JPH049660B2 - - Google Patents
Info
- Publication number
- JPH049660B2 JPH049660B2 JP1112735A JP11273589A JPH049660B2 JP H049660 B2 JPH049660 B2 JP H049660B2 JP 1112735 A JP1112735 A JP 1112735A JP 11273589 A JP11273589 A JP 11273589A JP H049660 B2 JPH049660 B2 JP H049660B2
- Authority
- JP
- Japan
- Prior art keywords
- cross
- layer
- fluid medium
- sectional
- curing radiation
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000012530 fluid Substances 0.000 claims description 65
- 239000007788 liquid Substances 0.000 claims description 52
- 238000000034 method Methods 0.000 claims description 47
- 239000000463 material Substances 0.000 claims description 28
- 230000005855 radiation Effects 0.000 claims description 27
- 230000004044 response Effects 0.000 claims description 9
- 230000015572 biosynthetic process Effects 0.000 claims description 8
- 238000010521 absorption reaction Methods 0.000 claims description 2
- 239000000470 constituent Substances 0.000 claims 4
- 238000010030 laminating Methods 0.000 claims 2
- 238000002211 ultraviolet spectrum Methods 0.000 claims 2
- 230000002745 absorbent Effects 0.000 claims 1
- 239000002250 absorbent Substances 0.000 claims 1
- 230000003247 decreasing effect Effects 0.000 claims 1
- 238000013461 design Methods 0.000 description 42
- 238000004519 manufacturing process Methods 0.000 description 41
- 239000004033 plastic Substances 0.000 description 20
- 229920003023 plastic Polymers 0.000 description 20
- 239000007787 solid Substances 0.000 description 13
- 230000008569 process Effects 0.000 description 12
- 239000011343 solid material Substances 0.000 description 8
- 230000002195 synergetic effect Effects 0.000 description 6
- 230000008859 change Effects 0.000 description 5
- 238000001723 curing Methods 0.000 description 5
- 238000001746 injection moulding Methods 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 230000001070 adhesive effect Effects 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- -1 benzoyl methyl ketone peroxide Chemical class 0.000 description 4
- 238000010894 electron beam technology Methods 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 4
- 239000013307 optical fiber Substances 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 239000000976 ink Substances 0.000 description 3
- 238000001459 lithography Methods 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 230000003287 optical effect Effects 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 238000007639 printing Methods 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 2
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 2
- XLYOFNOQVPJJNP-ZSJDYOACSA-N Heavy water Chemical compound [2H]O[2H] XLYOFNOQVPJJNP-ZSJDYOACSA-N 0.000 description 2
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 description 2
- 238000012356 Product development Methods 0.000 description 2
- 230000009471 action Effects 0.000 description 2
- 239000013043 chemical agent Substances 0.000 description 2
- 230000006870 function Effects 0.000 description 2
- 239000003999 initiator Substances 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 2
- 229910052753 mercury Inorganic materials 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 239000010453 quartz Substances 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000012552 review Methods 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical compound CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 description 1
- XFMDETLOLBGJAX-UHFFFAOYSA-N 2-methylideneicosanoic acid Chemical compound CCCCCCCCCCCCCCCCCCC(=C)C(O)=O XFMDETLOLBGJAX-UHFFFAOYSA-N 0.000 description 1
- FRIBMENBGGCKPD-UHFFFAOYSA-N 3-(2,3-dimethoxyphenyl)prop-2-enal Chemical compound COC1=CC=CC(C=CC=O)=C1OC FRIBMENBGGCKPD-UHFFFAOYSA-N 0.000 description 1
- 238000010146 3D printing Methods 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- CBENFWSGALASAD-UHFFFAOYSA-N Ozone Chemical compound [O-][O+]=O CBENFWSGALASAD-UHFFFAOYSA-N 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 238000003848 UV Light-Curing Methods 0.000 description 1
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- CHIHQLCVLOXUJW-UHFFFAOYSA-N benzoic anhydride Chemical compound C=1C=CC=CC=1C(=O)OC(=O)C1=CC=CC=C1 CHIHQLCVLOXUJW-UHFFFAOYSA-N 0.000 description 1
- RWCCWEUUXYIKHB-UHFFFAOYSA-N benzophenone Chemical compound C=1C=CC=CC=1C(=O)C1=CC=CC=C1 RWCCWEUUXYIKHB-UHFFFAOYSA-N 0.000 description 1
- 239000012965 benzophenone Substances 0.000 description 1
- 239000000227 bioadhesive Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000011960 computer-aided design Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000007334 copolymerization reaction Methods 0.000 description 1
- 238000012938 design process Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005670 electromagnetic radiation Effects 0.000 description 1
- 230000007717 exclusion Effects 0.000 description 1
- 239000003517 fume Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 150000004677 hydrates Chemical class 0.000 description 1
- 150000002432 hydroperoxides Chemical class 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 238000003384 imaging method Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000011344 liquid material Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000004377 microelectronic Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000006082 mold release agent Substances 0.000 description 1
- 231100000344 non-irritating Toxicity 0.000 description 1
