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Three dimensional (3D) printer with near instantaneous object printing using a … — Disney Enterprises, Inc. (US9656422B2)

Disney Enterprises, Inc. · Google Patents

Google Patents · Patents · License: Open Access

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disneyenterprises

patent, google patents, intellectual property, US9656422B2, Disney Enterprises, Inc., Lanny S. Smoot, en, 2017

ABSTRACT

Abstract

An apparatus or three dimensional (3D) printer is provided for generating a 3D object. The apparatus includes a print chamber and a liquid print matrix such as a photo-curing resin positioned in the print chamber. The apparatus includes an optical assembly focusing light into the print chamber in the form of a real image whose light initiates curing processes for a volume of the liquid print matrix to form the 3D object. The light focused into the print chamber has a wavelength within a wavelength curing range for the photo-curing resin. The real image may be formed using an optical assembly reflecting or redirecting and focusing light reflected from outer surfaces of an existing 3D object. The real image may also be provided in the form of a volumetric image displayed by a volumetric display device displaying planes of a 3D digital model or image of a 3D object.

Description

BACKGROUND

1. Field of the Description

The present invention relates, in general, to fabrication of three dimensional (3D) objects, and, more particularly, to a 3D printer adapted to provide nearly instantaneous printing via selective curing of a volume or portion of a photo-curing liquid, such as a photopolymer used to provide a fluid print matrix, with the cured volume/portion corresponding to a shape defined by a digital model of a 3D object or a direct, optically transferred, real image of the 3D object.

2. Relevant Background

Presently, 3D printing is a fabrication technology in which objects (or âprinted 3D objectsâ) are created from a digital file, which may be generated from software such as a computer aided design (CAD) program or another 3D modeling program or with a 3D scanner to copy an existing object that provides input to a 3D modeling program. To prepare the digital file for printing, software that is provided on a printer-interfacing computer or running on the 3D printer itself slices or divides the 3D model into hundreds to thousands of horizontal layers. Typically, only the outer wall or âshellâ is printed to be solid such that a shell thickness may be defined as part of modifying the 3D model for use in printing. Then, during printing, the shell is printed as a solid element while the interior portions of the 3D object are printed in a honeycomb or another infill design, e.g., to reduce the amount of material that has to be printed to provide the printed 3D object.

When the prepared digital file of the 3D object is uploaded into the 3D printer, the 3D printer creates or prints the object layer-by-layer. The 3D printer reads every slice (or 2D image) from the 3D model and proceeds to create the 3D object by laying down (or printing) successive layers of material until the entire object is created. Each of these layers can be seen as a thinly sliced horizontal cross section of the eventually completed or printed 3D object.

One of the more common 3D printer technologies uses fused deposition modeling (FDM) or, more generally, fused filament fabrication (FFF). FDM printers work by using a plastic filament (e.g., acrylonitrile butadiene styrene (ABS) or polylactic acid (PLA) provided as strands of filament that is 1 to 3 millimeters in diameter) that is unwound from a spool mounted onto the printer housing. The plastic filament is used to supply material to a print head with an extrusion nozzle, e.g., a gear pulls the filament off the spool and into the extrusion nozzle. The extrusion nozzle is adapted to turn its flow on and off. The extrusion nozzle (or an upstream portion of the print head) is heated to melt the plastic filament as it is passed into the extrusion nozzle so that it liquefies. The extrusion nozzle deposits the liquefied material in ultra fine lines, e.g., in lines that are about 0.1 millimeters across.

The extrusion head and its outlet are moved, in both horizontal and vertical directions to complete or print each layer of the 3D model, by a numerically controlled mechanism that is operated by control software running on the 3D printer, e.g., a computer-aided manufacturing (CAM) software package adapted for use with the 3D printer. The extruded melted or liquefied material quickly solidifies to form a layer (and to seal together layers of the 3D object), and the extrusion nozzle is then moved vertically prior to starting the printing of the next layer. This process is repeated until all layers of the 3D object have been printed.

