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United States Patent [19] Smalley et al.

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[11] Patent Number: 5,597,520 [45] Date of Patent: Jan. 28, 1997

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SIMULTANEOUS MULTIPLE LAYER CURING IN STEREOLITHOGRAPHY

Inventors: Dennis R. Smalley, 25029 Wheeler Rd., Newhall, Calif. 91321; Thomas J. Vorgitch, 4846 Summit Ave., Simi Valley, Calif. 93063; Chris R. Manners, 4337 Riverglen St., Moorpark, Calif. 93021; Charles W. Hull, 15605 Live Oak Springs, Santa Clarita, Calif. 91351; Stacie L. VanDorin, 27923 Harwood Dr., Saugus, Calif. 91350

Appl. No.: 233,027

Filed: Apr. 25, 1994

Related U.S. Application Data

Continuation-in-part of Ser. No. 16,202, Feb. 9, 1993, aban doned, which is a continuation of Ser. No. 606,802, Oct. 30, 1990, Pat. No. 5,192,469.

Int. Cl.6 ......................... .. B29C 35/08; B29C 41/02; B29C 41/52

U.S. Cl. ........................ .. 264/401; 118/429; 118/620;

118/712; 156/64; 156/2733; 156/2735; 156/2755; 156/307.1; 156/378; 156/3796; 250/4921; 264/40.l; 264/308; 364/468.27;

365/106; 365/107; 395/119; 425/135; 425/174.4; 427/8; 427/510; 427/512; 427/553; 427/554;

427/555 Field of Search .......................... .. 264/22, 40.1, 255,

264/308; 425/135, 174, 174.4; 156/64, 242, 273.3, 273.5, 275.5, 307.1, 378, 379.6, 538; 427/8, 393.5, 407.1, 430.1, 508, 510,

512, 553, 554, 581, 555; 118/429, 500, 620, 712; 250/492.1; 364/468, 476; 365/106,

107, 119, 120, 126, 127; 395/119

References Cited

U.S. PATENT DOCUMENTS

4,961,154 10/1990 Pomerantz et a1. ................... .. 395/119

5,151,813 9/1992 Yamamoto et al. .................. .. 359/202

FOREIGN PATENT DOCUMENTS

388129 9/1990 61-225012 10/1986 63-145015 6/1988

2-95831 4/1990 2-95830 4/ 1990

European Pat. Off. . Japan ..................................... .. 264/22

Japan ................................ .. 425/174.4

Japan .

Japan .

OTHER PUBLICATIONS

“A Photopolymerization Method of Preparing Three-dimen sional Terrain Models,” C. Claus, et al., Published in Pho tographic Science and Engineering, vol. 5, No. 4, Jul.—Aug. 1961, pp. 211-215. “A New Method of Three-Dimensional Micromachining,” E. Fudim, Published in Mechanical Engineering, Sep. 1985, pp. 54-59. “Sculpting with Light,” E. Fudim, Published in Machine Design, Mar. 6, 1986, pp. 102—106.

Primary Examiner—Leo B. Tentoni Attorney, Agent, or Firm—Dennis R. Smalley

[57] ABSTRACT

A method and apparatus for making high resolution objects by stereolithography utilizing low resolution materials which are limited by their inability to form unsupported structures of desired thinness and/or their inability to form coatings of desired thinness. Data manipulation techniques, based on layer comparisons, are used to control exposure in order to delay solidi?cation of the material on at least portions of at least some cross-sections until higher layers of material are deposited so as to allow down-facing features of the object to be located at a depth in the building material which is equal to or exceeds a minimum cure depth that can eifectively be used for solidifying these features. Similar data manipulations are used to ensure minimum reliable coating thicknesses exist, above previously solidi?ed mate rial, before attempting solidi?cation of a next layer. In addition, horizontal comparison techniques are used to pro vide enhanced cross-sectional data for use in forming the object.

4,575,330 3/1986 Hull .. 425/174.4 4,752,498 6/1988 Fudim 427/510 4,801,477 1/1989 Fudim ................................... .. 427/510 31 Claims, 148 Drawing Sheets

US. Patent Jan. 28, 1997 Sheet 1 of 148 5,597,520

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US. Patent Jan. 28, 1997 Sheet 2 of 148 5,597,520

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US. Patent Jan. 28, 1997 Sheet 5 of 148 5,597,520

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US. Patent Jan. 28, 1997 Sheet 9 of 148 5,597,520

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US. Patent Jan. 28, 1997 Sheet 14 of 148 5,597,520

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US. Patent Jan. 28, 1997 Sheet 17 of 148 5,597,520

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