- 231100000252 nontoxic Toxicity 0.000 description 1
- 230000003000 nontoxic effect Effects 0.000 description 1
- 150000001451 organic peroxides Chemical class 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
- 238000004382 potting Methods 0.000 description 1
- 150000003254 radicals Chemical class 0.000 description 1
- 239000012925 reference material Substances 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- GJBRNHKUVLOCEB-UHFFFAOYSA-N tert-butyl benzenecarboperoxoate Chemical compound CC(C)(C)OOC(=O)C1=CC=CC=C1 GJBRNHKUVLOCEB-UHFFFAOYSA-N 0.000 description 1
- CIHOLLKRGTVIJN-UHFFFAOYSA-N tertâbutyl hydroperoxide Chemical compound CC(C)(C)OO CIHOLLKRGTVIJN-UHFFFAOYSA-N 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000007666 vacuum forming Methods 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
Landscapes
- Photosensitive Polymer And Photoresist Processing (AREA)
- Exposure And Positioning Against Photoresist Photosensitive Materials (AREA)
- Heating, Cooling, Or Curing Plastics Or The Like In General (AREA)
- Polymerisation Methods In General (AREA)
Description
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ïŒLithographyïŒãå¿çšããç«äœé 圢ã«é¢ãããDETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] This invention relates to improvements in methods and apparatus for forming three-dimensional objects from a fluid medium, and in particular, for forming three-dimensional objects quickly, reliably, accurately and economically. to be able to do,
This field relates to three-dimensional modeling, which applies lithography to the production of three-dimensional objects.
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When manufacturing parts made of plastic,
First, it is common to first design a part and then painstakingly create a prototype of this part. All of these require considerable time, effort and expense. This design is then reviewed until the design is optimal.
This time-consuming process is often repeated many times. After the design is optimized, the next step is its manufacture. In most production, plastic parts are injection molded. Because the design time and tooling costs are so high, injection plastic parts are usually only practical in high volume production. Other methods such as direct machining, vacuum forming and direct molding can be used to manufacture plastic parts. However, these methods are typically cost effective only for short runs of production, and the parts produced are of inferior quality to injection molded parts.
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žåãç±³åœç¹èš±ç¬¬2775785å·ã第4041476å·ãå第
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è«æèªãVOL.J64â No.ïŒïŒ1981幎ïŒæïŒã
Hideo KodamaïŒAutomatic method for
fabricating ïœ threeâdimensional Plastic
model with photoâhardening polymerïŒ
Review of Scientific InstrumentsïŒ52(11)ïŒ
Nov.1981ïŒåã³Alan J.HerbertïŒSolid Object
GenerationïŒJournal of Applied Photographic
EngineeringïŒVOL8ïŒNo.ïŒïŒAugust 1982ã«èš
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ãšãã«ã®ãåããã Recently, very good methods have been developed to create three-dimensional objects in a fluid medium. The fluid medium is selectively stiffened by a beam of radiation selectively focused at predetermined points of intersection within a three-dimensional volume of the fluid medium. Typical devices for forming such three-dimensional objects are U.S. Pat. No. 2,775,785, U.S. Pat.
No. 4078229, No. 4238840, No. 4288861 JP-A-Sho
Publication No. 56-144478, Hideo Kodama, "Automatic 3D shape creation method as a method for displaying 3D information" (Transactions of the Institute of Electronics and Communication Engineers, VOL.J64-C No. 4, April 1981),
Hideo KodamaïŒAutomatic method for
fabricating a three-dimensional Plastic
model with photo-hardening polymer,
Review of Scientific Instruments, 52(11),
Nov.1981, and Alan J. Herbert, Solid Object
Generation, Journal of Applied Photographic
Engineering, VOL8, No. 4, August 1982. All of these devices use various extensive multiple beam schemes to extract synergistic energy at selected points deep within the fluid volume to the exclusion of all other points within the fluid volume. It relies on granting. In this regard, various conventional systems use a pair of electromagnetic radiation beams oriented such that they intersect at specific coordinates. In this case, the various beams may have the same or different wavelengths, or the beams may intersect the same point successively rather than simultaneously. However, in all of these cases, only the intersection points of the beams are energized to an energy level sufficient to accomplish the curing process necessary to form a three-dimensional object within the volume of fluid medium.
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å±€ããŸãå°é£ã§ãã€ãã(Problems to be Solved by the Invention) Unfortunately, however, such a three-dimensional molding apparatus has many problems in terms of resolution and exposure control. The reduction in radiation intensity as the point of intersection moves deeper into the fluid medium, and the reduction in resolution for imaging the focused spot, naturally result in complex control conditions. absorption,
Diffusion, dispersion, and analytical methods all make it difficult to process economically and reliably deep within a fluid medium. Therefore, it was difficult to form extremely thin layers, and automatic lamination was also difficult.