Presently, 3D printing is extremely slow and time consuming. For example, it may take several hours to print a single 3D object even if the 3D object is relatively small (e.g., a 3D object that is only several inches in diameter and four to twelve inches tall). The 3D printing process that uses conventional 3D printers such as an FFF-based 3D printer is limited in its speed by the speed of the mechanism moving the print heads to each new position on a print layer. Hence, there remains a need for 3D printing methods, and 3D printers that implement such methods, that can generate a 3D object with increased speed while retaining or even improving on the quality of the 3D object.

A further problem with existing 3D printing techniques is the need for printing a support structure for any overhanging components of a 3D object. For example, a figurine of a human-like character may have its arms extending outward from its body or torso, and the arms would be cantilevered out from the body or overhang from the adjacent portions of the body. A support structure would have to be included in layers printed below or in advance of the overhanging components or portions of the 3D object to provide material upon which to print the overhanging components. This slows the printing process further as a significant amount of material may have to be printed to provide the support structure. Upon completion of printing, the 3D object requires finishing including removal of the support structure and, in some cases, sanding or polishing of the surfaces from which the support structure was removed to match the finish of adjacent surfaces. These additional steps also increase the production time of the 3D object and typically must be performed manually, which further increases fabrication costs and complexities. Hence, it would be desirable to provide a 3D printing method, and associated 3D printer, that can âprintâ a 3D object without the need for support structures for overhanging or cantilevered features.

SUMMARY

Briefly, a 3D printer (and corresponding 3D print method) is described that is adapted for âprintingâ or generating a 3D object in a manner that circumvents the layer-by-layer approach of conventional 3D printers that has significantly limited achievable printing speeds. In one design approach, the 3D printer is configured with the assumption that a physical âoriginalâ of a 3D object already exists (not just a digital model of a 3D object). In this first 3D printer design, the 3D printer acts as a high speed 3D copying machine because it uses an optical assembly or a set of optics that relays a volumetric real image (versus a virtual image) of the existing or target 3D object into a vat or container holding a volume of a photo-curing liquid or resin (e.g., a photopolymer or photo-cure liquid polymer).

The light associated with the volumetric real image, which is provided by one or more light sources directing light onto the existing or target 3D object, causes a portion or volume of the photo-curing liquid to be cured in a nearly instantaneous manner to generate or produce the entire 3D object (rather than slowly and layer-by-layer as with conventional 3D printers). The printed or produced 3D object, which is floating in or supported in the uncured liquid (e.g., a resin selected to be translucent to transparent to light and also viscous to support the in- process 3D object), can simply be lifted out of the vat/container. In several testing operations, a 3D printer using photo-curing liquids has been proven effective in generating 3D objects in several minutes or less rather than in several hours.

More particularly, an apparatus or 3D printer is provided for generating (or âprintingâ in a nearly instantaneous manner) a physical three dimensional (3D) object. The apparatus includes a print chamber with one or more sidewalls enclosing an interior void adapted for containing liquids, and a liquid print matrix (such as a photo-curing resin or liquid, which may be a photopolymer or the like) positioned in the interior void of the print chamber. The apparatus includes an optical assembly operating to focus light into the interior void of the print chamber to initiate curing processes for a volume of the liquid print matrix to form a 3D object. The light focused into the print chamber has a wavelength within a wavelength curing range for the photo-curing resin.

In some cases, the photo-curing resin is transmissive (e.g., translucent to transparent) of light having a wavelength in the wavelength curing range when in liquid form and when in hardened form. In the same or other embodiments, the photo-curing resin has a first specific gravity in a liquid form and a second specific gravity when cured, and the second specific gravity may be in a range of 90 to 110 percent of the first specific gravity. In this way, the formed 3D object is supported by adjacent uncured portions of the photo-curing resin in the print chamber, and no supporting structure has to be printed for cantilevered or overhanging object features (such as arms of a figurine).

In some embodiments of the apparatus, the light focused into the print chamber displays or provides a real image defining at least an outer shell of the 3D object. In these cases, the apparatus may include a light source illuminating outer surfaces of a target 3D object, and the optical assembly may include a first curved mirror receiving and reflecting light reflected from the outer surfaces of the target 3D object and further include a second curved mirror receiving and reflecting the light reflected from the first curved mirror as the light focused into the print chamber. The curved mirrors may be parabolic mirrors or reflectors to implement the apparatus.

