand with object, with complanation device drag force or the vacuum power relevant that contacts or pass through with being close to object with printhead, gravity on the air pressure relevant and object of producing because of its deadweight) with any air-flow that is used for cooling object.Wherein some power depends on the quality of object and increases with the degree of depth of entering part.Like this, can in necessary interval, provide the intensity of growth by higher negative slightly thermograde (promptly by the reduction of the nearest layer that forms to the temperature of the layer that forms the earliest), and make the layer of nearest formation can be in sufficiently high temperature and cause minimum warpage and other distortion simultaneously to lower level.Can adopt the one or more positions in this part and calculate the simple gravity of making summation with inertial force and calculate (the Y directional acceleration that stands according to quality and it of this part) approximate as by the required minimum shear resistance of the material that solidifies.This determines to combine with the temperature variant test of material shear stress and can be used to the approximate formation upper temperature limit of arbitrary position work in the object is calculated.Certainly preferably change the thin layer of considering in addition specially near the nearest formation of object, because the object that forms in part with by the contact position of the material of spreading dynamic thermal effect is taken place just, this relates to the melting phenomenon again and the thermal capacity phenomenon of the geometric parameter, the temperature difference and the cooling technology that depend on object.Therefore, in fact whole maximum formation temperature is lower than above estimated value mostly.

On the other hand, point out that can reduce warpage and other distortion greatly by constituting in the temperature that raises, the high more distortion of temperature this moment is few more as top.Think this distortion minimizing since the ability in the temperature current downflow that improves of being increased of material combine with the lower ability of its support shear load and obtain, this make some material can produce distribution more therefrom reduction cause the stress of distortion.Also think, approaching, be in or preferably be higher than any solid-state phase changes temperature (as the critical temperature of crystallization temperature or glass) operation and will cause the fastest of stress and distortion and may be the most great reduction.Because these phase change take place in a very wide scope usually, the benefit of various varying levels is thought and will be depended on the position of working temperature in these scopes and possible processing time.Melt temperature and/or temperature of solidification and solid-state critical temperature can utilize differential scanning calorimeter (Differential Scanning Calovimetry DSC) technology to determine that it is used further to suitable formation temperature range then.In addition, suitably constituting temperature range also can do to test definite.Certainly,, rely on that any temperature operation can obtain some income on the room temperature, and estimate to move to approach melt temperature and/or temperature of solidification more, income is big more.Like this, operating temperature range just can be set conduct along room temperature and fusion or temperature of solidification, or the percentage of the distance between the temperature of the minimum shear resistance of room temperature and estimation.Perhaps, the temperature in the time of working temperature can being chosen as a certain percentage that material has its room temperature shear resistance.(formation) temperature of for example can wishing to work set make shear resistance become its maximum house temperature 75%, 50%, 25% or even be 10%.Increase surface smoothness

The formation embodiment that is useful on stiffener surface smooth finish in addition is utilize that practice by preferred SDM technology obtains attractive in appearance towards upper surface.Effectively increase significant surface in these embodiments and then design defined minimizing by original object to the quantity of lower surface towards the quantity of upper surface (as whole zone).This comprises the orientation that object is divided into two or more a plurality of part and changes divided portion, so that critical surfaces as much as possible can be made towards last surface, vertical surface or combination towards last/vertical surface, and do not have true outside surface or only seldom critical surfaces still as prone surface.The object parts that these separate are constituted then independently of each other, the suitable orientation of respectively asking for.Remove to support then and will be at last parts wait combination by bonding so that a complete object is mainly by towards last and vertical surface is regional forms.If wish coarse surface rather than smooth surface, then above-mentioned technology can be used to guarantee that critical surfaces is formed prone surface.As an alternative, desire to make coarse can forming by the support of stretching out simply from it towards last surface.

Figure 25 a～e illustrates giving an example of this formation technology.The desire that shows Figure 25 a adopts the structure (the object design of wishing like that) of the object 60 of SDM formation.If object directly thus design form, object will by towards last surface promptly surface 50,52 and 54 and face down the surface promptly surface 56 and 58 both sides form.As discussed earlier, the formation of prone CONSTRUCTED SPECIFICATION requires the front to form a supporting construction, and it will be used as the material spreading working surface in the above that forms this prone details.After object forms and removes support, find that the prone surface that stays has coarse and irregular surface smoothness.If wish this prone surface smoothing, this object to need just must stand the additional aftertreatment of sandblast carefully or filling.