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ãšããŠããã But to be able to move quickly and reliably from the design stage to the prototype stage and then to final production. In particular, the long-standing desire for a virtually instantaneous direct transition from computer-based design to prototypes for such plastic parts, as well as equipment for economical and automatic mass production, has greatly increased the field of design and manufacturing. still exists.
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ããã¹ãŠã®èŠæã«ååå¿ãããã®ã§ããã Therefore, those involved in the development and manufacture of three-dimensional plastic objects, etc. can move from design to prototype to manufacturing while avoiding the complex focusing, alignment and exposure problems of traditional three-dimensional manufacturing equipment. It has been recognized that it would be desirable to further develop a more rapid, reliable, economical and automatic means by which the transfer of data may be carried out quickly. This invention satisfactorily meets all these needs.
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The present invention constructs a three-dimensional object by forming successive adjacent cross-sectional laminates of this object on the surface of a fluid medium that can change its physical state in response to appropriate synergistic energies. Provides new and improved equipment for making. Successive laminates are automatically tightly integrated as they are formed to form the desired three-dimensional object.
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èšèšïŒCADïŒåã³èšç®æ©ã®å©ããåãã補é
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æã®ããã«çšããããšãã§ããã By way of example, and not by way of limitation, in the presently preferred embodiment, the invention utilizes the idea of computer-generated graphics in combination with lithography. In other words, in order to apply lithography technology to the manufacture of three-dimensional objects and directly manufacture three-dimensional objects from computer instructions, computer-assisted design (CAD) and computer-assisted design are necessary. Carry out manufacturing (CAM) at the same time. The invention can be used for forming templates and prototypes at the design stage of product development, or as a manufacturing device, or for the formation of purely artistic objects.
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For example, a method and apparatus for making objects by "printing" thin layers of infrared curable material on top of each other. A programmed light source that illuminates a surface or layer of liquid that can be cured with UV (ultraviolet) light.
A moving spot beam of UV light is used to form a solid cross section of an object on the surface of a liquid. The object is then moved away from the surface of the liquid by one layer thickness in a programmed manner, after which the next cross-section is formed and adhered to the immediately previous layer to form the object. Continue this process until the entire object is formed.
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ã«ãã€ãŠäœãããšãäžå±€å®¹æã«ãªãã The method of the invention allows the formation of almost any form of object. Complex shapes are made easier to create by using computer functions to generate program instructions and then send program signals to the stereolithography device.
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It would not be outside the scope of the invention to practice the invention using other types of suitable synergistic energy to the curable fluid medium, such as radiation.
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ãã§ããã By way of example, in practicing the invention, a body of fluid medium capable of solidifying in response to a predetermined energy may first be contained in any suitable container to form successive cross-sectional laminates therein. Confining selected working surfaces of the fluid medium such that
Thereafter, synergistic energy of a suitable type, such as spots of ultraviolet light, is applied in a graphic pattern to a specified working surface of the fluid medium to form a thin, solid, discrete layer on this surface. As they are formed, successive adjacent layers, each layer representing an adjacent cross-section of the three-dimensional object to be created, are automatically superimposed on each other to unite the layers and form the desired three-dimensional object. form. In this regard, when the fluid medium is cured and the solid material is formed as a thin laminate on the working surface, a suitable platform to which the first laminate is fixed is moved by any suitable actuating device, typically all It is moved away from the work surface in a programmed manner under the control of a microcomputer or the like. In this way, the solid material initially formed on the working surface is moved away from this surface, and new liquid flows into the position of the working surface. A portion of this new liquid is converted into a solid material by a programmed UV light spot to define a new laminate, and this new laminate is bonded to the material adjacent to it, i.e. the immediately previous laminate. Joined. This process continues until the entire three-dimensional object is formed. After this, the formed object is removed from the container and
The device is ready to create another object identical to the first object, or an entirely new object generated by the computer.
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ãã§ããã®ã§ããã®çºæã®æ¹æ³ã¯ããã«åœ¹ç«ã€ã The stereolithography method and apparatus of the present invention has many advantages over methods currently used to create plastic objects. That is, the method of this invention creates a design layout and drawings,
There is no need to create processing drawings and tools. The designer can work directly with the computer and stereolithography equipment and, when satisfied with the design displayed on the computer's output screen, can manufacture the part for direct inspection. If the design has to be modified, this can be easily done through a computer and then another part can be made to confirm that the design changes were correct. If a design calls for several parts with interacting design parameters, the entire design of the part can be quickly changed and rebuilt, and the entire assembly can be built and tested iteratively if necessary. The method of the present invention is even more useful because it can.
