WO2014037826A1

WO2014037826A1 - Device for producing three dimensional objects

Info

Publication number: WO2014037826A1
Application number: PCT/IB2013/055903
Authority: WO
Inventors: Jose Carlos De Oliveira VELOSO
Original assignee: VELOSO, Jose Carlos De Oliveira Junior
Priority date: 2012-09-04
Filing date: 2013-07-18
Publication date: 2014-03-13

Abstract

The application provides an apparatus module for manufacturing a three-dimensional object. The apparatus module comprises a stationary machine bed, a movable trough with a transparent portion, a tilting actuator and at least one hinging element connecting the stationary machine bed and the trough with each other. The transparent portion of the trough is provided with a stretchable transparent sheet of polymer material that is inwardly directed. In use, the movable trough retains a liquid material that solidifies under the influence of light.

Description

DEVICE FOR PRODUCING THREE DIMENSIONAL OBJECTS

This application relates a device for producing a three- dimensional (3D) object by solidifying a liquid material in layers.

German Patent document 93 19 405 Ul describes an apparatus for manufacturing a three-dimensional object by solidifying in layers a liquid material which can be solidified under the in- fluence of light at locations corresponding to the cross- section of the object. The apparatus has a trough for holding the liquid material, a light source, a device for projecting the area to be exposed onto the surface according to the cross-section of the object to be solidified, a positioning device for positioning the object to be formed relative to the trough. The surface of the material to be exposed is covered by a transparent plate, which is provided in the bottom of the trough . US 7 052 263 discloses an apparatus for manufacturing a three- dimensional object. The apparatus includes a trough and an exposure and projection unit. The trough is used for holding material, which can be solidified under the influence of light. The trough has on its lower side a transparent plate, wherein a resilient layer is provided on the transparent plate and on sidewalls of the trough, and the solidified material detaches more easily from the resilient layer than the transparent plate. The exposure and projection unit serves to expose and solidify the material in the trough from below through the transparent plate.

It is an objective of the application to provide an improved apparatus for producing a three-dimensional object. It is believed the apparatus can be improved by increasing the speed of producing the three-dimensional object.

The application provides an apparatus module for manufacturing a three-dimensional (3D) object. The apparatus module is also called a 3D printer.

The surface of the 3D object can be represented by mathematical representations. Using the mathematical representations, the apparatus module can produce the 3D object.

The apparatus module includes a stationary machine bed, a movable trough with a transparent portion, together with a tilting actuator and at least one hinging element. The tilting actuator and the at least one hinging element connect the stationary machine bed and the trough with each other.

The transparent portion of the trough is provided with a stretchable transparent sheet of polymer material that is inwardly directed. In other words, the stretchable transparent sheet is directed towards an inner portion of the trough.

In use, the movable trough retains or contains a liquid mate- rial that solidifies under the influence of light. A light source can transmit a pattern of light that corresponds to a layer of the three-dimensional object to the liquid material, wherein the light pattern traveIs via the stretchable trans- parent sheet to the liquid material .

The stretchable transparent sheet is inwardly directed such that any wrinkle in the stretchable transparent sheet is removed and a portion of the stretchable transparent sheet, which receives the light for solidifying a layer of liquid material, is flat. The solidified layer of liquid material is positioned next to the stretchable transparent sheet and to a movable platform. The tilting actuator and the at least one hinging element are used to separate easily and quickly the stretchable transparent sheet from the said solidified layer while the solidified layer remains attached to the movable platform. This separation allows another layer of liquid material to be solidified for producing another layer of the 3D object, wherein the new- ly solidified layer is attached to the previously solidified layer .

The tilting actuator acts to tilt the tough together with the stretchable transparent sheet. In particular, the stretchable transparent sheet is tilted relative to the solidified layer of liquid material. This tilting causes the stretchable transparent sheet to peel away from the said solidified layer. This peeling action requires only a small amount of force, wherein one end portion of the stretchable transparent sheet separates from the solidified layer. The separated end portion then enlarges until the entire stretchable transparent sheet is separated from the solidified layer. This manner of separation also allows the separating to be done quickly while allowing the solidified layer to be attached to the movable platform.