Figure 25 b shows the first step of implementing above-mentioned technology.This first step be with original be that desirable object design is divided into two or more parts.Carry out this cut apart so that the crucial details of all of object can be formed vertical surface or towards last surface (preferably as be more preferably towards last surface as do not have above it prone surface towards last surface, so that needn't form the support that begins and damage it thus towards last surface).To be discussed further in the back about other details of support formation and associated problem.In this example, all surface 50,52,54,56 and 58 all is looked at as crucial and should be formed towards last surface.

Figure 25 b shows the object 60 that is divided into two parts 62 and 64.Part 62 comprise the outside details 50,52 of original face and 54 and new be interim towards outer details 72 and 74.Part 64 comprise original be desirable towards outer details 56 and 58 and new be interim towards outer details 72 ' and 74 '.

Figure 25 c shows the preferred orientation (facing up) of part 62 during the formation, so that surface 50,52 and 54 can be formed towards last details.Figure 25 d show part 64 during the formation preferred orientation (putting upside down) so that surface 56 and 58 can form towards last details.After forming each several part 62 and 64, remove support and temporary table in the face of 72 and 72 ', and 74 and 74 ' cooperate with preparation.Figure 25 e shows that part 62 and 64 is connected to form object 60, and wherein all keys all have surface of good smooth finish towards outer part (being initial surface 50,52,54,56 and 58).Additional formation pattern

Other constitute patterns comprise following one or more: 1) adopt high-resolution at the direction of scanning spreading; 2) in facing down the surface, formation adopts the unit area dropping liquid density that is higher than in the formation interior of articles zone; 3) adopt the extension rim surface zona that faces down of N times (as 5～10) on the surface that faces down at least; 4) when forming, adopt the unit area dropping liquid density that is higher than when forming the interior of articles district towards upper surface; 5) adopt extend under the upper surface N floor (as 5～10) at least towards the upper epidermis district; 6) adopt the dropping liquid density that is higher than the unit area when forming inner area when forming the marginarium of object, this marginarium extends into interior of articles L dropping liquid wide (as 2～4) at least; With 7) form the inner area of object and form the marginarium by raster scanning by vector scan.Support pattern

The application's next part is primarily aimed at the formation of support.But should be understood that because support is to be formed by the material that deposits, so all aforementioned formation technology all are applicable to the formation process that supports.As will be appreciated, all aspects of support formation process are applicable to all that also object constitutes.

Supporting construction must satisfy the needs that several may be opposition: 1) they be preferably formed as be used for constituting in the above the object thin layer and even the works fine face of the support thin layer that continues; 2) they preferably are easy to the prone surface removal from they supports; 3) if they are begun by the surface towards last of object, they preferably are easy to be removed by them; 4) when removing, support best opposite and only cause minimum harm, be preferably in and have the excellent surface smooth finish of allowing at least on these surfaces to upper surface and prone surface; 5) they are preferably in vertical direction (as the Z direction) upward with the rational speed formation of each section; 6) they preferably utilize the quantity of passing through of every layer of minimum to form; With 7) their formation is preferably reliable.The many different patterns that support of the balance of having developed or having advised between these demands, to reach different.

Be optimization formation speed, vertical accumulation is very important, thereby wishes that the formation that supports can have near identical speed with the object formation.Particularly, the vertical accumulation of preferably supporting (as by every layer single by) the desired bed thickness that sets with the using planar device at least is the same big.Support accumulation more near the accumulation of object, it is few more to be removed layer during the available thick more then complanation of layer, thereby has improved the efficient that constitutes process.For a given material and facility, by different supports with constitute material that pattern carries out vertical constitute can test definite, as previously mentioned, rely on part of detecting that constitutes each depositional pattern and the pattern (complanation grade) that adopts different bed thickness, measure these parts then and when lag behind by desired expectation thickness of institute's deposited layers and desired bed thickness with the formation of determining material.Can bed thickness (complanation grade) be set to suitable value to the desirable combination that constitutes and support pattern by this information, perhaps can be set at and reach the required support of desirable bed thickness and constitute pattern.

Some preferably supports pattern embodiment and focuses on formation speed, keeps the removal easiness, but stays coarse surface smoothness in the interval that is removed support.These support pattern and comprise that formation is separated solid post by little gap.Particularly, in an optimum decision system, data on X and Y twocouese with per inch 300 pixels provide, object and support utilize 4 ID over prints to form at directions X (main scanning direction).Each supporting layer comprises 3 * 3 pixel regions, wherein propping material will come spreading with a plurality of posts, and these posts are gone up at main scanning direction (directions X) with the pixel region of the deposition of two no pixels definition with at the pixel region that sub scanning direction (Y direction) is gone up the deposition that defines with a no pixel to be separated.The data cases that defines these pixel regions is as shown in Figure 15 a." X " among the figure shows the pixel that contains the drop data, and " 0 " indicates the pixel of " dripless " data among the figure.Square frame 50 is indicated around " X " district so that the shape of outstanding sedimentary province.But because the ID over print of directions X, suitable narrowing down (almost a pixel is wide) done in two pixel gaps in fact when actual deposition takes place.Actually like this obtain closer approximate 4 * 3 pixels of sedimentation model wide (12～14mils * 9～10mils) posts, though have fillet, these posts at X and Y twocouese with the wide gap of a pixel (3.3mils) separately.This situation roughly as shown in figure 18.