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ãã After the design is complete, manufacturing of the parts can begin immediately, avoiding weeks or months of turnaround time between design and manufacturing. The final production rate and cost of parts should be similar to current injection molding costs for short run production, with labor costs even lower than for injection molding. Shot molding is economical only when a large number of identical parts are required. With no tooling required and very short production set-up times, stereolithography lends itself to short production runs. Similarly, design changes and custom parts are easily obtained using this method. Because the parts are easy to manufacture, stereolithography allows the use of plastic parts in many places where parts of metal or other materials are currently used. Additionally, a plastic model of the object can be quickly and economically made before a decision is made to make parts of expensive metal or other materials.
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åšããèŠæã«å¿ãããã®ã§ããã Therefore, the three-dimensional modeling method and apparatus of the present invention address the long-standing need for a CAD or CAM system that can quickly, reliably, accurately, and economically design and manufacture three-dimensional plastic parts. This is a response to the following.
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Next, embodiments of the present invention will be described with reference to the drawings.
FIGS. 1 and 2 are flowcharts showing the basic method and apparatus of the present invention for creating a three-dimensional object by stereolithography.
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ã³ã«ãã®ä»ã®ç¹æ®ãªåéã«çŸåšäœ¿ãããŠããã The immobilization of polymers by ultraviolet (UV) irradiation, electron beam visible light, non-visible light irradiation, ink jets or other types of synergistic energy such as reactive chemicals applied through a suitable mask A number of liquid state chemical agents are known that can be induced to transform into plastics. UV-curable chemicals are currently used as inks in high-speed printing, as adhesives in coating processes for paper and other materials, and in other specialty areas.
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åã¯èšç®æ©ã§ç¬Šå·åãããç©äœã®æ åã§ããã Three-dimensional modeling is a technology that reproduces graphic objects using various methods. Current examples include photocopying, xerography, and microengraving, such as those used in the manufacture of microelectronic circuits. Computer-generated graphics displayed on a plotter or cathode ray tube are also lithographic forms;
An image is an image of an object encoded by a computer.
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A typical example of CAD is in the field of electronic printed wiring design. In this case, a typical example of a CAM is a numerically controlled milling machine, where the computer and plotter draw the design of a printed wiring board, once the design parameters are given as data input to the computer, and the appropriate programming instructions are given. , calculators and milling machines process metal parts. CAD too
CAM is also an important and rapidly growing technology.
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ã©ããšããŠäœ¿ãããšãã§ããã The main purpose of this invention is to utilize computer-generated graphic ideas in combination with UV-curable plastics to simultaneously execute CAD and CAM to create three-dimensional objects directly from computer instructions. It is. This invention is called three-dimensional modeling, and can be used to form templates and prototypes at the design stage of product development, as a manufacturing device, or as artistic forms.
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A fluid that can change its physical state in response to appropriate synergistic energy, such as a jet or a chemical agent applied by spraying through a mask adjacent to the surface of the fluid. A three-dimensional object is created by creating a cross-sectional pattern of the object to be formed on a selected surface of a medium, such as a UV-curable liquid. Successive adjacent laminates representing successive adjacent cross-sections of the object are automatically formed and integrated to create a graded layered or laminar configuration of the object, and during such forming steps, the fluid medium is A three-dimensional object is formed and pulled from a generally planar or sheet surface.
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ãªçµåæ§ããã€äœã®åããšããã The method described above is described in more detail in FIG. In FIG. 2, step 12 requires containing a fluid medium capable of solidifying in response to a predetermined reactive energy. Step 13 applies this energy in a graphic pattern to a selected fluid surface to form a thin, solid, discrete layer on that surface. Each layer represents an adjacent cross section of the three-dimensional object being created. It is desirable that each such layer be made as thin as possible while practicing this invention to maximize the resolution and accurate reproduction of the three-dimensional object being formed, as well as to reduce fabrication time. For this reason, an ideal theoretical situation would be such that the object is made with only selected working surfaces of the fluid medium, resulting in an infinite number of laminates, each with a thickness less than zero. The hardening depth should also be only slightly large (eg, less than 1 mm). By forming such a thin layer, the accuracy of the formed object can be improved, and it is also possible to form a molded part without a support on the surface. Of course, when this invention is used in practice, each laminate is a thin laminate, but suitable bonding is required when bonding to adjacent laminates to form a cross-section and define other cross-sections of the object being formed. The thickness should be such that it has the properties.