In other implementations, the optical assembly may include a curved mirror, a light source directing light through the curved mirror, and a rotation mechanism rotating the curved mirror and the light source along a circular path about a target 3D object. In such an apparatus, the light source illuminates a plurality of vertical strips or lines of outer surfaces of the target 3D object as the light source and the curved mirror are moved along the circular path (e.g., to provide circumferential scanning). The curved mirror is configured to reflect light reflected from the outer surfaces of the target 3D object to provide the light focused into the print chamber, e.g., to provide a plurality of real image strips or slits of light that accumulate in the print chamber to provide a 3D real image of the target or existing 3D object being copied by operation of the apparatus.

Alternatives to curved mirrors may include refractive optical systems, which can include focusing lenses that are able to generate a real image of the object, or portions of the object, to be copied and are also able to focus it into the print chamber. It should be understood that although the attached figures illustrate embodiments using curved mirrors the analogous optical function accomplished with focusing lenses may be applied to successfully practice the invention(s) described herein.

In some embodiments of the apparatus or 3D printer, the real image displayed in the print chamber or vat is a volumetric image displayed by a volumetric display device. In such embodiments, the volumetric image can be defined by a 3D digital model that includes numerous frames used to sequentially display a plurality of real image display planes (or slices or layers of the overall 3D real image) in an image space coinciding with the interior void of the print chamber. This causes near-concurrent curing of a plurality of layers or planes within the liquid print matrix contained in the print chamber to form or print the 3D object.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a functional block diagram of a 3D printer (or 3D object generation system) during its use or operation to print or create a 3D object;

FIG. 2 is a flow diagram for a method of fabricating or printing a 3D object using a 3D printer of the present description such as the printer or object generation system of FIG. 1 ;

FIG. 3 is a side sectional and schematic view of a 3D printer with one exemplary optical assembly of the present description for providing a real image within a print chamber or vat of photo-curing resin;

FIG. 4 is a functional block view showing another 3D printer using an optical assembly including a rotating curved mirror to provide real images in a vat of photo-curing resin; and

FIG. 5 is a functional block drawing of a 3D printer using a volumetric display device to display a volumetric image in a volume of photo-curing resin in a print chamber or vat to form a 3D object.

DETAILED DESCRIPTION

The inventors recognized that existing or conventional 3D printers, such as FFF-based 3D printers, are extremely slow in printing a 3D object. Further, conventional 3D printers require that support structure must be printed for any overhanging portions of the 3D object, which further slows the printing process and requires post-printing fabrication steps to remove the support structure. To address these and other issues with conventional 3D printers, a 3D printer (or 3D object generation system) is taught herein that, instead of building up an object by creating successive layers, builds or forms a 3D object by concurrently curing a volume or portion of a photo-curing liquid (e.g., a photopolymer resin).

In some embodiments, an existing 3D object is copied, and the 3D printer includes a light source for illuminating the existing 3D object and an optical assembly for generating (reflecting and/or redirecting light) a real image from light reflected from the 3D object. The light corresponding to the real image is directed into a print chamber or vat of the photo-curing liquid (and this volume may be thought of as a liquid print matrix) for a time falling within a curing range for the photo-curing liquid, which is usually a relatively short time such as several minutes or less to provide nearly instantaneous âprintingâ or forming of a 3D object in the print chamber. The cured volume of the photo-cure liquid may correspond with the outer surfaces of the target or existing 3D object so as to provide a solid outer shell (e.g., a hollow 3D object is printed).

In other embodiments, a volumetric image is projected or displayed within the photo-curing liquid or resin of the print chamber using a real image source, which may provide spatially offset frames defining a 3D image or volumetric image of a target 3D object. For example, a volumetric display device may be used to provide the light used to cure the photo-curing resin (âthe curing lightâ), and, in this way, an outer shell may be formed or printed and, optionally, an internal structure or in-fill may also be formed. These embodiments of the 3D printer (and associated 3D print methods) may be used to create things that are not in the physical world or are not available for scanning or copying, and the 3D printers may be used to provide internal features/elements that cannot be copied by illuminating outer surfaces of an existing 3D object.