See that in the practice that constitutes object the support of above-mentioned formation is accumulated with the approaching speed identical with object, thereby can utilize each dropping liquid place single by forming support and the object on each layer.Find that also above-mentioned supporting construction is easy to be separated by object but causes the smooth finish on the very poor surface that faces down.Therefore, be superior with regard to the above-mentioned pattern of formation speed, but from surface smoothness, the very big leeway that will improve in addition.

A kind of variant be adopt the spreading head repeatedly by to form the support of a section.Another replacement scheme be periodically the support section that divides of spreading one volume in case can balancedly support with object between vertical buildup of material.

Another kind of variant is to make to support the formation one layer or more that forms the object that can lag behind, so that eliminate or reduce contingent planarization problem when constituting fragile the support.Problem is, if the support section of a section during identical with the homologue body portion of this section passing through by spreading, the complanation device just can make these supports distort.By the hysteresis that enables to take place one layer or more, can avoid supporting with the complanation device between excessive contacting.To be minimum and can predict the last support distortion that gets.

Other columnar stays structure also is possible, comprises the post of different size or shape.For example, the size that generates actual post that data layout can be combined with the over print technology approaches: 3 * 3 pixel sizes (9～10mils * 9～10mils), 2 * 3 or 3 * 2 pixel sizes (these can cause vertical accumulation to reduce), 2 * 2 pixel sizes (6～7mils * 6～7mils) (having loss on vertical cumulative speed), 4 * 4 pixel sizes (12～14mils * 12～14mils) (may difficult removal and the feasible body surface that further jeopardizes) or bigger size.Also can adopt the post of other section configurations.These comprise and make more approaching round-shaped structure (for example octagon or sexangle), decussate texture, have the structure of different length and wide shape ratio or the combination of the structure that can be mixed.

Other replacement scheme is included in one of major and minor direction of scanning or both sides' skew support column alternately.For example at sub scanning direction every 1/2 of a support column offset pillars interbody spacer.This as shown in Figure 19.Might make the spacing broad of support column, if particularly certain technology for example adopts arch or bifurcated to support the next gap that reduced between the support column before running into the prone surface of object.Figure 21 a and 21b show the example of two arch support, wherein the pixel side-play amount of Cai Yonging (or dropping liquid displacement control at least) difference.Bifurcated supports

Illustrated as top several places, some preferred embodiments adopt and can be used as the support that bifurcated supports explanation.Arch formula discussed above is supported for one type the example that bifurcated supports.Support bifurcated or dichotomous is the supporting construction that constitutes like this, and promptly the part of some thin layer is protruding with the solidification zone on the thin layer of the urgent front of cantilever position.These protruding pixel locations that can layer identical with interlayer (promptly fix) are foundation.In other words, these protruding wide displacements of mark pixel in can the pixel location of some or all interlayer are as foundation.Another alternative can be to be foundation with the pixel mode that changes some or all interlayer.Some bifurcateds supports embodiment and produces than the more indivedual supporting constructions of wanting supported surface that support the supporting construction that originated from a lower level bifurcated.

Except that the various embodiment that disclose previously (can see bifurcated basically as supports), Figure 28 a, 28b, 29a～e, 30a～m, 31a～c, 32a～d show other preferred bifurcation structure example.Figure 28 a represents to support 504,506 and 508 side view with surface 500 beginnings with to the post of advancing in surface 502.These posts support and are interconnected by bifurcated element 510,512,514 and 516.Figure 28 b represents from the survey view of surface 500 to the dichotomous support embodiment of surperficial 502 work.Show and support every two-layer bifurcated.In this two-dimensional space view, some bifurcated shows as two road forked patterns and other bifurcated only goes out along a unipath branch.Same supporting construction shown in Figure 28 b is observed by the different visuals field in Figure 31 a～c and 32a～d.