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ã«ããããšãã§ããã In step 14 of FIG. 2, successive adjacent layers or laminates are superimposed on each other as they are formed to integrate the various layers and form the desired three-dimensional object. In the normal practice of this invention, when the fluid medium is cured and the solid material is formed to form a laminate, the laminate is moved away from the working surface of the fluid medium and the previously formed laminate The next laminate is formed in the new liquid replacing the laminate, so that each successive laminate is superimposed on every other cross-sectional laminate (by the natural adhesive properties of the hardened fluid medium). Become one. For this reason, the process of manufacturing such cross-sectional laminates is repeated many times until the entire three-dimensional object is formed. after that,
The object is removed and the device is ready to produce another object. This object may be the same as the previous object, or it may be made into a completely new object by replacing the program controlling the stereolithography device.
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Continue this process.
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Make 7. By movement of a mirror or other optical or mechanical element (not shown) that is part of the light source 26, the spot 27 can be moved across the surface 23. The position of spot 27 on surface 23 is controlled by a computer or other programming device 28. A movable lifting platform 29 inside the container 21 can be selectively raised and lowered. The position of the platform 29 is controlled by a computer 28. When the apparatus operates, a three-dimensional object 30 is formed by progressively stacking unitary laminates such as 30a, 30b, and 30c.
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ãã§ããã The surface of the UV curable liquid 22 is maintained at a constant height within the container 21 and exposed to a spot 27 or other suitable type of UV light of sufficient intensity to cure the liquid and convert it into a solid material. reactive energy is transferred across the work surface 23 in a programmed manner. When the liquid 22 hardens to form a solid material, the lifting platform 29, which was initially just below the working surface 23, is lowered from this working surface in a programmed manner by means of a suitable actuator. Ru. In this way, the initially formed solid material comes to be below the surface 23 and the new liquid 22 flows into the surface 23. A portion of this new liquid is converted into a solid material by the programmed UV light spot 27, and this new material is bonded to the underlying material by adhesive. This process continues until the entire three-dimensional object 30 is formed. Object 30 is then removed from container 21 and the device is ready to make another object. Thereafter, another object can be created, or by replacing the program on the computer 28, a new object can be created.
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Azo compounds such as 2'-azobis(isobutyronitrile); hydroperoxides such as cumene hydroperoxide, t-butyl hydroperoxide, methyl ethyl ketone hydroperoxide; hydrates such as t-butyl perbenzoate, t-butyl peracetate peresters that decompose into peracid compounds; photosensitive compounds such as benzophenone and benzoyl ether; A spot 27 of UV light is generated that is strong enough to cure quickly enough to be practical. source 26
is configured such that it can be programmed to turn on and off and to move the focusing spot 27 across the surface 23 of the liquid 22. Thus, as the spot 27 moves, it hardens the liquid 22 into a solid and forms a pattern on a surface in much the same way that a chart recording or drafting device uses a pen to draw a pattern on a piece of paper. Draw a solid pattern.
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3. Form a focal point to obtain a region of high strength and rapidly diverge to a lower strength to limit the depth of the curing process to obtain the thinnest cross-sectional laminate suitable for the object being formed. It is desirable that the This uses a lens with a short focal length and the source 2
6 as close to the work surface as possible to maximize divergence in the focal cone entering the fluid medium. As a result, the resolution is substantially higher.
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limited by the response of the UV curable liquid.
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ãããšã ãã§ããã The computer 28 of the three-dimensional modeling apparatus of this invention basically has two functions. First, it helps the operator design a three-dimensional object in such a way that it can be created. Second, convert this design into appropriate commands for stereolithography and send these commands so that the object is formed. In some applications, there is a design of the object, and the only action of the computer is to issue appropriate commands or commands.
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You can see it in three dimensions on the CRT screen of the calculator 28. When the operator completes the design, he commands the computer 28 to create the object, and the computer issues appropriate commands for three-dimensional modeling.
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8 is an HP9816 and uses a basic operating system. A typical program is shown in the attached reference material. This system is programmed by the operator using the HP Graphics Language (command structure for the 3497A) and Basic Language commands.
The operator must also set the appropriate exposure time and speed for the UV cure time. In order to operate this device, we create an image of the object and write a program to drive the three-dimensional modeling device to create this object.
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ã容æã«éæããããšãã§ããã A constant level of liquid 22 at work surface 23 can be maintained using a computer-controlled pump (not shown). This necessity is due to the following reasons. That is, when the liquid is exposed to light, it contracts due to a change in its capacitance, and the liquid level changes. Further, when the lifting table 29 moves into the liquid, the volume of the liquid changes, and thereby the liquid level changes.
The thickness of the liquid layer is determined by the depth of the previous layer formed below the liquid level, so if the liquid level is not kept constant, the actual thickness of the layer formed will be This is because the thickness of the layer differs from the desired thickness, and a layer with an accurate thickness cannot be formed. Suitable liquid level sensing devices and feedback circuits known in the art are used to drive a fluid pump or to drive a liquid displacement device to move the platform out of the fluid medium as it moves deeper into the fluid medium. solid rod (not shown)
is driven, the amount of change in fluid volume is smoothed out, and surface 23
A constant fluid level can be maintained. Alternatively, the light source 26 can be moved relative to the sensed liquid level 22 and automatically maintain sharp focus on the work surface 23. All of these alternatives can be easily accomplished with conventional software working in conjunction with computer controller 28.
