Solid imaging apparatus and method

Abstract

A solid imaging device is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transfer membrane for layered transfer of build material from the cartridge to a surface of a construct in an image plane. Operators using the device can continue solid imaging with essentially no interruption simply by removing spent cartridges and replacing them with new ones. The device also includes the ability to withdraw and insert the imager without requiring a separate alignment step by the operator. Brushes attached to the transfer film and forming part of the cartridge are able to remove excess uncured build material intra-laminarly. If desired, the device can produce fully reacted constructs. A high intensity UV source cures the build between layers. Injection molded build pads are designed to hold the build in an inverted position for improved builds. The present invention also proposes tilting the structure elevator to reduce air entrapment and release the structure from the image plane.

Description

technical field [0001] The present invention relates to solid imaging devices and methods. Background technique [0002] Solid imaging devices have been used for rapid prototyping of product development models and, more recently, in manufacturing operations. Solid imaging devices typically produce three-dimensional objects from fusible powders or photocurable liquids by exposure to radiation in response to computer control. The data representing the thin cross-sectional layers of the three-dimensional object provides the computer with control parameters for a procedure that typically automates the building of the object in layers. A laser or other radiation source suitable for solid imaging sequentially irradiates individual thin layers of build material, in response to the layer-by-layer conversion of the material into a solid to create a solid imaged product. [0003] Solid imaging is sometimes referred to as "rapid prototyping" and includes different techniques such as ...

AI Technical Summary

Problems solved by technology

[0004] Despite the development of various devices and methods for solid imaging, there are still many shortcomings to be addressed

The devices and methods used to perform solid imaging tend to be somewhat characterized by excessive moving parts and complex systems which can require considerable effort to care, maintain and operate

Laser imaging and UV imaging systems tend to be costly, making these systems impractical for many applications

Complicated and tedious alignment steps to align radiation source and image plane reduce efficiency and increase cost

Large volumes of liquid resin used in stereolithography are expensive and can be contaminated with cured resin clumps

Images