The other preferred bifurcated pattern of illustration among Figure 29 a～e.Figure 29 a～e represents the top view of the continuous bifurcated section of a single spanning tree, only obtains 4 support bifurcateds altogether with the bifurcated of X and Y and by single support trunk here.This single supporting construction can be referred to as " trunk " of spanning tree or structure.Will clearly, this trunk can be regarded by 4 still identical parts of keeping their independent individuals that separate and form as following as they can come as logical process together is that arbitrary given layer generates scan pattern for being easy to data management.Certainly, the real zone that will be supported in the practice may need a plurality of mutual this trunk elements that separate suitably.

Figure 29 b shows first bifurcated of directions X.As among following other figure, diagram shade solid area is represented the sedimentary province of current section, and the district that is represented by dotted lines represents the bifurcated of tight front.Do thisly to show that the method for sedimentary province is for making the registration between bifurcated true clearly.This first bifurcated can occur in and form after one or more trunk layer.As other bifurcateds that the figure about this figure and back will illustrate below, bifurcated can make the material of spreading stretch out the part of a pixel, whole pixel or a plurality of pixel by supported district, this depends on the dilatory order that adopted, with the quantity (can compensate deficiency) of the wide pixel width of comparing of dropping liquid, the same layer that more than anterior layer, will form when anterior layer, partly do not added ability of support or the like.As some other bifurcated that the back will be discussed, this bifurcated can be regarded as two or two road bifurcateds of more a plurality of initial overlapping compositions (be in the positive directions X one the road and negative directions X in another road) or regard two or the single channel bifurcated of more a plurality of initial overlapping compositions as.As being seen that by the explanation of back this first bifurcated can be considered to a single channel bifurcated of 4 initial parts, wherein two parts are followed each bifurcated direction.Can be according to the boolean sum of these parts by these 4 parts as the material of reality deposition, so that avoid multiple deposition on the overlay region.

Figure 29 c shows next bifurcated of tree, and wherein the one layer or more behind this bifurcated bifurcated that can show in Figure 29 b takes place.This bifurcated of object parts with Figure 29 b in the same direction seen take place.

Figure 29 d shows two bifurcateds in dichotomous each the Y direction shown in Figure 29 c.This still can be looked at as the single bifurcated on the Y direction of independent component on the principle.Bifurcated shown in Figure 29 d is first bifurcated that begins the separation process of all 4 compositions.

Figure 29 e shows the last bifurcated of this embodiment, wherein makes the additional Y direction bifurcated of each parts.This last bifurcated can be used to the supporting object surface when suitable.If body surface is placed on these last bifurcateds several layers, structure (as post) that can extension bitmap 29e is until reaching body surface.If the body surface of all 4 bifurcateds is not in same level, then indivedual posts of post or part are extensible when needed.The extension of this bearing height is similar to other preferred posts discussed here and supports embodiment, and can comprise the application of bridge layer etc.Certainly, if that wishes this four posts bifurcated is supported with different structure (for example shape, position etc.), can make modification (as changing bifurcated order, bifurcated direction, extending number of plies between class, the bifurcated or the like) to illustrated embodiment and this will be obvious to the present technique skilled person according to the principle here.The trunk of support shown in Figure 29 a can be formed on the object section of a front at first or initially serve as a contrast on the base.Perhaps, this trunk can begin at the top of another supporting construction as shown in Figure 28 a.And adopting a plurality of trees as desire, the bifurcated of tree can not begin on one deck yet, and may may not can cause forming after the identical number of plies each bifurcated yet.Select where to begin bifurcated and when make follow-up bifurcated thereafter, can form the geometric configuration of object according to desire.Might wish to a specific tree run at first one desire the pre-surface of supporting (as prone body surface) before several layers reach final bifurcated pattern.

The bifurcated routine of relevant execution with the embodiment that illustrates among Figure 29 a～e can be summarized in the big table:

Parts #1	Parts #2	Parts #3	Parts #4
				No bifurcated ground constitutes the desirable number of plies, and (Figure 29 a)
The desirable amount A of+directions X bifurcated (Figure 29 b)	The desirable amount A of+directions X bifurcated (Figure 29 b)	The desirable amount A of-directions X bifurcated (Figure 29 b)	The desirable amount A of-directions X bifurcated (Figure 29 b)
				No bifurcated constitutes the desired number of plies
The desirable amount A of+directions X bifurcated (Figure 29 c)	The desirable amount A of+directions X bifurcated (Figure 29 c)	The desirable amount A of-directions X bifurcated (Figure 29 c)	The desirable amount A of-directions X bifurcated (Figure 29 c)
				No bifurcated ground constitutes the desirable number of plies
The desirable amount A of+Y direction bifurcated (Figure 29 d)	The desirable amount A of-Y direction bifurcated (Figure 29 d)	The desirable amount A of+Y direction bifurcated (Figure 29 d)	The desirable amount A of-Y direction bifurcated (Figure 29 d)
				No bifurcated ground constitutes the desirable number of plies
The desirable amount A of+Y direction bifurcated	The desirable amount of-Y direction bifurcated	The desirable amount A of+Y direction bifurcated	The desirable amount A of-Y direction bifurcated
				No bifurcated ground constitutes until realizing a new support pattern or until a surface of running into object

According to hope, each parameter of summarizing in the last table can add modification.For example, the bifurcated amount of the amount of getting A here.As suitable, this amount can change with different fork level, perhaps even can change different parts at same fork level.