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Raise the height and remove the object from the stand. Typically, this is followed by ultrasonically cleaning the object in a solvent, such as acetone, that does not dissolve the hardened solid medium, but dissolves the liquid state of the unhardened fluid medium. The object 30 is then placed under a strong ultraviolet light flood, typically a 200 watts per inch UV curing lamp;
Complete the curing process.
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åãæ¿ããäžå±€å®¹æã§ããã A UV light source 26 in FIG. 4 focuses a spot 27 on the interface between liquid 22 and an immiscible intermediate liquid layer (mold release agent) 32. The UV radiation passes through a suitable UV-transparent window 33 made of quartz or the like supported in the bottom of the container 21. The curable liquid 22 is provided as a very thin layer on top of the immiscible layer 32, thus limiting the depth of curing since ideally a very thin laminate should be produced. There is the advantage of directly limiting the layer thickness instead of relying solely on adsorption etc. Therefore, the formation area is more sharply limited, and if the apparatus shown in FIG.
Certain surfaces are formed more smoothly than the device shown. Additionally, the UV curable liquid 22 requires less volume and is easier to replace one curable material with another.
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There is no movable UV light source 26, and instead of a programmed source 26 and focusing spot 27, a collimated wide UV light source 35 and a suitable aperture mask 36 are used. The aperture mask 36 is placed as close as possible to the work surface 23 so that collimated light from the UV source 35 passes through the mask 36 to expose the work surface 23, thus similar to the embodiment of FIGS. , making successive adjacent laminates.
However, by using a fixed mask 36 that represents the cross-sectional shape of the object to be formed, a three-dimensional object with a constant cross-sectional shape can be obtained. When changing this cross-sectional shape, create a new mask 3 for that particular cross-sectional shape.
6 and have to match it correctly. Of course, by providing a web of the mask (not shown) which is successively moved into alignment with the surface 23, the mask can be changed automatically.
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äœãéå®ããçžæ¬¡ãæé¢ç©å±€æ¿ã圢æããã FIG. 6 also shows a three-dimensional modeling apparatus similar to that previously described with respect to FIG. However, the light source 26
and as a replacement for the focal spot 27, a cathode ray tube (CRT) 38, an optical fiber face plate 39;
and a water or other template layer 40. To this end, the image provided by the computer 28 to the CRT 38 forms an image on the UV-emitting phosphor surface of the tube, where it passes through the optical fiber layer 39 and the template layer 40 and into the working surface 23 of the fluid medium 22. In all other respects,
The apparatus of FIG. 6 forms successive cross-sectional laminates that define the desired three-dimensional object to be formed, just as in the previously described embodiments.
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çãªæ§é ïŒïŒãéžæçã«åœ¢æããããšãã§ããã 7 and 8 show a three-dimensional modeling apparatus in which the lifting platform 29 has additional degrees of freedom, allowing different sides of the object 30 to be exposed for other construction methods. Similarly, this stereolithography method can be used as an "add-on" method, and the lift platform 29 can be used to pick up and position additional parts for supplementary stereolithography processing. In this respect, the apparatus shown in FIGS. 7 and 8 is the same as that shown in FIG. 3, except that in the apparatus of FIGS. Or, it differs in that it has a second degree of freedom of automatically controlled rotation. In this regard, FIG. 7 shows the adjustable lifting platform 29a in the normal position.
FIG. 8 shows the table 29a rotated by 90 degrees, so that an auxiliary structure 41 formed by three-dimensional modeling can be selectively added to one side of the three-dimensional object 30. can be formed into
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ãããã€ãŠããã Practical stereolithography devices have additional components and subsystems beyond those previously described for the devices shown schematically in FIGS. 3-8. For example, a practical device has a frame and housing and a control panel. Additionally, means may be provided to shield the operator from excess UV and visible light, and may also be provided to allow the operator to view the object 30 while it is being formed. Practical equipment includes safety measures to control ozone and harmful fumes, as well as high pressure safety protection and interlocking devices. Such practical devices also have means for effectively shielding sensitive electronic circuitry from noise sources.
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ç·ããŒã ãçšããŠéåãããããšãã§ããã As already explained, many other devices can be used to carry out the three-dimensional modeling method of the present invention. For example, instead of the UV light source 26,
A suitable fluid medium that hardens in response to a particular type of reactive energy, which can be an electron source, a visible light source, a laser light source, a shot arc light source, a high energy particle light source, an X-ray source or other radiation source;
For example, photopolymerizable materials can be used. For example, alpha octadecyl acrylic acid, which has been slightly prepolymerized using UV light, can be polymerized using an electron beam. Similarly, poly(2,3-
dichloro-1-propyl acrylate) can be polymerized using an X-ray beam.