FIG. 1 is a functional block diagram of a 3D printer or 3D object generation system 100 during printing or building operations to create a <figure-callout id="180" label

BACKGROUND

1. Field of the Description

2. Relevant Background

SUMMARY

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a functional block diagram of a 3D printer (or 3D object generation system) during its use or operation to print or create a 3D object;

FIG. 2 is a flow diagram for a method of fabricating or printing a 3D object using a 3D printer of the present description such as the printer or object generation system of FIG. 1 ;

FIG. 4 is a functional block view showing another 3D printer using an optical assembly including a rotating curved mirror to provide real images in a vat of photo-curing resin; and

FIG. 5 is a functional block drawing of a 3D printer using a volumetric display device to display a volumetric image in a volume of photo-curing resin in a print chamber or vat to form a 3D object.

DETAILED DESCRIPTION

FIG. 1 is a functional block diagram of a 3D printer or 3D object generation system 100 during printing or building operations to create a 3D object 180 . As shown, the 3D printer 100 includes a print chamber or vat (or container) 110 with one or more sidewalls 112 that are adapted to contain a volume of a photo-curable resin (or a liquid print matrix) 114 , e.g., a volume that is greater than a volume of cured material required to obtain the generated 3D object 180 . The print chamber 110 may be rectangular in shape as shown or take another form such as a cylinder. The sidewalls 112 (or at least one sidewall) is transparent (or substantially so) to light to allow curing light 166 to be directed into a plurality of depths in the liquid print matrix 114 to allow light with sufficient brightness or energy to be provided in the interior void of the print chamber to cure a portion or volume of the matrix 114 to create the 3D object 180 .

The liquid print matrix 114 may take a plurality of forms to practice the 3D printer 100 . Generally, the liquid print matrix 114 is made up of a liquid that is light transmissive to allow a real image 170 to be created within the chamber 110 via light of a particular wavelength or energy. In some embodiments, the liquid used for the print matrix 114 is also chosen to have a minimum viscosity such that uncured portions of the liquid print matrix 114 function to support portions of the 3D object 180 as they are being formed or âprintedâ including any cantilevered or overhanging elements (e.g., overhanging features 144 on the target 3D object 140 ). In some cases, a print platform 116 is provided in the chamber 110 , and its upper surface 117 is used to support lower portions of the 3D object 180 as it is being formed by curing a portion or a volume of the liquid print matrix 114 . In some embodiments, the matrix 114 is provided by placing a volume of a photopolymer or other photo-curing resin or liquid into the print chamber or vat 110 .

Prior to turning to other components of the 3D printer, it may be useful to discuss more generally the process of curing the print matrix 114 to form a 3D object 180 . In a first approach, the 3D object 180 is generated by curing a subset or portion (or a volume) of the liquid print matrix 114 by projecting or displaying a 3D real image 170 in the vat 110 . To this end, particular properties are preferred for the photo-curing resin used to provide the liquid print matrix 114 . The resin can contain photoinitiators that absorb a certain wavelength of light, which initiates a crosslinking or polymerization process to happen where the real image is the brightest (e.g., outer surface of the 3D real image 170 ). This causes the polymer to physically harden or to be cured.

The resin can cure at either a visible or invisible wavelength. This depends on the wavelength absorbed by the photoinitiator. In prototype testing of a 3D printer like the one shown in FIG. 1 at 100 , the inventors cured photo-curing resin using blue light (wavelength of approximately 450 nm), violet light (wavelength of approximately 405 nm), and ultraviolet light (wavelength of approximately 365 nm). Resins that cure with invisible wavelengths are less affected by ambient light, which may make them useful in some 3D printers 100 .

The resin for print matrix 114 should be selected to both absorb and transmit light (be transmissive) at the curing wavelength. Higher absorption results in a faster rate of curing, but it also provides a shorter maximal curing depth in the print chamber 110 . The maximal curing depth determines the size of the largest object that can be cured. Higher transmission results in a slower rate of curing, but it also provides a greater maximal curing depth, which may be desirable in some 3D printers 100 . These two competing parameters of the photo-curing resin used for the print matrix 114 mean that there exists a tradeoff between curing rate and the maximum size for the cured object 180 .