Figure 30 a～30m shows that the bifurcated that is similar to Figure 29 a～29e supports embodiment, and not existing together is that the single trunk shown in Figure 30 a will produce 16 bifurcateds as indicating among Figure 30 m.For ease of understanding and might realize, trunk shown in Figure 30 a can be considered to be made up of 16 other but identical parts.To one do to limiting-members bifurcated operating period only along in X or the Y direction one be offset.Above-mentioned all considerations of pointing out in the explanation of Figure 29 a～e all can be applicable to illustrative embodiment and embodiment subsequently among these figure.

Figure 31 a～c shows another embodiment, and wherein single trunk is branched into 4 elements as shown in Figure 31 c shown in Figure 31 a.Not existing together among this embodiment and Figure 29 a～29c is that bifurcated occurs in X and Y direction two aspects simultaneously.As described, the bifurcated scope is identical at X with Y direction both sides.But the bifurcated scope changes between can be in these areas.

The embodiment that Figure 32 a～32d continues to illustrate among Figure 31 a～31c is to generate 16 independently bifurcated supports.These figure go back the structure among the key diagram 28b, and two layers of each bifurcated wherein are described.

In other preferred embodiments, also have other bifurcated patterns.For example, replace and as showing in the above-mentioned example, to be bifurcated the rectangular array of support, can form hexagonal array, triangular array, half garden shape array by indivedual trunks generations, or the like.If resulting pattern can not cooperate satisfactorily jointly, can wish to adopt mixed mode, it with suitable form alternate the good cooperation or the engagement of supporting construction to the end so that prone surface energy is supported suitably.The bifurcated that other preferred embodiment may adopt a plurality of trunks to support single group supports.

Can predict these bifurcateds supports embodiment and may produce the better prone surface that reaches than some other embodiment, because can believe that the final supporting construction that touches object will be separated more equably.Point out that as top the support embodiment of Shuo Ming bifurcated can be a bigger supporting construction or a part of mixing supporting construction here.Other modification to above embodiment will be very obvious to the person skilled in the art that study these disclosure.

If adopt the above-mentioned geometric configuration and the interleaving technique of orientation-sensitive, just may constitute than minor diameter and/or the structure that more closely separates provides better working surface, still has reasonably vertical cumulative speed simultaneously.

In this preferred embodiment, the dropping liquid diameter of deposition is near (about 2.9～3.4mils) is identical with preferred pixel diameter.But it is more not crucial than the separation of the relevant dropping liquid diameter (as 2mils) that falls and (promptly depositing) dropping liquid diameter of clashing into that the pixel between general the support is separated (for example separation between support column).The level interval of (as support column) is less than 6 dropping liquid diameters on the layer of the tight front of the layer that contains the prone surface of wanting supported between preferably supporting.Be more preferably, this spacing falls the dropping liquid diameter less than 3, and preferably this spacing falls the dropping liquid diameter less than 1 to 2.

Find, when the bridging element that includes interruption between the support column helps high growth at them, limit their abilities by their desirable XY position displacements.Usually the support column diameter is more little, just more often needs bridging element and layer.The in height extensible one layer or more of these bridging elements.In this preferred embodiment, found that (1～2mils) bridging element is not exclusively effectively to an individual layer, and (5～10mils) then make whole supporting construction too hard more than 5 layers.Like this, when adopting preferred 3 * 3 pixels to support, bridge layer it is desirable to height, and (2～4mils) and 5 layers (between 5～10mils), and it would be desirable highly be 3 layer (3～6mils) at 2 layers.But also find, preferably every 75mils to the 2 cun repetition of bridge layer, comparatively ideal is per 100 to 300mils repetitions, is preferably per 100～200mils and repeats.For being used for other materials, constituting parameter or structure condition, can utilize the formation and the analysis of part of detecting are determined effective bridge joint thickness and isolated thickness.

