Light engines for photo-curing of liquid polymers to form three-dimensional objects

Patent metadata

Field	Value
Publication number	US-2018126646-A1
Application number	US-201815864510-A
Country	US
Kind code	A1
Filing date	Jan 8, 2018
Priority date	Oct 2, 2015
Publication date	May 10, 2018
Grant date	—

Abstract

Three-dimensional objects are formed by photo-curing a liquid polymer by exposure to a radiation, which radiation (e.g., at 410 nm) is provided by a collimated light source composed of an array of light emitting diode (LED) sources, an array of baffles, and an array of lenses. The baffles limit beam widths of each individual LED source in the array of LED, and the array of lenses is located one focal length from said array of LED sources.

First claim

What is claimed is:

1 . A method for forming three-dimensional objects by photo-curing a photo-curing liquid polymer exposed to a radiation, wherein said three-dimensional objects form by growth, due to the progressive curing of said photo-curing liquid polymer, in a space between a sheet transparent to said radiation and a supporting plate, that is, a portion already formed of said objects, said supporting plate progressively moving away from said transparent sheet, characterized in that said photo-curing liquid polymer undergoes curing by irradiation from a collimated light source.

2 . The method for forming three-dimensional objects according to claim 1 , characterized in that said collimated light source includes an array of light emitting diode (LED) sources.

3 . The method for forming three-dimensional objects according to claim 2 , characterized in that said LED sources emit radiation at a wavelength between 400-700 nm.

4 . The method for forming three-dimensional objects according to claim 2 , characterized in that said LED sources emit radiation at a wavelength of 410 nm.

5 . The method for forming three-dimensional objects according to claim 2 , characterized in that said collimated light source includes an array of baffles, and an array of lenses, said baffles arranged so as to limit a beam width of each individual LED source in the array of LED sources to approximately a diameter of a lens of the array of lenses, and the array of lenses is located one focal length from said array of LED sources.

6 . An apparatus for forming three-dimensional objects by photo-curing a photo-curing liquid polymer by exposure to a radiation, comprising a tank for containing the liquid polymer, and a collimated light source to emit said radiation by which said photo-curing liquid polymer undergoes curing through an opening in said tank.

7 . The apparatus for forming three-dimensional objects according to claim 6 , wherein said collimated light source comprises an array of light emitting diode (LED) sources, at least some of which LED sources are configured to emit radiation at a wavelength between 400-700 nm.

8 . The apparatus for forming three-dimensional objects according to claim 7 , wherein said collimated light source comprises an array of light emitting diode (LED) sources, at least some of which LED sources are configured to emit radiation at a wavelength of 410 nm.

9 . The apparatus for forming three-dimensional objects according to claim 8 , wherein said collimated light source further comprises an array of baffles and an array of lenses, said baffles arranged so as to limit a beam width of each individual LED source in the array of LED sources to approximately a diameter of a lens of the array of lenses, and the array of lenses is located one focal length from said array of LED sources.

10 . The apparatus for forming three-dimensional objects according to claim 7 , wherein said collimated light source is configured to constrain light emitted from each individual LED source in the array of LED sources to a spatial radiation pattern no wider than approximately 10 degrees radially from a central axis thereof.

11 . The apparatus for forming three-dimensional objects according to claim 7 , wherein one or more of said LED sources are configured to emit radiation at a plurality of wavelengths.

12 . The apparatus for forming three-dimensional objects according to claim 11 , wherein said collimated light source further comprises an array of baffles and an array of lenses, said baffles arranged so as to limit a beam width of each individual LED source in the array of LED sources to approximately a diameter of a lens of the array of lenses, and the array of lenses is located one focal length from said array of LED sources.

13 . The apparatus for forming three-dimensional objects according to claim 12 , wherein said collimated light source further comprises a liquid crystal display including a plurality of filters, each filter of the plurality of filters corresponding to one of said wavelengths of emitted radiation.

14 . The apparatus for forming three-dimensional objects according to claim 7 , wherein said collimated light source further comprises a liquid crystal display (“LCD”) said LCD positioned between said array of LEDs and an area within said tank within which an object undergoes fabrication by photo-curing of said photo-curing liquid polymer.

15 . The apparatus for forming three-dimensional objects according to claim 6 , wherein said collimated light source comprises a plurality of multifrequency light emitting diode (LED) sources, each of said LED sources configured to emit radiation at a plurality of wavelengths.

16 . The apparatus for forming three-dimensional objects according to claim 15 , wherein said plurality of LED sources are arranged in an array.

17 . The apparatus for forming three-dimensional objects according to claim 16 , wherein said collimated light source further comprises an array of baffles and an array of lenses, said baffles arranged so as to limit a beam width of each individual LED source in the array of LED sources to approximately a diameter of a lens of the array of lenses, and the array of lenses is located one focal length from said array of LED sources.

18 . The apparatus for forming three-dimensional objects according to claim 17 , wherein said collimated light source further comprises a liquid crystal display (“LCD”).

19 . The apparatus for forming three-dimensional objects according to claim 18 , wherein said LCD includes a plurality of filters, each filter of the plurality of filters corresponding to one of said wavelengths of emitted radiation.

20 . The apparatus for forming three-dimensional objects according to claim 6 , wherein said collimated light source comprises a plurality of light emitting diode (LED) sources, one or more of said LED sources comprising a plurality of LED emitters, each of said emitters configured to emit radiation at one or more wavelengths.

21 . The apparatus for forming three-dimensional objects according to claim 6 , wherein said collimated light source comprises:
a plurality of light emitting diode (LED) groups, and, corresponding to each of the LED groups, (i) a baffle configured to constrain and direct a first beam of electromagnetic radiation propagating from the LED group; (ii) a lens arrangement configured to receive the first beam of electromagnetic radiation, and project a second beam of electromagnetic radiation, said second beam of electromagnetic radiation being characterized by substantially parallel light rays.

22 . The apparatus for forming three-dimensional objects according to claim 21 , wherein each of the plurality of LED groups comprises more than one LED.

23 . The apparatus for forming three-dimensional objects according to claim 21 , wherein the lens arrangement comprises a first lens configured to receive the first beam of electromagnetic radiation, and project an intermediate beam of electromagnetic radiation; and a second lens configured to receive the intermediate beam from the first lens, and project the second beam of electromagnetic radiation towards the photo-curing liquid polymer.

24 . The apparatus for forming three-dimensional objects according to claim 23 , wherein the second lens has six side surfaces.

25 . The light source of claim 21 , wherein the baffle corresponding to each of the LED gr

Assignees

• Nexa3D Inc

Inventors

• Zitelli Gianni
• Reichental Avi N
• Tringali Luciano

Classifications

• B29C64/182

  in parallel batches · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y30/00 Primary

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B29C37/0067

  Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other (separating agents B29C33/60) · CPC title

• B29C64/135

  the energy source being concentrated, e.g. scanning lasers or focused light sources · CPC title