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The stereolithography method and apparatus of the present invention has many advantages over methods currently used for manufacturing plastic objects. The method of the present invention does not require the creation of design layouts and drawings, nor does it require the creation of processing drawings and tools. Designers can work directly with computers and stereolithography equipment, and when they are satisfied with the design displayed on the computer's output screen, they can directly review it.
Parts can be manufactured. When a design needs to be changed, it can be easily done through a computer, and then another part can be made to verify that the change was correct. If a design requires several parts with interacting design parameters, the design of all parts can be quickly changed and recreated. This allows the entire assemblage to be constructed and tested repeatedly, if necessary.
The method of this invention is further useful.
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Injection molding is economical only when large numbers of identical parts are required. Stereolithography is useful for short-term production. This is because no tools are required and the production set-up time is very short. Similarly, design changes and custom parts are easily obtained using this method. Because it is easy to make parts,
Stereolithography allows plastic parts to be used in many places where parts of metal or other materials are currently used. Additionally, a plastic model of the object can be made quickly and economically before a decision is made to manufacture the more expensive metal or other material parts.
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ãåŸæ¥é·ãéãã€ãèŠæã«å¿ããã This invention allows three-dimensional plastic parts to be designed quickly, reliably, accurately, and economically.
This responds to a long-standing demand for CAD and CAM equipment that can be manufactured.
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ãããããšã¯ãªãã While the invention has been illustrated and described in a particular form, it will be obvious that various modifications may be made within the scope of the invention. Therefore, this invention is not limited only to the scope of the claims of the present application.
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1 and 2 are flowcharts showing the basic idea used to implement the three-dimensional modeling method of this invention, and FIG. 3 is a cross section of a currently preferred embodiment of an apparatus for implementing this invention. 4 is a sectional view of a second embodiment of the invention, FIG. 5 is a sectional view of a third embodiment of the invention, and FIG. 6 is a sectional view of a third embodiment of the invention. FIGS. 7 and 8, which are cross-sectional views of still another embodiment, are partial cross-sectional views of the three-dimensional modeling apparatus of FIG. 3 modified to incorporate a lifting platform with multiple degrees of freedom. 21... Container, 22... UV curable liquid, 23... Work surface, 26... Light source, 28... Calculator, 29... Lifting platform, 30... Object.
Claims (1)
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äžæ¬¡å ç©äœã圢æããè£ çœ®ã[Scope of Claims] 1. A method for automatically creating a three-dimensional object from a hardenable fluid medium, comprising: creating data representing a cross-section of the three-dimensional object to be created; and hardening data generated in response to the data. Exposure of said fluid medium on a work surface designated for irradiation to form a first profiled cross-sectional layer, said curing irradiation having a slit size of 1 mm or less in diameter and at least 1 watt to speed up stereolithography. /cm 2 and having a thickness of 1 mm or less, automatically laminated to the first cross-sectional layer, and exposing the next fluid layer to curing radiation to form the second cross-sectional layer. forming, said fluid medium having sufficient absorbency of the curing radiation to form a constituent layer having a thickness of 1 mm or less, and said next fluid medium being absorbent for the curing radiation to form said next fluid layer. A method of adhering said second cross-sectional layer to said first cross-sectional layer while exposing the layers to form a three-dimensional object from a plurality of sequentially adhered cross-sectional layers. 2. An apparatus for automatically creating a three-dimensional object from a hardenable fluid medium, comprising: an arithmetic device that generates data representing a cross section of the three-dimensional object to be created; a container containing the fluid medium; the fluid medium has sufficient absorption of curing radiation to form a constituent layer having a thickness of 1 mm or less, the fluid medium defines a designated working surface, and the fluid medium is responsive to the data; a curing radiation source that is exposed to generated curing radiation to form a first cross-sectional layer on the work surface; a spot size of 1 mm or less in diameter for the curing radiation to speed up three-dimensional modeling; Automatically attaching to said first cross-sectional layer as a next fluid layer having a thickness of 1 mm or less, with the formation of a second cross-sectional layer having a strength of at least 1 watt/cm 2 and being adhered to said first cross-sectional layer. apparatus for forming a three-dimensional object from a plurality of sequentially bonded cross-sectional layers. 3. Apparatus for forming three-dimensional objects according to claim 2, wherein the fluid medium comprises a photopolymer material. 4. Apparatus for forming three-dimensional objects according to claim 2, wherein each said cross-sectional layer formed is sufficiently strong to maintain an integral structure. 5. Apparatus for forming three-dimensional objects according to claim 2, wherein the fluid medium is adapted to respond rapidly to curing radiation. 6. Apparatus for forming three-dimensional objects according to claim 2, wherein the fluid medium absorbs curing radiation within the ultraviolet spectrum. 7. Apparatus for forming a three-dimensional object according to claim 2, wherein each cross-sectional layer formed is adhered to the immediately preceding cross-sectional layer during curing irradiation. 8. A device for directly creating a three-dimensional object designed and created by a computer, comprising: an arithmetic device that generates an image output;