This is unlike most other apparatuses for producing 3D objects, which separates the solidified layer from its light pattern window by pulling the solidified layer in a direction, which is vertical to the light pattern window. A rather large force is required for separation because the separating force needs to overcome the pressure of the liquid material. This separating also slow in order to allow solidified layer to remain attached to the movable platform. For ease of implementing the tilting action of trough, the actuator is often provided at one end portion of the trough while the hinging element is often provided at an opposite end portion of the trough.

The hinging element can comprise a level adjustment mechanism, a spring element, and a vertical slot. The level adjustment mechanism is used for adjusting a height of a portion of the trough while the spring element pushes the trough and the stationary machine bed apart. The vertical slot prevents the said portion of the trough for rising or ascending beyond a maximum pre-determined height.

The actuator can comprise an electric motor, a level adjustment mechanism, a spring element, and a nut screwed onto a screw. The screw is attached to the electric motor. In use, the level adjustment mechanism changes a height of a portion of the trough. The nut contacts the trough and is used for adjusting an actuation distance of the trough.

This actuator provides two states. In the first state, the spring element pushes the trough and the stationary machine bed apart such that the trough is level or horizontal. In the second state, the motor actuates the screw element and the nut element towards the motor by a pre-determined actuation distance. The actuation also causes the nut to push one part of the trough towards motor. In effect, this causes the trough to tilt .

The stretchable transparent sheet often comprise at least one material selected from a group consisting of Polytetrafluoro- ethylene (PTFE) , polychlorotrifluoroethylene (PCTFE) , per- fluoroalkoxy polymer (PFA) , fluorinated ethylene-propylene (FEP) , polyethylenetetrafluoroethylene (ETFE) , and polyeth- ylenechlorotrifluoroethylene (ECTFE) . These materials are usually resistant to chemicals of the liquid material. In other words, these materials essentially do not chemically interact with the liquid material. In particular, these materials are resistant to solvents in photopolymers of the liquid material. In other words, these solvents do not damage these materials. These materials also do not normally stick to the liquid material, wherein the sticking can lead to stoppages of the apparatus module. Furthermore, these materials are often able to withstand heat from a heater element.

The stretchable transparent sheet is often connected to the trough by a clamping mechanism, which pushes and secures outer edges of the stretchable transparent sheet to an opening of the trough.

The apparatus module often includes a projecting platform for inwardly directing the stretchable transparent sheet. This directing acts to remove any wrinkle in the stretchable transparent sheet.

The projecting platform can include a round portion for contacting the stretchable transparent sheet to stretch the stretchable transparent sheet.

The stretchable transparent sheet can include a round outline such that the projecting platform extends or stretches parts of the stretchable transparent by essentially the same amount.

The stretchable transparent sheet is often provided at a bottom portion of the trough for ease of implementation.

The apparatus module can include a heater element for heating the liquid material. The heating changes the viscosity of the liquid material. In other words, the heating element can be used for selecting a viscosity of the liquid material which is suitable for quick and fast production of the 3D object. The application also provides another apparatus for manufacturing a three-dimensional object. The apparatus includes a movable platform, a positioning device, and the above apparatus module that includes a tilting actuator. In use, the movable platform attaches to a solidified layer of liquid ma- terial while the positioning device positions the movable platform .

The apparatus often includes a control unit being connected to the movable platform and to the tilting actuator for allowing the control unit to control these parts.

The application also provides a further apparatus for manufacturing a three-dimensional object. The apparatus includes the above apparatus module that includes a tilting actuator and a light source. The light source is used for transmitting a pattern of light to a stretchable transparent sheet of the apparatus module, wherein the light pattern corresponds to a layer of the 3D object. The apparatus often includes a control unit being connected to the light source and to the tilting actuator for allowing the control unit to control these parts.

The application also provides another apparatus for manufac- turing a three-dimensional object. The apparatus includes a movable platform, a positioning device, the above apparatus module that includes a tilting actuator, and a light source. In use, the movable platform attaches to a solidified layer of liquid material while the positioning device positions the movable platform. The light source transmits a pattern of light to a stretchable transparent sheet of the apparatus mod- ule, wherein the light pattern corresponds to a layer of the 3D object.

The apparatus often includes a control unit being connected to the light source, to the positioning device, and to the tilt- ing actuator for controlling these parts.

