Patents by Inventor Charles W. Hull
Charles W. Hull has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 8048359Abstract: There is provided methods and apparatus for compensation of intensity profiles of imagers used in three-dimensional modelers. The intensity profile of the actinic radiation projected from the imager is determined by a variety of techniques, including but not limited to manually operated sensors, exposed and scanned actinic radiation-sensitive paper, and intensity profilers. Once the intensity profile of the imager is determined, each layer of the solidifiable liquid material is cured by projecting a plurality of patterns (as opposed to a single pattern) defining the two-dimensional cross-section of the part being cured. The patterns vary in duration, number, and/or shape to correlate to the intensity profile so that a single layer of selectively cured solidifiable liquid material is cured with a substantially equivalent (or otherwise controlled) amount of actinic radiation per unit of surface area to provide generally controlled and consistent part quality.Type: GrantFiled: October 20, 2008Date of Patent: November 1, 2011Assignee: 3D Systems, Inc.Inventors: Hongqing V. Wang, Soon-Chun Kuek, Charles W. Hull, Richard Ora Gregory, II, Thomas Alan Kerekes
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Patent number: 8046097Abstract: Methods for generating supports (30) for parts (50) produced by solid freeform fabrication (“SFF”) are disclosed. The method includes defining a plurality of layers (L) that make up the part, and for each layer, determining those regions (R) that require support. The method also includes merging the regions for the different layers (L) into one or more common regions that require support, and providing at least one support for each of the one or more common regions. The result is that fewer supports are used as compared to conventional SFF fabrication methods.Type: GrantFiled: September 17, 2008Date of Patent: October 25, 2011Assignee: 3D Systems, Inc.Inventors: Charles W. Hull, Rajeev Kulkarni, Medhi Mojdeh, Hongqing V. Wang, John Corbin West
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Publication number: 20110207057Abstract: A solid imaging apparatus and method employing sub-pixel shifting in multiple exposures of the digitally light projected image of a cross-section of a three-dimensional object on a solidifiable liquid medium. The multiple exposures provide increased resolution, preserving image features in a three-dimensional object and smoothing out rough or uneven edges that would otherwise be occur using digital light projectors that are limited by the number of pixels in an image projected over the size of the image. Algorithms are used to select pixels to be illuminated within the boundary of each image projected in the cross-section being exposed.Type: ApplicationFiled: June 9, 2010Publication date: August 25, 2011Applicant: 3D Systems, Inc.Inventors: Charles W. Hull, Jouni P. Partanen, Charles R. Speny, Patrick Dunne, Suzanne M. Scott, Dennis F. McNamara, Chris R. Manners
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Patent number: 8003039Abstract: A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build.Type: GrantFiled: September 17, 2007Date of Patent: August 23, 2011Assignee: 3D Systems, Inc.Inventors: Charles R. Sperry, Dennis F. McNamara, Jr., Suzanne M. Scott, Charles W. Hull, Mehdi Mojdeh
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Patent number: 7906061Abstract: A solid imaging apparatus and method employing build material transfer means effective to transfer solidifiable liquid build material from a first side of a radiation transparent build material carrier to a receiving substrate without entrapping air bubbles in layers of transferred solidifiable liquid build material and to cleanly separate the solidified build material from the radiation transparent build material carrier as each layer is formed during the layerwise building of a three-dimensional object. An expandable membrane forming an arcuate dome and a reciprocatible flexible film are employed to effect transfer of the solidifiable liquid build material.Type: GrantFiled: March 15, 2006Date of Patent: March 15, 2011Assignee: 3D Systems, Inc.Inventors: Jouni P. Partanen, Raymond M. Soliz, Dennis F. McNamara, Jr., Charles R. Sperry, Charles W. Hull
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Patent number: 7785093Abstract: An improved stereolithography apparatus for forming three-dimensional objects using multiple chambered resin vats and a quick disconnect mounting system to permit concurrent use of multiple photopolymer build materials and easy change over of resin vats is disclosed. The apparatus permits easy change over from multiple chambered vat use to single chamber vat use and vice versa or change over between multiple chambered vats.Type: GrantFiled: May 21, 2008Date of Patent: August 31, 2010Assignee: 3D Systems, Inc.Inventors: Scott B. Holmboe, Gary L. Reynolds, Matthew K. Stonesmith, Charles W. Hull, Abraham N. Reichental