a container defining two thin cross-sections and containing a fluid medium;
a curing radiation source, the fluid medium defining a designated working surface, the fluid medium having an absorbency of curing radiation sufficient to form a constituent layer having a thickness of less than mm; a computer controller for exposing to curing radiation generated in response to the image output to form a first cross-sectional layer on the work surface, the curing radiation having a diameter of 1 mm to speed up stereolithography;
The following fluid having a spot size of: a computer controller for automatically laminating said first cross-sectional layer in layers; and during irradiation for curing said next fluid layer, automatically forming a next fluid layer adhered to an immediately preceding layer to form a three-dimensional layer. A device for forming three-dimensional objects, comprising: a computer control device that allows automatic formation of objects; 9. A device for automatically creating a three-dimensional object from a hardenable fluid medium, comprising: an arithmetic device that generates data representing a cross section of the three-dimensional object to be created; a container containing the fluid medium; Thickness less than 0.8 mm and absorbing enough curing radiation to form constituent layers with sufficient adhesion that are not partially supported by any other layer during formation. a liquid level control device for controlling a liquid level of a predetermined fluid medium on the working surface, the fluid medium defining a designated work surface; a curing radiation source that is exposed to curing radiation to form a first cross-sectional layer on the working surface; the curing radiation has a spot size of 1 mm or less in diameter to speed up stereolithography; said first fluid layer having a strength of 1 watt/cm 2 and decreasing in thickness to a next fluid layer having a thickness of less than 1 mm in preparation for the formation of a second cross-sectional layer adhered to said first cross-sectional layer; and a device for automatically laminating cross-sectional layers with a fluid, whereby a plurality of sequentially bonded cross-sectional layers form a three-dimensional object. 10. An apparatus for forming three-dimensional objects according to claim 9, wherein the fluid medium comprises a photopolymer material. 11. An apparatus for forming a three-dimensional object according to claim 9, wherein each said cross-sectional layer formed is sufficiently strong to maintain an integral structure. 12. Apparatus for forming three-dimensional objects according to claim 9, wherein the fluid medium responds rapidly to curing radiation. 13. Apparatus for forming three-dimensional objects according to claim 9, wherein the fluid medium absorbs curing radiation within the ultraviolet spectrum. 14. Apparatus for forming three-dimensional objects according to claim 9, wherein each cross-sectional layer formed adheres to the immediately preceding layer during curing irradiation.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP1112735A JPH0236929A (en) | 1989-05-01 | 1989-05-01 | Method and device for preparing three-dimensional body |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP1112735A JPH0236929A (en) | 1989-05-01 | 1989-05-01 | Method and device for preparing three-dimensional body |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP60173347A Division JPS6235966A (en) | 1984-08-08 | 1985-08-08 | Method and apparatus for generating 3-d object |
Publications (2)
Publication Number | Publication Date |
---|---|
JPH0236929A JPH0236929A (en) | 1990-02-06 |
JPH049660B2 true JPH049660B2 (en) | 1992-02-20 |
Family
ID=14594236
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP1112735A Granted JPH0236929A (en) | 1989-05-01 | 1989-05-01 | Method and device for preparing three-dimensional body |
Country Status (1)
Country | Link |
---|---|
JP (1) | JPH0236929A (en) |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS56144478A (en) * | 1980-04-12 | 1981-11-10 | Hideo Kodama | Stereoscopic figure drawing device |
JPS57125906A (en) * | 1981-01-30 | 1982-08-05 | Nippon Telegr & Teleph Corp <Ntt> | Production of optical guide |
JPS5830755A (en) * | 1981-08-17 | 1983-02-23 | Teijin Ltd | Exposing method |
JPS60247515A (en) * | 1984-05-23 | 1985-12-07 | Oosakafu | Optical shaping method |
-
1989
- 1989-05-01 JP JP1112735A patent/JPH0236929A/en active Granted
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS56144478A (en) * | 1980-04-12 | 1981-11-10 | Hideo Kodama | Stereoscopic figure drawing device |
JPS57125906A (en) * | 1981-01-30 | 1982-08-05 | Nippon Telegr & Teleph Corp <Ntt> | Production of optical guide |
JPS5830755A (en) * | 1981-08-17 | 1983-02-23 | Teijin Ltd | Exposing method |
JPS60247515A (en) * | 1984-05-23 | 1985-12-07 | Oosakafu | Optical shaping method |
Also Published As
Publication number | Publication date |
---|---|
JPH0236929A (en) | 1990-02-06 |
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