Abstract: An apparatus and method for making a three-dimensional object from a solidifiable material using a linear solidification device is shown and described. In certain examples, the linear solidification device includes a laser diode that projects light onto a scanning device, such as a rotating polygonal mirror or a linear scanning micromirror, which then deflects the light onto a photohardenable resin. As a result, the linear solidification device scans a line of solidification energy in a direction that is substantially orthogonal to the direction of travel of the laser diode. In other examples, the linear solidification device is a laser device array or light emitting diode array that extends in a direction substantially orthogonal to the direction of travel of the array.

Abstract: The invention relates to a process or a device for the production of a three-dimensional object by layer-wise solidification of a photo-polymerizable resin by means of a planar or essentially planar construction/reference plane, at which the photo-polymerizable resin contained in the liquid material is to be hardened by electromagnetic irradiation, and wherein the material application for the subsequent layer automatically results from the separation of the last hardened layer from the construction/-reference plane, whereby the construction/reference plane is formed by an elastic film. The film is fixed in a frame, and the height position of the frame with the film is adjusted in a basin containing the liquid material such that the pressure of the liquid material compensates the sagging of the film (formation of a negative meniscus), and that the lower side of the film is permanently in contact with the material during the whole construction process.

Abstract: A solidification substrate assembly for making a three-dimensional object from a solidifiable material includes a solidification substrate assembly. In certain examples, the solidifiable material solidifies in contact with the solidification substrate, and the tilting of the substrate and/or or the use of a peeling member facilitates separation of the substrate from the solidified material. In other examples, the solidification substrate assembly includes a film that is adjacent to a rigid or semi-rigid layer. The solidifiable material solidifies in contact with the film, and a peeling member peels the film away from the solidified material. Intelligent solidification substrate assemblies are also described in which a force sensor determines when to expose the solidifiable material to solidification energy and/or whether to use a peeling member to separate the solidification substrate from a solidified objection section.

Abstract: An apparatus and method for making a three-dimensional object from a solidifiable material using a linear solidification device is shown and described. In certain examples, the linear solidification device includes a laser diode that projects light onto a scanning device, such as a rotating polygonal mirror or a linear scanning micromirror, which then deflects the light onto a photohardenable resin. As a result, the linear solidification device scans a line of solidification energy in a direction that is substantially orthogonal to the direction of travel of the laser diode. In other examples, the linear solidification device is a laser device array or light emitting diode array that extends in a direction substantially orthogonal to the direction of travel of the array.

Abstract: A method and apparatus for making a three-dimensional object from a solidifiable material such as a photopolymer is shown and described. In accordance with the method, positions relative to a build axis are subdivided into first and second exposure data subsets, and the first and second exposure data subsets are solidified in alternating sequences to reduce the surface area of solidified material in contact with a solidification substrate.

Abstract: Methods and apparatuses for making three-dimensional objects from multiple solidifiable materials is shown and described. Multiple solidifiable material container assemblies are provided for holding different solidifiable materials. Relative movement between the solidifiable material container assemblies and a build platform allows the solidifiable materials to be switched as an object is built. Several exemplary cleaning stations are provided for removing residual solidifiable materials from the surface of the three-dimensional object as it is built to better ensure smooth transitions between materials on the finished object.

Abstract: Device for producing a three-dimensional object by solidification of a material solidifiable under the action of electromagnetic radiation by means of energy input via an imaging unit comprising a predetermined number of discrete imaging elements (pixels), said device comprising a computer unit, an IC and/or a software implementation respectively with the ability of adjusting and/or controlling the energy input via a specific gray value and/or color value in a voxel matrix.

Abstract: The present invention describes a process for producing a three-dimensional object, comprising: providing a material to be solidified, the material comprising a filler and a binder; delivering electromagnetic radiation and/or synergistic stimulation in a pattern or an image to a building region for solidifying said material; wherein said delivering of electromagnetic radiation and/or synergistic stimulation is performed selectively to a defined area or volume of said material to be solidified; and wherein an energy density of electromagnetic radiation and/or synergistic stimulation is varied within said pattern or image and/or between patterns or images of different building regions of said material. The present invention may be directed also to a system where different first and second materials are to be solidified.