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Patent number: 7771183Abstract: Solid imaging apparatus and methods for use are disclosed that reduce the amount of uncured solid imaging build material remaining on a completed build object following the completion of the solid imaging build process. The amount of uncured build material is reduced through the use of either an uncoating web that removes excess build material from the build object during the course of the building process or an ink jet source of build material that uses only as much build material as is necessary for the fabrication of the build part. Also disclosed is an imager assembly for use with such a solid imaging apparatus that incorporates two or more individual imagers in an array and accounts for variations in the intensity and alignment of adjacent imagers. The apparatus can be modified for semi-continuous operation and for integrating into a manufacturing operation, if desired.Type: GrantFiled: September 17, 2007Date of Patent: August 10, 2010Assignee: 3D Systems, Inc.Inventors: Charles W. Hull, Jouni Partanen, Ray Soliz, William J. Pappas
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Patent number: 7758799Abstract: A solid imaging apparatus and method employing sub-pixel shifting in multiple exposures of the digitally light projected image of a cross-section of a three-dimensional object on a solidifiable liquid medium. The multiple exposures provide increased resolution, preserving image features in a three-dimensional object and smoothing out rough or uneven edges that would otherwise be occur using digital light projectors that are limited by the number of pixels in an image projected over the size of the image. Algorithms are used to select pixels to be illuminated within the boundary of each image projected in the cross-section being exposed.Type: GrantFiled: April 1, 2005Date of Patent: July 20, 2010Assignee: 3D Systems, Inc.Inventors: Charles W. Hull, Jouni P. Partanen, Charles R. Sperry, Patrick Dunne, Suzanne M. Scott, Dennis F. McNamara, Chris R. Manners
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Patent number: 7731887Abstract: Solid imaging apparatus and methods for use are disclosed that reduce the amount of uncured solid imaging build material remaining on a completed build object following the completion of the solid imaging build process. The amount of uncured build material is reduced through the use of either an uncoating web that removes excess build material from the build object during the course of the building process or an ink jet source of build material that uses only as much build material as is necessary for the fabrication of the build part. Also disclosed is an imager assembly for use with such a solid imaging apparatus that incorporates two or more individual imagers in an array and accounts for variations in the intensity and alignment of adjacent imagers. The apparatus can be modified for semi-continuous operation and for integrating into a manufacturing operation, if desired.Type: GrantFiled: September 17, 2007Date of Patent: June 8, 2010Assignee: 3D Systems, Inc.Inventors: Charles W. Hull, Jouni Partanen, Ray Soliz, William J. Pappas, Mehdi Mojdeh
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Patent number: 7706910Abstract: Solid imaging apparatus and methods for use are disclosed that reduce the amount of uncured solid imaging build material remaining on a completed build object following the completion of the solid imaging build process. The amount of uncured build material is reduced through the use of either an uncoating web that removes excess build material from the build object during the course of the building process or an ink jet source of build material that uses only as much build material as is necessary for the fabrication of the build part. Also disclosed is an imager assembly for use with such a solid imaging apparatus that incorporates two or more individual imagers in an array and accounts for variations in the intensity and alignment of adjacent imagers. The apparatus can be modified for semi-continuous operation and for integrating into a manufacturing operation, if desired.Type: GrantFiled: September 17, 2007Date of Patent: April 27, 2010Assignee: 3D Systems, Inc.Inventors: Charles W. Hull, Jouni Partanen
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Publication number: 20100098835Abstract: There is provided methods and apparatus for compensation of intensity profiles of imagers used in three-dimensional modelers. The intensity profile of the actinic radiation projected from the imager is determined by a variety of techniques, including but not limited to manually operated sensors, exposed and scanned actinic radiation-sensitive paper, and intensity profilers. Once the intensity profile of the imager is determined, each layer of the solidifiable liquid material is cured by projecting a plurality of patterns (as opposed to a single pattern) defining the two-dimensional cross-section of the part being cured. The patterns vary in duration, number, and/or shape to correlate to the intensity profile so that a single layer of selectively cured solidifiable liquid material is cured with a substantially equivalent (or otherwise controlled) amount of actinic radiation per unit of surface area to provide generally controlled and consistent part quality.Type: ApplicationFiled: October 20, 2008Publication date: April 22, 2010Inventors: Hongqing V. Wang, Soon-Chun Kuek, Charles W. Hull, Richard Ora Gregory, II, Thomas Alan Kerekes