The apparatus can provide a forming position and a release position. In the forming position, the positioning device positions the movable platform such that a layer of the liquid ma- terial is provided between the movable platform and the stretchable transparent sheet. The light source transmits a pattern of light that corresponds to a layer of the three- dimensional object via the stretchable transparent sheet to the layer of liquid material. In the release position, the tilting actuator tilts a trough of the apparatus module such that one portion of the stretchable transparent sheet separates from the layer of liquid material.

The application also provides a method for manufacturing a three-dimensional object. The method includes a step of providing a liquid material in a trough, wherein the liquid material solidifies under the influence of light. A movable platform is then positioned above a stretchable transparent sheet of the trough such that layer of the liquid material is provided between the movable platform and the stretchable transparent sheet. A pattern of light that corresponds to a layer of the three-dimensional object is later transmitted via the stretchable transparent sheet to the layer of liquid material. The trough is afterward tilted such that one portion of the stretchable transparent sheet separates from the layer of liquid material.

The method can include a step of heating the liquid material for changing the viscosity of the liquid material.

Fig. 1 illustrates a side cross-sectional view of an apparatus for manufacturing a three-dimensional object,

Fig. 2 illustrates an exposure and projection unit of the apparatus of Fig. 1,

Fig. 3 illustrates the exposure and projection unit projecting an image onto a liquid material of the apparatus of Fig. 1,

Fig. 4 illustrates a levelling mechanism of the apparatus of Fig. 1,

Fig. 5 illustrates a polymerisation chart of the liquid material of Fig. 3,

Fig. 6 illustrates a solidified polymer layer of the liquid material of Fig. 3,

Fig. 7 illustrates a chart of adhesive force of the solidified polymer of Fig. 6,

Fig. 8 illustrates an extension chart of a stretchable

transparent sheet of Fig. 6,

Fig. 9 illustrates a first stage of a peeling mechanism of the solidified polymer of Fig. 6, and

Fig. 10 illustrates a second stage of the peeling mechanism of Fig. 9.

In the following description, details are provided to describe embodiments of the application. It shall be apparent to one skilled in the art, however, that the embodiments may be practiced without such details. Some parts of the embodiments, which are shown m the Figs., have similar parts. The similar parts have the same names or similar part numbers with a prime symbol or with an alphabetic symbol. The description of such similar parts also applies by reference to other similar parts, where appropriate, thereby reducing repetition of text without limiting the disclosure.

Fig. 1 shows an apparatus 10 for manufacturing a three- dimensional (3D) object 5.

As better seen in Fig. 1 and Fig. 3, the apparatus 10 comprises a trough module 12 that is placed below a carrier platform 13 and above a light generation unit 14. The trough module 12 holds a polymerisation liquid material 15 while the carrier platform 13 is attached to a height adjustment device 17. An opaque hood covers both the carrier platform 13 and the trough module 12. The opaque hood is not shown in the Figs. 1 and 3.

In one implementation, the carrier platform 13 comprises glass although other material is also possible.

Referring to Fig. 1, the light generation unit 14 includes a housing unit 19 with a top cover 21 that includes an aperture 22. The housing unit 19 encloses an exposure and projection unit 25.

As seen in Fig. 2, the exposure and projection unit 25 includes a light source 30 as well as a mask production device 33. The mask production device 33 has an optical semiconductor chip with a large number of movable micro-mirrors 35. The exposure and projection unit 25 also includes a reflector 37 and a light blocking unit 38. Both the exposure and projection unit 25 and the light blocking unit 38 are connected to a central computer unit 51, as illustrated in Fig. 1. Referring to Fig. 1, the trough module 12 includes a trough unit 55 being attached to a pair of plates, namely a movable upper plate 57 and a stationary lower plate 58. The trough unit 55 is placed above the upper plate 57 and it is fixed to the upper plate 57 while the upper plate 57 is movably attached to the lower plate 58. The lower plate 58 is fixed to a stationary bedding 59. The trough unit 55 has sidewalls 61 and a stretchable transparent sheet 63. The sidewalls 61 are placed above the transparent sheet 63. The sidewalls 61 project upward from outer areas of a top surface of the transparent sheet 63. The side- walls 61 and an inner area of the top surface of the transpar- ent sheet 63 form a container for holding the said liquid material 15.

The upper plate 57 is placed below the transparent sheet 63. The upper plate 57 is secured to the trough unit 55 by clamps 68 such that the upper plate 57 and the trough unit 55 are fixed to each other. The fixing also presses the sidewalls 61 onto the outer areas of the transparent sheet 63 and presses the outer areas of the transparent sheet 63 onto the upper plate 57.