The threshold for curing depends on the wavelength as opposed to the intensity of light. This is because the interaction between light and photoinitiators is quantum mechanical in nature. Light intensity only determines the rate of curing, but it has no bearing on whether the curing process is started. Assuming a sufficient density of photoinitiating molecules, the curing rate scales linearly with light intensity. Ideally, a resin would have a curing rate of zero below a certain intensity threshold. Such a resin would have a highly nonlinear curing rate as a function of intensity, ideally approaching a step function. Hence, it is desirable to have the 3D real image 170 be provided with curing light 166 of a wavelength suited to the particular photoinitiators of the photo-curing resin (e.g., within a predefined curing wavelength range) and also above a minimum curing intensity (with nearby portions of the matrix 170 being exposed to lower intensity light). In this way, the curing process will be initiated at the location of the 3D real image 170 at a relatively quick curing rate (e.g., several minutes or less) to limit or avoid curing of nearby portions of the matrix 114 .

In some preferred implementations of the 3D printer 100 , the specific gravities of the cured and uncured resin should be as close to each other as possible. This is to ensure that the position of the cured portion of the resin (i.e., the generated 3D object 180 ) does not change with respect to position of the liquid resin during the curing process as this ensures or facilitates creation of a distortion-free cured object 180 . Further, the indices of refraction of the cured and uncured resin should be as close to each other as possible. Depending on the shape of the object, it is highly likely that light will need to transmit through cured portions of resin. If the cured resin has a different index, light will refract and cause the image to distort. Still further, the photo-curing resin undergoes a chemical reaction during the curing process. This chemical reaction should be as isothermal as possible so as not to induce temperature gradients inside the vat 110 . Such temperature gradients would cause the uncured resin to flow, which distorts the cured object. In reality, most photo-curing resins are exothermic to some degree, and this can place an upper limit on curing rate. Hence, there is likely an inherent tradeoff between the curing rate and print resolution due to temperature gradients inside the vat 110 of resin 114 .

A different approach to selectively curing a portion or volume of the liquid print matrix 114 to generate the 3D object 180 is to use dual-wavelength excitation. In this embodiment of the 3D printer, the photo-curing resin used would include phosphors that absorb at two wavelengths and emit a third wavelength, the resin's curing wavelength. These phosphors would be mixed into the resin and emit the wavelength necessary for curing. Such phosphors exist and can be engineered for photo-curing applications. In this approach, two or more real images 170 can be projected 166 by an optical assembly 160 into the resin 114 using light 128 , 150 of different wavelength. These images 170 would need to be accurately superimposed to generate the 3D object 180 . In this implementation of the 3D printer 100 , only resin 114 exposed to both wavelengths will cure, which both enhances curing rate and the maximum possible size of the cured object. The other aforementioned resin properties still apply in this approach.

Referring again to FIG. 1 , the 3D printer 100 is shown to include one or more light sources 120 that are selectively operated or controlled by a controller 122 with control signals 124 (wired or wireless communications). The controller 122 may be a computer or computing device including a processor(s) that manages input/output (I/O) devices to allow user input (e.g., to initiate a print operation, to select a curing time, and so on). The processor of controller 122 may also manage one or more storage devices/memory that store executable instructions (e.g., a printing program) to generate the control signals 124 . The control signals 124 may include or define a curing or exposure time for the matrix 114 , and curing times for each of a plurality of potential photo-curing resins used to provide the liquid print matrix 114 may be stored in memory or data storage of the controller 122 .

The light source(s) 120 is chosen to output illuminating light 128 with a wavelength falling in a curing wavelength range for the photo-curing resin 114 in the print chamber 110 . Also, the illuminating light 128 provide by the light source(s) 120 is of an intensity that is greater than a predefined intensity needed to achieve a desired curing rate of the photo-curing resin 114 (e.g., great enough intensity to account for intensity losses through the 3D printer components to the 3D real image 170 ). The light source(s) 120 preferably is adapted to illuminate the entire outer surface 142 of a 3D object 140 targeted (or a target 3D object) for copying with the 3D printer 100 , and, in this regard, two, three, or more bulbs or other components, positioned around or encircling the 3D object, may be included in light source 120 to direct the illuminating light 128 onto each and every side (except a bottom or base side in this example) of the 3D object 140 .

