Method and apparatus for photo-curing photo-sensitive materials for the formation of three-dimensional objects using extraction plate with continuous motion

Abstract

Methods and apparatus for forming three-dimensional objects by photo-curing a photo-curing liquid polymer exposed to a radiation in a space between a base transparent to the radiation and a supporting plate. The supporting plate moves progressively, in some cases continuously, away from said transparent base during the printing process, and that movement is characterized in that it is tilting, swinging, rotating, and/or swirling in three-dimensional space, based on the print geometry, in order to expedite printing speed and resin propagation throughout the build area. In one embodiment, the movement may resemble a spiral or helical path from the standpoint of points around its circumference.

What is claimed is: 
     
         1 . A method for forming three-dimensional objects by photo-curing a photo-curing liquid polymer collected in a tank and exposed to a radiation, wherein said three-dimensional objects form by growth, due to a progressive curing of said photo-curing liquid polymer, in a space in said tank between a base of said tank that is transparent to the radiation and a supporting plate, and wherein said supporting plate continuously moves away in a swinging manner from said transparent base during the photo-curing of said photo-curing liquid polymer. 
     
     
         2 . The method of  claim 1 , wherein a motion of said supporting plate comprises translation with six degrees of freedom that varies in amplitude. 
     
     
         3 . The method of  claim 2 , wherein a hexapod effects said motion of the supporting plate. 
     
     
         4 . The method of  claim 2 , wherein a plurality of piezo actuators effects said motion of the supporting plate. 
     
     
         5 . The method of  claim 1 , wherein a motion of said supporting plate varies in frequency along one or more axes. 
     
     
         6 . An apparatus for forming three-dimensional objects by photo-curing a photo-curing liquid polymer through exposure to a radiation, said apparatus including a tank for collecting said photo-curing liquid polymer, a base of the tank being transparent to said radiation, a supporting plate configured to support an object being formed, and a controller that includes a processor and memory, the memory storing instructions that when executed by the processor, cause the supporting plate to continuously move away in a swinging manner from said transparent base during the photo-curing of said photo-curing liquid polymer. 
     
     
         7 . The apparatus of  claim 6 , wherein the controller is configured to control said supporting plate to continuously move away from the transparent base of the tank such that a motion of said supporting plate varies in amplitude along one or more axes. 
     
     
         8 . The apparatus of  claim 6 , wherein the controller is configured to control said supporting plate to continuously move away from the transparent base of the tank such that a motion of said supporting plate varies in frequency along one or more axes. 
     
     
         9 . The apparatus of  claim 6 , further comprising a hexapod, wherein the supporting plate is affixed to the hexapod, and wherein the controller is configured to control a movement of the hexapod, which in turn controls a movement of the supporting plate. 
     
     
         10 . The apparatus of  claim 6 , further comprising a plurality of piezo actuators, wherein the supporting plate is affixed to the plurality of piezo actuators, and wherein the controller is configured to control a movement of the plurality of piezo actuators, which in turn controls a movement of the supporting plate.