The upper plate 57 also has a circular hollow center 70. A transparent plate 72, which is placed above the hollow center 70, covers the first hollow center 70. The transparent plate 72 is placed below the transparent sheet 63. The transparent plate 72 is seated on a circular platform 71, which rests on a top surface of the upper plate 57.

A heater element 75 is placed below the transparent sheet 63. Similarly, the lower plate 58 has another hollow center 77, which is placed below the first hollow centre 70 of the upper plate 57.

A level adjustment stopper 78, which is fixed to one end of the lower plate 58, blocks a one end of an upper surface of the upper plate 57. The stopper 78 includes an arm 81 and a level stopper screw 80 that is screwed to an upper part of the arm 81. A lower part of the arm 81 is fixed to the lower plate 58 while the stopper screw 80 blocks one end the upper surface of the upper plate 57. A spring 82 is placed between one end area of a lower surface of the upper plate 57 and one end area of an upper surface of the lower plate 58. The spring 82 contacts these end areas and it pushes the upper plate 57 away from the lower plate 58 while the upper plate 57 is blocked by the stopper screw 80.

Similarly, as better seen in Figs. 1 and 4, a second level adjustment stopper 78a is fixed to a second end of the lower plate 58 and it blocks a second end of the upper surface of the upper plate 57. The stopper 78a includes a second arm 81a and a second level stopper screw 80a that is screwed to an upper part of the second arm 81a. A lower part of the second arm 81a is fixed to the lower plate 58 while the second level stopper screw 80a blocks a second area of the upper surface of the upper plate 57. A second spring 82, which is placed between a second end area of the lower surface of the upper plate 57 and a second end area of the upper surface of the lower plate 58, contact these second end areas and pushes these second end areas away from each other.

A tilting module 85 is attached to one end of the lower plate 58. The tilting module 85 comprises a tilting motor 87 and an actuating arm 86, which is movable in the vertical direction. The tilting motor 87 is attached to an outer area of a lower surface of the lower plate 58. The actuating arm 86 includes a shaft 88 and an adjustable nut 90. A lower part of the shaft 88 is attached to the tilting motor 87. The shaft 88 is inserted in an arm opening of the lower plate 58 and an arm opening of the upper plate 57. The nut 90 is screwed to an upper part of the shaft 88. The nut 90 is positioned above the upper surface of the upper plate 57. The nut 90 is sized such that it is larger than the said opening of the upper plate 57, wherein the nut 90 cannot be inserted into the said arm open- ing of the upper plate 57.

A middle part of the shaft 88 has an adjustable blocking plate 91 that is screwed to the middle part of the shaft 88 such that the blocking plate 91 is placed between the upper plate 57 and a recess 92 of the lower plate 58. The shaft 88 is inserted in the spring 82, wherein the spring 82 presses against the blocking plate 91 and the upper plate 57.

A seen in Fig. 4, one end of the upper plate 57 has a blocking screw that is inserted into an aperture 95 of the arm 81a.

The height adjustment device 17 holds the carrier platform 13 above the transparent sheet 63 of the trough unit 55, wherein the carrier platform 13 is movable in the vertical direction. The carrier platform 13 is also adapted for holding a 3D object 5. The height adjustment device 17 is also connected to the central computer unit 51.

In use, a user instructs the central computer unit 51 to pro- duce a 3D object 5.

The central computer unit 51 generates a digitalized or half tone process geometrical layer data of the desired 3D object 5, which is selected by the user. The central computer unit 51 also instructs the height adjustment device 17 to adjust the height of the carrier platform 13 The height adjustment allows a layer of the polymerisation liquid material 15 with a pre-determined thickness to form between a bottom surface of the carrier platform 13 and an upper surface of the transparent sheet 63 of the trough unit 55.

The mask production device 33 acts as a digitally controlled mirror system for producing an image a layer of the desired 3D object 5. The mirror system is also called a digital mirror display. The central computer unit 51 adjusts the orientation -of the micro-mirrors 35 of the mask production device 33 according the layer data generated by the computer unit 51 for producing the said layer image.

The light source 30 is used for emitting the visible light rays 76. The micro-mirrors 35 receive these light rays 76 from the light source 30 and reflect the received light rays 76 ac- cording to their adjusted orientation to project an image of a layer of the desired 3D object 5 onto the bottom surface of the liquid material 15, which is placed in the trough unit 55.