The 3D printer 100 is shown to include a support or alignment stand 130 upon Which the target or existing 3D object 140 is positioned. For example, the stand 130 may include a planar upper surface 131 with one or more alignment markings provided to indicate a print position for the 3D object 140 to ensure light 150 reflected from its outer surface(s) 142 is directed by the optical assembly or optics 160 as curing light 166 fully into the liquid print matrix 114 in the print vat 110 (e.g., wholly place the 3D real image 170 within the liquid print matrix 114 to print a 3D object matching that of the target 3D object 140 ). One or more of the outer surfaces 142 of the 3D object 140 may be treated to provide equal or more equal reflection of the illuminating light 128 so that all the surfaces 142 are more equally represented in the object-reflected light 150 (e.g., to provide more equal illumination of all surfaces 142 of the object 140 and avoid some that may absorb more light 128 , which may result in poorer quality 3D object 180 as portions of the real image 170 may not be as bright (or as well defined)).

The target 3D object 140 is shown to include one or more overhanging (or cantilevered) features 144 , with wings and arms shown in FIG. 1 , and, significantly, these features 144 do not require the generated 3D object 180 to include support structures as a portion or volume of the liquid print matrix 114 associated with the 3D real image 170 is nearly instantaneously cured and because the uncured portions of the matrix 114 underneath and nearby the overhanging features of the 3D object 180 act to support these forming or in-process features (e.g., due to the like specific gravities of the cured and uncured portions of the photo-curing resin chosen to provide the liquid print matrix 114 as discussed above).

The 3D printer 100 further includes an optical assembly or optics 160 that includes components that are selected and arranged to receive the object-reflected light 150 from the surfaces 142 of the target 3D object, and, in response, to reflect or direct light (i.e., curing light) 166 into the liquid print matrix 180 so as to display or project a 3D real image 170 . As discussed above, the light 166 providing the 3D real image 170 has a brightness or intensity that is greatest at its portions corresponding to the outer surfaces 142 of the target 3D object 140 and that is greater than some predefined minimum intensity to achieve a desired curing rate. Also, the light 166 providing the 3D real image 170 is at a wavelength within a curing wavelength range for the photo-curing resin of the liquid print matrix 114 .

The image 170 is a ârealâ image versus a âvirtualâ image. In optics, a real image is an image which is located in the plane of convergence for the light rays that originate from a given object. Examples of real images include the image seen on a cinema screen (the source being the projector), the image produced on a detector in the rear of a camera, and the image produced on an eyeball retina (the camera and eye focus light through an internal convex lens). A real image occurs where rays converge, whereas a virtual image occurs where rays only appear to converge. In other words, real images, such as 3D real image 170 , are formed by actual light rays and, thus, can be used to cure the photo-curing resin or photopolymer 114 in the print vat 110 . The optical assembly 160 may include concave mirrors and converging lenses when the object 140 is placed further away from the mirror/lens than the focal point, but this real image 170 may be inverted in the 3D printer or additional components or design steps may be taken to make the 3D real image not inverted if useful for obtaining a better quality 3D object (e.g., one with a missing side or surface in a base portion as shown in FIG. 1 rather than at an upper and likely exposed surface of the 3D object 180 ). If a viewer sees a reflected/redirected image 170 from the side in which the light rays leave the lens or mirror of the optical assembly 160 , a real image is one on the same side of the lens or mirror as the viewer, whereas a virtual image is one on the opposite side of the lens or mirror.

FIG. 2 illustrates a 3D print method (or object generation method) 200 of the present description, which may be carried out by operation and/or use of the 3D printer 100 of FIG. 1 . The method 200 starts at 210 such as with the selection of a photo-curing resin for use in forming 3D objects by exposing a portion or volume of the photo-curing resin concurrently to light in the form of or defining a real image. Further, an optical assembly may be selected for creating real images of 3D objects in step 210 along with one or more light sources for illuminating all or most of the outer surfaces of the 3D objects with light that is useful for curing the selected photo-curing resin.