Abstract: The present invention provides a process for producing at least one three-dimensional object, comprising: providing a material to be solidified; delivering electromagnetic radiation and/or synergistic stimulation in a pattern or an image to a building region for solidifying said material; wherein said delivering of electromagnetic radiation and/or synergistic stimulation is performed selectively to a defined area or volume of said material to be solidified; and wherein an energy density of electromagnetic radiation and/or synergistic stimulation is controlled and/or adjusted in a border region of said pattern or image and/or is varied in border regions of patterns or images of different building regions of said material, to have an energy density different from the building region other than said border region(s), wherein the controlling and/or adjustment is dependent on, alone or in combination: (a) intensity of electromagnetic radiation and/or synergistic stimulation delivered to said defined area or volume

Abstract: The present invention provides a process for producing at least one three-dimensional object, comprising: providing a material to be solidified; delivering electromagnetic radiation and/or synergistic stimulation in a pattern or an image to a building region for solidifying said material; wherein said delivering of electromagnetic radiation and/or synergistic stimulation is performed selectively to a defined area or volume of said material to be solidified; and wherein an energy density of electromagnetic radiation and/or synergistic stimulation is controlled and/or adjusted in a border region of said pattern or image and/or is varied in border regions of patterns or images of different building regions of said material, to have an energy density different from the building region other than said border region(s), wherein the controlling and/or adjustment is dependent on, alone or in combination: (a) intensity of electromagnetic radiation and/or synergistic stimulation delivered to said defined area or volume

Abstract: The invention relates to a process or device for the production of a three-dimensional object by layer-wise solidification of a material which is solidifiable under the application of electromagnetic irradiation by means of mask illumination, wherein the mask is produced using an image forming unit having a prescribed resolution, which is formed from a constant number of image forming elements (pixels) being discrete and being arranged in a spatially mutually fixed manner. For the improvement of the resolution along the outer and inner contours of the sectional areas of the object to be generated layer-wise in the sub-pixel range, a multiple illumination per layer is performed, which consists of a series of multiple images that are mutually shifted in the sub-pixel range in the image/construction plane, wherein a separate mask/bitmap is produced for each shifted image.

Abstract: The invention relates to a process or device for the production of a three-dimensional object by layer-wise solidification of a material which is solidifiable under the application of electromagnetic irradiation by means of mask illumination, wherein the mask is produced using an image forming unit having a prescribed resolution, which is formed from a constant number of image forming elements (pixels) being discrete and being arranged in a spatially mutually fixed manner. For the improvement of the resolution along the outer and inner contours of the sectional areas of the object to be generated layer-wise in the sub-pixel range, a multiple illumination per layer is performed, which consists of a series of multiple images that are mutually shifted in the sub-pixel range in the image/construction plane, wherein a separate mask/bitmap is produced for each shifted image.

Abstract: The invention describes device and method for producing a three-dimensional object by solidifying a solidifiable material under an action of electromagnetic radiation by means of energy input via an imaging unit comprising a predetermined number of discrete imaging elements (pixels). The energy input related to a specific cross-sectional area of the three-dimensional object is controlled by exposure by means of multiple successive raster masks (bitmaps; e.g. bitmap 1 and bitmap 2 and possibly additional ones). The imaging unit is suitably controllable such that at least two masks can be generated, including a first overall mask covering the cross-sectional area (bitmap 1; with pixel-specific area elements exposing in white light) and a partial mask (bitmap 2; in which only a fraction of the area elements are exposed pixel-specifically with white light) within the overall mask. A voxel matrix may be formed.

Abstract: A solidification substrate assembly for making a three-dimensional object from a solidifiable material includes a solidification substrate assembly. In certain examples, the solidifiable material solidifies in contact with the solidification substrate, and the tilting of the substrate and/or or the use of a peeling member facilitates separation of the substrate from the solidified material. In other examples, the solidification substrate assembly includes a film that is adjacent to a rigid or semi-rigid layer. The solidifiable material solidifies in contact with the film, and a peeling member peels the film away from the solidified material. Intelligent solidification substrate assemblies are also described in which a force sensor determines when to expose the solidifiable material to solidification energy and/or whether to use a peeling member to separate the solidification substrate from a solidified objection section.