When bridge layer was used intermittently, they can be bonded to all support columns together or only their part are bonded to together, and wherein, the bridge layer that other posts are fixedly done the front is with fixing work bridge application subsequently maybe.In other words, bridging element can form the surface that is deposited material, and perhaps they can only form surface (as checker board pattern), and it connects together some post.Support column may or can not be moved by they previous XY positions when beginning after they are forming bridge layer again.

Another is called as the smooth finish that preferred support structure that checkerboard type supports focuses on the good surface that faces down that is easy to remove and object is generated.The section that shows this supporting construction among Figure 14 is formed.Deposit every a pixel (300 pixel/inch) along the capable utilization of each grating, and the deposition pixel is done the wide displacement of a pixel along this row in the adjacent gratings row.A preferred version of this support does not adopt the ID over print and can adopt DD over print or multiexposure, multiple exposure to increase deposition for every layer.Be restricted to 0.4 to 0.5mils when no DD over print or multiple-exposure, the support of this pattern of bed thickness in adopting this preferred embodiment, rather than available by aforementioned some preferred embodiment near 1.3mils.Do not adopt the DD over print or the multiple-exposure of these structures, might not utilize the preferred ID over print of object, only deposition materials (for example every layer 0.3 to 0.5mils) in thin layer.Need not to utilize the over print of object because extra material only needs to be removed during complanation.Since the speed that adopts raster scanning and form one deck with or the speed with over print is not identical, so according to the formation pattern of these technology 3～4 times near the suitable formation pattern that is lower than 4 over prints of employing.Though great increase was arranged on the time but improvement on the surface smoothness can guarantee its application under a stable condition in formation.

When constituting the checkerboard type support, the normal use of bridge layer is guaranteed the integrality of post by preferential (for example per 30 of the Z height to 100mils).Bridge layer should comprise that the layer of enough quantity is to guarantee its validity (same thickness that for example is about bridge layer discussed above).Dropping liquid-Tong/dropping liquid-disconnected pattern (wide by dropping liquid) is 1 dropping liquid wide (depositing wide) for the element that solidifies, and the spacing between the central point of element is wide but wide less than 2 dropping liquids greater than 1 dropping liquid in succession.

Row supports (wide by dropping liquid) and comprises the units of width near a bump liquid-drop diameter, wherein and the spacing between the tangent element in the orientation of row less than 1 dropping liquid wide (promptly overlapping), and wide greater than 1 dropping liquid perpendicular to going the interelement spacing in orientation.Preferably also wide less than 2 dropping liquids perpendicular to the interelement spacing in row orientation.

NXN post support (pressing pixel) leads to (best 1) for N-on principal direction or 2-is disconnected, breaks for the logical and best 1-of N-on direction of index.Wide and the spacing therebetween of post can be according to the situation of pitch of pixels, dropping liquid diameter and used arbitrary over print is calculated.The preferred distance of the storeroom that deposits in the adjacent post is under one or two liquid-drop diameters.

Another possible support pattern is to adopt dotted line whole or that be interrupted, it is preferably better less than 3 pixels wide (less than 10mils) to be that width is 1～2 pixel or littler (less than 3.3-6.6mils), and is separated material with 1 to 2 pixel or not deposition still less (less than 3.3～6.6mils).These supports can be along main scanning direction, sub scanning direction or the operation of other directions.The support of another kind of pattern is to follow the curve of object edge to support.Perhaps, this support modes can be different in the zones of different of section.It also may be in the direction of scanning by the edge dislocation N pixel (or dropping liquid is wide) of object, or at shift direction displacement M pixel (or dropping liquid is wide).

Some other replacement scheme comprises by the material different with forming object surfaces or marginarium material therefor and constitutes support.Other replacement scheme can only adopt different propping materials at one or more layer that is contiguous to object.Mix and support

The supporting construction type that can be used for the local deposits moulding that has again supports for mixing.On the simplest meaning, mixing support is a kind of supporting construction that includes two kinds of dissimilar supporting constructions at least.Best, the structure that is adopted in mix supporting is by the Level Change that supports, and more specifically says, can be with being made progress by this one side to object and/or the distance on prone surface is decided in the structure of any set point.In other words, supporting construction is trimmed to only structure according to the distance on object.In an exemplary embodiments, under being positioned at a surface that faces down, point changes support modes during predetermined number of layers (as 4～9).In another, the dropping liquid density of the unit area of support is that dropping liquid density reduces near prone surface the time than (being defined as the dropping liquid of per unit area and the ratio of non-dropping liquid).In the variant of these embodiment when adopting the layer of one or more inclinations (centre) layer during than the supporting construction transition to lower dropping liquid density by higher.