At 220 , the method 200 continues with providing a volume of the photo-curing resin in a container. The volume of resin is chosen to provide enough material to form a chosen 3D object (e.g., the bigger the 3D object the more resin will be required and can be provided in step 220 ). The container provided in step 220 includes at least one wall or portion of a wall that is transparent (or substantially transmissive) to light in the wavelength range required for curing the photo-curing resin. Typically, one or more sidewalls of the container will be formed of a glass or clear plastic, ceramic, or the like to provide the desired level of light transmission.

At step 230 , a 3D object is chosen for copying, and the 3D object is positioned at a predefined position and with a predefined alignment or orientation relative to the optical assembly of the 3D printer. In general, the 3D object printing location is one that allows light reflected from its surfaces to be received by the optical assembly at a desired level of intensity and then redirected with adequate focus into the photo-curing resin in the container.

At step 240 , the method 200 continues with illuminating outer surfaces of the 3D object with light having a wavelength(s) that is useful for initiating the curing process of the photo-curing resin in the 3D printer's container or print chamber. For example, the photo-curing resin may have a curing wavelength range of 350 nm to 500 nm, and the light provided in step 240 may fall within this range, e.g., be light from a blue light source, from a violet light source, from an ultraviolet (UV) source, a combination of such sources, or the like. The light sources chosen to perform the illuminating step 240 are selected to provide light of an adequate intensity, even considering losses in the system, to exceed a predefined minimum light intensity to achieve a desired curing rate. Further, the light sources are positioned relative to the 3D object's print location/position to direct light onto all surfaces that are to be copied or included in the printed/generated 3D object (e.g., all surfaces, all surfaces except a base or supporting surface upon which the 3D object stands or is supported, and the like).

At step 250 , the optical assembly is used to generate a real image or 3D real image of the 3D object illuminated in step 240 by receiving light reflected from the 3D object's surfaces and reflecting and/or redirecting the light. The generated 3D real image is displayed or projected within the photo-curing resin in the container via the transparent wall (or portion of a sidewall) of the container. Due to the wavelength of the light used to form the real image, the curing process is initiated, and this process generally occurs at the highest rate where the real image is the brightest (i.e., at the portions of the real image corresponding to the outer surfaces of the 3D object illuminated in step 240 with a properly designed optical assembly). At step 260 , the method 200 continues with a determination of whether or not a time falling within the curing time range for the photo-curing resin has elapsed (e.g., this may vary with the intensity of the light but may range from 0 to 5 minutes or the like). If not, the method 200 continues at 260 .

If the time has elapsed and the resin is fully cured by the real image light, the method 200 continues at 270 with halting the illumination of the 3D object with the light sources. Step 270 may also include removing the cured resin from the container, in other words, removing the generated or printed 3D object from the uncured photo-curing resin in the container. At step 280 , the method 200 may continue with replenishing the photo-curing resin in the container such as by providing a replacement volume for that used to form the 3D object, by removing all resin and providing a new volume of the same or a different photo-curing

CLAIMS

Claims ( 16 )

We claim:

1. An apparatus for generating a physical three dimensional (3D) object, comprising:

a print chamber with one or more sidewalls enclosing an interior void adapted for containing liquids;

a liquid print matrix positioned in the interior void of the print chamber;

an optical assembly operating to focus light into the interior void of the print chamber to initiate curing processes for a volume of the liquid print matrix to form a 3D object, wherein the light focused into the print chamber displays a real image defining at least an outer shell of the 3D object; and

a light source illuminating outer surfaces of a target 3D object,

wherein the optical assembly comprises a first curved mirror receiving and reflecting light reflected from the outer surfaces of the target 3D object, and

wherein the optical assembly further comprises a second curved mirror receiving and reflecting the light reflected from the first curved mirror as the light focused into the print chamber.