Abstract: The invention relates to a process or a device for the production of a three-dimensional object by layer-wise solidification of a photo-polymerizable resin by means of a planar or essentially planar construction/reference plane, at which the photo-polymerizable resin contained in the liquid material is to be hardened by electromagnetic irradiation, and wherein the material application for the subsequent layer automatically results from the separation of the last hardened layer from the construction/-reference plane, whereby the construction/reference plane is formed by an elastic film. The film is fixed in a frame, and the height position of the frame with the film is adjusted in a basin containing the liquid material such that the pressure of the liquid material compensates the sagging of the film (formation of a negative meniscus), and that the lower side of the film is permanently in contact with the material during the whole construction process.

Abstract: The invention describes a process and a device for producing at least one three-dimensional object, a photo-polymerizable material is solidified by means of simultaneous or almost simultaneous exposure of a build area or partial build area in a building plane via electromagnetic radiation, wherein a distance between a support plate, at which the object to be generated is built, and the building plane is changed during at least one exposure phase. It is possible according to the invention to solidify the three-dimensional object in a main direction during a radiation phase exceeding a current prescribed hardening depth, without interrupting supply of electromagnetic energy during the irradiation phase. Further, it is possible to control a current hardening depth of the photopolymerizable material during a building phase. Embodiments of suitable devices are also described.

Abstract: The invention describes device and method for producing a three-dimensional object by solidifying a solidifiable material under an action of electromagnetic radiation by means of energy input via an imaging unit comprising a predetermined number of discrete imaging elements (pixels). The energy input related to a specific cross-sectional area of the three-dimensional object is controlled by exposure by means of multiple successive raster masks (bitmaps; e.g. bitmap 1 and bitmap 2 and possibly additional ones). The imaging unit is suitably controllable such that at least two masks can be generated, including a first overall mask covering the cross-sectional area (bitmap 1; with pixel-specific area elements exposing in white light) and a partial mask (bitmap 2; in which only a fraction of the area elements are exposed pixel-specifically with white light) within the overall mask. A voxel matrix may be formed.

Abstract: The invention relates to a process or device for the production of a three-dimensional object by layer-wise solidification of a material which is solidifiable under the application of electromagnetic irradiation by means of mask illumination, wherein the mask is produced using an image forming unit having a prescribed resolution, which is formed from a constant number of image forming elements (pixels) being discrete and being arranged in a spatially mutually fixed manner. For the improvement of the resolution along the outer and inner contours of the sectional areas of the object to be generated layer-wise in the sub-pixel range, a multiple illumination per layer is performed, which consists of a series of multiple images that are mutually shifted in the sub-pixel range in the image/construction plane, wherein a separate mask/bitmap is produced for each shifted image.

Abstract: The invention relates to a process or a device for the production of a three-dimensional object by layer-wise solidification of a photo-polymerizable resin by means of a planar or essentially planar construction/reference plane, at which the photo-polymerizable resin contained in the liquid material is to be hardened by electromagnetic irradiation, and wherein the material application for the subsequent layer automatically results from the separation of the last hardened layer from the construction/-reference plane, whereby the construction/reference plane is formed by an elastic film. The film is fixed in a frame, and the height position of the frame with the film is adjusted in a basin containing the liquid material such that the pressure of the liquid material compensates the sagging of the film (formation of a negative meniscus), and that the lower side of the film is permanently in contact with the material during the whole construction process.

Abstract: A method and apparatus for making a three-dimensional object from a solidifiable material such as a photopolymer is shown and described. In accordance with the method, positions relative to a build axis are subdivided into first and second exposure data subsets, and the first and second exposure data subsets are solidified in alternating sequences to reduce the surface area of solidified material in contact with a solidification substrate.