In another exemplary embodiments, leave towards on surface (for example leaving the surface 4 that makes progress of one side or more multi-layered) time dropping liquid density than increasing.In the optional variant of this embodiment, utilizing inclination (centre) layer of one layer or more during than the supporting construction transition to higher dropping liquid density by lower.Also preferably supporting construction not only equally also changes according to horizontal range according to the vertical range to object.For example when contiguous this object flatly dissimilar support may than leave object a certain apart from the time more useful.

Side-looking ground shows that one mixes the support example among Figure 20.As shown, this structure is by being to constitute platform or may being that stretch out to support prone surperficial 24 on the surface 23 on the surface that makes progress of the one side of the object in just constituting.Show among the figure that this supporting construction is made up of 5 parts: 1) the fine fibre shape post 25 of surface in contact 23 (can not omit) if surface 23 is not these parts towards last surperficial many supporting constructions of object; (2) be arranged on the thicker post 26 in fibrous post 25 tops; (3) middle layer 27 (being final bridge layer); (4) be arranged on the fine fibre shape post 28 on the downward surface 24 of the direct contact surface at top, middle layer; (5) be used for two or more thick post are melted to together and are distributed in the bridge layer 29 in post 26 each places.

(3.3 * 3.3mils) also form " chessboard " pattern as shown in Figure 14 a to be 1 pixel on buttress shaft 25 and 28 both sections.A series of thin fibrous posts that the result obtains apart from adjacent post 1 pixel and is easy to separate with 24 from surface 23.These are equivalent to checkerboard type discussed above and support.The sedimentation model of these logical according to a pixel, that a pixel is disconnected supports, dropping liquid density ratio approaches 1.If support be not object towards on the surface begin then post 25 can be jumped and removed.

Post 25 and 28 in height should be between 3mils and 15mils and is preferably about 4～6mils.This height should remain minimum, supports utilizations that combine with the object that just forms with 4 ID over prints because wish these, and because in that they will be accumulated with the speed far below object when not making over print to these supporting constructions employing singles.On the other hand, wish that also these supports have certain height, needle member is tended to be melted to above them during by spreading on the surface that faces down of object.

Post 26 transversal section be 3～3 pixels (9.9mils * 9.9mils), in the direction of scanning apart from 2 pixels of adjacent post, in direction of index apart from adjacent post 1 pixel.These rod structures are equivalent to maximum support discussed above.As above-mentioned, the main cause of exceptional space is to be that these supports will receive over print 4 times on the main scanning direction.The section pattern that is formed by these posts is as shown in Figure 15 and 18.The gained result is a series of posts that are coarser than fibrous post 25 and 28.

These posts are different with other, can be random height.Reason be the bigger section of these posts make post can with the same speed of this part itself growth (about 1.3mils/ layer).As discussed earlier, preferably utilize bridge joint 29 with adjacent post 26 discontinuously clinkering to together to prevent in " drift " that constitute contingent these posts in back by a certain distance.The spacing of bridge joint is preferably in the scope of previous discussion.

Middle layer 27 representatives can play the final layer of optional bridge joint of the transitional function between post 26 and the post 28.The useful reason of transition bed is, post 28 is for identical or less with the spacing of 26 on post approximately when big or small, and the result just may not drop in the middle of these spacings as there being this transition bed post 28.In this preferred way, unfavorable be used as holistic middle layer but at the top of post 26 displacement post 28 or only utilize the necessary part of layer 27 carefully.

If preferably be used, these middle layers are same thickness with bridge layer previously discussed just.

Should be appreciated that between post 25 and post 28 to need not the middle layer because post 26 on the section greater than the spacing between the post 25.Thereby these posts can directly be based upon than the top of pillar and need not the middle layer.

Other possible mixed structures are to take other and combination aforementioned support component.Mix the interior section that also can be used to form object with other supporting constructions.

Also there is other replacement scheme for constituting to support.For example, also may constitute support by the material different with the material that is used to constitute this part.Another kind of possibility be in the interval of above-mentioned supporting construction in addition fluid for example water so that additional support is provided and also helps heat radiation.In such measure, it is useful adopting a kind of fluid that has bigger density than constituent material.This dropping liquid of constituent material that will award the compartment that drops on post is with buoyancy.This material also should be selected as to make being complementary of its surface energy and constituent material form male and fomale(M﹠F) so that can prevent between fluid and post.A kind of like this examples of material is a surfactant.

Another kind may be the jet airstream that makes progress between the interval of post.In the method, can obtain radiating effect and buoyancy.Another may be the interval (as spaced apart 0.1 to 1 inch or more post) of filling up the post support that is lowered quantity with plasmid.And such plasmid is formed by constituent material, this point can rely on impels drop can solidify (for example to increase the distance between spreading head and the working surface) before they arrive working surface, perhaps relies on drop and applies them before with distillation that is direct the landing by the solid-state material that enters steam state.