The light blocking unit 38 allows the light rays 76 from the micro-mirrors 35 to transmit out of the light generation unit 14 for a pre-determined duration, as instructed by the central computer unit 51.

The heater element 75 is placed such that the heater element 75 does not block these visible light rays 76 for projecting the image of the object layer.

The second hollow centre 77 and the first hollow centre 70 are also sized and are aligned to allow the liquid material 15 within the trough unit 55 to receive these light rays 76, which projects the said image of the object layer. These light rays 76 travel from the exposure and projection unit 25, to the second hollow centre 77, to the first hollow centre 70, to the transparent plate 72, to the transparent sheet 63, and to a bottom surface of the liquid material 15.

The liquid material 15 contains a monomer, which polymerises under the influence of visible light. The polymerisation re- fers to a chemical reaction in which two or more molecules combine to form larger molecules. The liquid material 15 also has a light blocking agent that prevents the received light rays 76 from penetrating the liquid material 15 to solidify inner parts of the liquid material 15.

The transparent sheet 63 may include material, such as Poly- tetrafluoroethylene (PTFE) , polychlorotrifluoroethylene (PCT- FE) , perfluoroalkoxy polymer (PFA) , fluorinated ethylene- propylene (FEP) , polyethylenetetrafluoroethylene (ETFE) , and polyethylenechlorotrifluoroethylene (ECTFE) .

These materials allow the transparent sheet 63, which is contact with the liquid material 15, to be resistant to chemicals of the liquid material 15. Put differently, the transparent sheet 63 essentially does not chemically interact with the liquid material 15. In particular, the transparent sheet 63 is resistant to solvents in photopolymers of the liquid material 15. These solvents do not damage the transparent sheet 63. These materials do not enable the transparent sheet 63 to stick to the liquid material 15. The sticking can lead to stoppages of the apparatus 10. These materials are also able to withstand heat from the heater element 75. Certain material may not be included in the transparent sheet 63.

The photopolymer of the liquid material 15 can stick to acryl- ic material. Additionally, solvents in the photopolymers can damage the acrylic material after a short period of use. The acrylic material can also be damaged by heat from the heating element 75. The photopolymer can also stick to optical quartz material or borosilicate glass material.

The solvents in the photopolymers can also damage silicone material after a short period. The photopolymer can also stick to the silicone material while the silicone material can also be damaged by heat from the heater element 75.

The photopolymer can also stick to polycarbonate material. The polycarbonate material can be damaged by from the heater ele- ment 75.

In effect, the exposed liquid material 15 solidifies to form parts of the desired 3D object 5. A bottom part of the liquid material 15, which is placed above and in contact with the transparent sheet 63 of the trough unit 55, receives the light rays 76 from the micro-mirrors 35. The exposed portions of the bottom part solidify to form a layer of the desired 3D object 5. The gap between the transparent sheet 63 of the trough unit 55 and the carrier platform 13 is selected such the solidified layer contacts the bottom surface of the carrier platform 13 as well as contacting the top surface of the transparent sheet 63. The carrier platform 13 includes a material, wherein the solidified layer, which attaches to the carrier platform 13, does not come off the carrier platform 13 upon moving of the carrier platform 13.

5 For producing the next solidified layer of the 3D object 5,

the carrier platform 13 with the already solidified layer is separated further away from the transparent sheet 63 by a predetermined distance. The next solidified layer would contact and attach to the already solidified layer and to the transit) parent sheet 63.

The platform 71 enables the transparent plate 72 to project towards the carrier platform 13, such that the transparent plate 72 presses against the transparent sheet 63, wherein the

15 pressing stretches the transparent sheet 63. The stretching

removes any wrinkle in the transparent sheet 63. During application of heat by the heating element 75, the transparent sheet 63 may also expand. This expansion is taken up by the stretching such that the transparent sheet 63 to remain flat

20 against the transparent plate 72. The circular shape of the

transparent plate 72 allows an even application of force on the transparent sheet 63.

The lower plate 58, which is fixed to the stationary bedding 25 59, does not move.

A user turns the level stopper screws 80 and 80a to adjust the level of the upper plate 57 while the springs 82 and 82a pushes the upper plate 57 against the level stopper screws 80 and 30 80a.