2. The apparatus of claim 1 , wherein the liquid print matrix comprises a volume of a photo-curing resin.

3. The apparatus of claim 2 , wherein the photo-curing resin comprises a photopolymer.

4. The apparatus of claim 2 , wherein the light focused into the print chamber has a wavelength within a wavelength curing range for the photo-curing resin.

5. The apparatus of 4 , wherein the photo-curing resin is transmissive of light having a wavelength in the wavelength curing range when in liquid form and when in hardened form.

6. The apparatus of claim 4 , wherein the photo-curing resin has a first specific gravity in a liquid form and a second specific gravity when cured and wherein the second specific gravity is in a range of 90 to 110 percent of the first specific gravity, whereby the formed 3D object is supported by adjacent uncured portions of the photo-curing resin in the print chamber.

7. An apparatus for generating a physical three dimensional (3D) object, comprising:

a print chamber with one or more sidewalls enclosing an interior void adapted for containing liquids;

a liquid print matrix positioned in the interior void of the print chamber; and

an optical assembly operating to focus light into the interior void of the print chamber to initiate curing processes for a volume of the liquid print matrix to form a 3D object,

wherein the light focused into the print chamber displays a real image defining at least an outer shell of the 3D object,

wherein the optical assembly comprises curved mirror, a light source directing light through the curved mirror, and a rotation mechanism rotating the curved mirror and the light source along a circular path about a target 3D object, wherein the light source illuminates a plurality of vertical strips of outer surfaces of the target 3D object as the light source and the curved mirror are moved along the circular path, and wherein the curved mirror reflects light reflected from the outer surfaces of the target 3D object to provide the light focused into the print chamber.

8. The apparatus of claim 7 , wherein the liquid print matrix comprises a volume of a photo-curing resin.

9. The apparatus of claim 8 , wherein the photo-curing resin comprises a photopolymer.

10. The apparatus of claim 8 , wherein the light focused into the print chamber has a wavelength within a wavelength curing range for the photo-curing resin.

11. The apparatus of 24 , wherein the photo-curing resin is transmissive of light having a wavelength in the wavelength curing range when in liquid form and when in hardened form.

12. The apparatus of claim 10 , wherein the photo-curing resin has a first specific gravity in a liquid form and a second specific gravity when cured and wherein the second specific gravity is in a range of 90 to 110 percent of the first specific gravity, whereby the formed 3D object is supported by adjacent uncured portions of the photo-curing resin in the print chamber.

13. A 3D printer, comprising:

a tank containing a volume of a photo-curing liquid;

a light source directing light, having a wavelength that initiates curing of the photo-curing liquid, onto a 3D object; and

optics receiving portions of the light reflected from surfaces of the 3D object and, in response, displaying a real image within the photo-curing liquid,

wherein the optics include a first parabolic mirror positioned to focus upon the 3D object and further include a second parabolic mirror receiving the reflected light from the surfaces of the 3D object via reflection from the first parabolic mirror, and

wherein the second parabolic mirror is configured to focus within the tank to provide display the real image.

14. The 3D printer of claim 13 , wherein the photo-curing liquid comprises a photopolymer with a first specific gravity when liquid and a second specific gravity when cured to a solid that is within 10 percent of the first specific gravity and wherein the photopolymer has a first transmissivity to light when liquid and a second transmissivity that is substantially equal to the first transmissivity to light when cured to a solid.

15. A 3D printer, comprising:

a tank containing a volume of a photo-curing liquid;

a light source directing light, having a wavelength that initiates curing of the photo-curing liquid, onto a 3D object; and

optics receiving portions of the light reflected from surfaces of the 3D object and, in response, displaying a real image within the photo-curing liquid,

wherein the optics comprise a curved mirror and light source rotating circumferentially about the 3D object and to direct a plurality of linear scan strips into the tank that in combination provide the real image.

16. The 3D printer of claim 15 , wherein the photo-curing liquid comprises a photopolymer with a first specific gravity when liquid and a second specific gravity when cured to a solid that is within 10 percent of the first specific gravity and wherein the photopolymer has a first transmissivity to light when liquid and a second transmissivity that is substantially equal to the first transmissivity to light when cured to a solid.

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