Support and preferably object is separated 50 to 300mils by the surface that constitutes platform.In addition, object can directly be formed on the platform.In this replacement scheme, platform can be capped with a flexible sheet material, and this will make object can be easy to by hard platform separation sheet separation thus again.Electric knife can be used to support is separated by platform, preferably object is placed 150～300mils on the platform surface in this case.The thin pectination device of having found a kind of belt length tooth is very effective to removed support by platform.In this case, between the thickness requirement object of device and platform required spacing generally between 50 to 200mils.Support is removed and can be utilized little control side device such as dental instrument by cleaning, brush or relying on by object.

Another kind of variant is this embodiment to be incorporated into one include in the system ensemble of a ability that self-winding parts removes and a cooling bench.Other replacement schemes then are to adopt the different material in low melting material or dropping liquid place capable as constituent material, a material filter or different grating.

Some replacement schemes are to adopt the dropping liquid that constitutes greater than part to supporting to constitute again.Another replacement scheme is to adopt the powdered that drop can be solidified be shaped before they arrive at working surface as described above to support.

Other embodiment can locate (as Y or Z) according to different main scanning directions, other sub scanning direction locatees (as X or Z) and other accumulation location (as X and Y) constitutes.Other embodiment can utilize other absolute motion scheme to realize desirable relative motion between object and printhead.For example the absolute motion of printhead occurs on all three directions in certain embodiments, and absolute in other embodiments object of which movement can be present in all three directions.In certain other embodiments again, can adopt the non-Cartesian motion of printhead or object and layer by layer or layer partly change injection direction one by one.

Though some embodiment be under the title of being pointed out in the instructions, illustrate these embodiment can not be considered to be only applicable to the specified theme of title.Though title is to be used for increasing the readability of this explanation, all announcements of the particular topic that relevant title is narrated should not be considered to be limited within these single chapters and sections.Here all embodiment of Jie Shiing all can use dividually or with other embodiment that disclosed in combination.

Though represented and embodiments of the invention and application have been described, will be obviously to skilled person in the art, do not deviate from principle of the present invention and can do many corrections.Therefore not limited by other the spirit of the present invention in listed claim.

Claims (9)

1. the starting of generation expression object section in the fast rapid-result prototype system/stop the method for transition data comprises step:

Receive the three-dimensional data of expression object as input;

Sliced layer is relevant with the object section;

Three-dimensional data statement and a plurality of picture element scan row are intersected in each layering; With

Joining between scan line and three-dimensional body statement generates the transition data of section.

2. method according to claim 1, wherein fast rapid-result prototype system is. a local deposits formation system.

3. in the fast rapid-result prototype system the given layer of object one is generated the method for the data of describing the Support, comprising step:

Determine all floor more than the given thus floor combination topped district;

Ask of this given floor to distinguish that the boolean between the summation district is poor therewith; With

Utilize the Support of this difference as this given layer.

4. as method as described in the claim 3, wherein fast rapid-result prototype system is a local deposits formation system.

5. in fast rapid-result prototype and the system of processing, the method for the resolution of the direction of scanning of increase printhead comprises step:

One processor is set;

First and second timers are set, will make countdown after they are loaded and completely start injection in the back in the time;

One of capable sequence of scrambler that is prescribed at printhead by the time interrupt handler;

Calculate printhead by the capable average velocity of several scramblers;

Utilize described average velocity to calculate the variation in next time of spraying the place is walked in expression by a scrambler first value;

Described value is loaded into described first timer;

Utilize described average velocity to calculate expression and walk to this second value that the variation in the time in place is sprayed in second behind next injection place by a scrambler; With

If described second was loaded into described second timer with described second value with spraying before this next scrambler is capable.

6. as method as described in the claim 5, wherein fast rapid-result prototype system is a local deposits formation system.

7. in fast rapid-result prototype and the system of processing, the method for the different piece of the section that distribution formation pattern to is desired to solidify comprises step:

It is right that the part of desiring to add the section that solidifies is expressed as starting and stops the transition data;

Distribute to described data to the formation pattern, the data that actual starting of its modulation and the place that stops to obtain modulating; With

Be subjected to adjusting data spreading material so that set up described section according to described.

8. as method as described in the claim 5, wherein fast rapid-result prototype system is a local deposits formation system.

9. in the fast rapid-result prototype system of processing, increase the method for resolution on the direction of index by the described data of setovering.

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