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Patent number: 7614866Abstract: A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build.Type: GrantFiled: September 17, 2007Date of Patent: November 10, 2009Assignee: 3D Systems, Inc.Inventors: Charles R. Sperry, Dennis F. McNamara, Jr., Suzanne M. Scott, Charles W. Hull, Jouni Partanen, Mehdi Mojdeh, William J. Pappas, Richard O. Gregory, II
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Publication number: 20090072447Abstract: Methods for generating supports (30) for parts (50) produced by solid freeform fabrication (“SFF”) are disclosed. The method includes defining a plurality of layers (L) that make up the part, and for each layer, determining those regions (R) that require support. The method also includes merging the regions for the different layers (L) into one or more common regions that require support, and providing at least one support for each of the one or more common regions. The result is that fewer supports are used as compared to conventional SFF fabrication methods.Type: ApplicationFiled: September 17, 2008Publication date: March 19, 2009Applicant: 3D Systems, Inc.Inventors: Charles W. Hull, Rajeev Kulkarni, Medhi Mojdeh, Hongqing V. Wang, John Corbin West
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Publication number: 20080226346Abstract: Solid imaging apparatus and methods for use are disclosed that reduce the amount of uncured solid imaging build material remaining on a completed build object following the completion of the solid imaging build process. The amount of uncured build material is reduced through the use of either an uncoating web that removes excess build material from the build object during the course of the building process or an ink jet source of build material that uses only as much build material as is necessary for the fabrication of the build part. Also disclosed is an imager assembly for use with such a solid imaging apparatus that incorporates two or more individual imagers in an array and accounts for variations in the intensity and alignment of adjacent imagers. The apparatus can be modified for semi-continuous operation and for integrating into a manufacturing operation, if desired.Type: ApplicationFiled: September 17, 2007Publication date: September 18, 2008Applicant: 3D Systems, Inc.Inventors: Charles W. Hull, Charles R. Sperry
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Publication number: 20080217818Abstract: An improved stereolithography apparatus for forming three-dimensional objects using multiple chambered resin vats and a quick disconnect mounting system to permit concurrent use of multiple photopolymer build materials and easy change over of resin vats is disclosed. The apparatus permits easy change over from multiple chambered vat use to single chamber vat use and vice versa or change over between multiple chambered vats.Type: ApplicationFiled: May 21, 2008Publication date: September 11, 2008Inventors: Scott B. Holmboe, Gary L. Reynolds, Matthew K. Stonesmith, Charles W. Hull, Abraham N. Reichental
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Publication number: 20080206383Abstract: Solid imaging apparatus and methods for use are disclosed that reduce the amount of uncured solid imaging build material remaining on a completed build object following the completion of the solid imaging build process. The amount of uncured build material is reduced through the use of either an uncoating web that removes excess build material from the build object during the course of the building process or an ink jet source of build material that uses only as much build material as is necessary for the fabrication of the build part. Also disclosed is an imager assembly for use with such a solid imaging apparatus that incorporates two or more individual imagers in an array and accounts for variations in the intensity and alignment of adjacent imagers. The apparatus can be modified for semi-continuous operation and for integrating into a manufacturing operation, if desired.Type: ApplicationFiled: September 17, 2007Publication date: August 28, 2008Inventors: Charles W. Hull, Jouni Partanen, Ray Soliz, William J. Pappas
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Publication number: 20080179786Abstract: A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build.Type: ApplicationFiled: September 17, 2007Publication date: July 31, 2008Inventors: Charles R. Sperry, Dennis F. Mcnamara, Suzanne M. Scott, Jason A. Rittenhour, Charles W. Hull, Mehdi Mojdeh
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Publication number: 20080179787Abstract: A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build.Type: ApplicationFiled: September 17, 2007Publication date: July 31, 2008Inventors: Charles R. Sperry, Dennis F. Mcnamara, Suzanne M. Scott, Charles W. Hull, Mehdi Mojdeh
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Publication number: 20080181977Abstract: A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build.Type: ApplicationFiled: September 17, 2007Publication date: July 31, 2008Inventors: Charles R. Sperry, Dennis F. McNamara, Suzanne M. Scott, Charles W. Hull, Mehdi Mojdeh
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Patent number: D575313Type: GrantFiled: January 17, 2007Date of Patent: August 19, 2008Assignee: 3D Systems, Inc.Inventors: Charles W. Hull, Charles R. Sperry, Suzanne M. Scott, Dennis F. McNamara, Jr., Jason Rittenhour