The tilting module 85 provides a rest state and a tilted state. In the rest state, the tilted motor 87 does not actuate the shaft 88. In the tilted state, the tilted motor 87 actuates the shaft 88 together with the nut 90 towards the tilted motor 87, wherein the nut 90 pushes a portion of the upper surface of the upper plate 57 towards the lower plate 58. This movement also moves the blocking plate 91 towards the lower plate 58, wherein at a pre-determined position of the blocking plate 91, the lower plate 58 blocks the blocking plate 91. This blocking also stops the downward movement of the pushed por- tion of the upper plate 57. At the same time, the spring 82a and the blocking screw 93 of the upper plate 57 together with the aperture 95 act as hinge for the upper plate 57. The spring 82a pushes the one end of the upper plate 57 away from the lower plate 58 while at a pre-determined position of the blocking screw 93, the aperture 57 blocks the upward movement of the blocking screw 93.

Fig. 6 shows adhesive force ε binding the solidified layer of the liquid material 15 to the transparent sheet 63.

Fig. 7 shows the adhesive force ε being proportional to the surface area of contact between said solidified layer and the transparent sheet 63. Fig. 8 shows the stretchable transparent sheet 63 being stretched or extended by a pre-determined length δ, beyond which it will break.

Fig. 9 shows a surface area X of the solidified layer of the liquid material 15 being bound or attached to the transparent sheet 63. Upon tilting of the transparent sheet 63, the surface area X of contact between said solidified layer and the transparent sheet 63 reduces by distance "d" as illustrated in Fig. 10.

In effect, one end part of the transparent sheet 63 peels and separates away from the solidified layer. This manner of separating the transparent sheet 63 from the solidified layer requires only a small force. This is unlike other application, wherein the separation occurs without this peeling action. Instead, a vertical separation force is exerted to move the solidified layer of the liquid material 15 away from the transparent sheet 63. The amount of the vertical separation force required for this is rather large for overcoming pressure of the liquid material 15. With the peeling action provided by this embodiment, this large force is not needed.

This is important as avoidance of the large force allows the 3D object 5 to be produced quicker and more easily. In one implementation of this embodiment, the production time of the 3D object 5 improves by 10 times.

The heater element 75 serves to heat the liquid material 15 between the transparent sheet 63 of the trough unit 55 and the carrier platform 13. The heating adjustment acts to adjust viscosity of the liquid material 15 for faster production of the 3D object 5. This is because a higher than needed viscosity would slow the cycle time of producing the 3D object 5.

The opaque hood prevents light rays from other source from reaching the liquid material 15.

A method of producing the 3D object 5 is described below. The height adjustment device 17 positions the carrier platform 13 in the trough unit 55 in such a way that a pre-determined precise gap remains between the carrier platform 13 and the transparent sheet 63 of the trough unit 55

The light blocking unit 38 opens, which allows the exposure and projection unit 25 to project a first layer of the image of the cross-section of the 3D object 5 onto the bottom surface of the liquid material 15. The light blocking unit 38 closes after a pre-determined duration. The exposed areas of the liquid material 15 harden to form a solidified layer, which sticks to the bottom surface of the carrier platform 13 and the upper surface of the transparent sheet 63. After this, the trough unit 55 is tilted, wherein the tilting caused the transparent sheet 63 to peel away from the solidified layer while the solidified layer continues to stick to the carrier platform 13. The carrier platform 13 is then lifted higher by a pre-determined distance.

The above step for forming the next solidified layer is then performed. The next solidified layer sticks to the first solidified layer and to the transparent sheet 63. The above step of peeling is afterward done to remove the transparent 63 from the next solidified layer.

The heater element 75 is also powered on for adjusting the temperature of the liquid material 15. The 3D object 5 is then formed a layer at a time.

These steps allow the 3D object 5 to produce quickly with less separation force. The embodiments can also be described with the following lists of features or elements being organized into items. The respective combinations of features, which are disclosed in the item list, are regarded as independent subject matter, respectively, that can also be combined with other features of the application .

An apparatus module for manufacturing a three-dimensional object, the apparatus module comprising

a stationary machine bed,

a movable trough with a transparent portion for retaining a liquid material that solidifies under the influence of light,

a tilting actuator and at least one hinging element connecting the stationary machine bed and the trough with each other,

wherein the transparent portion of the trough is provided with a stretchable transparent sheet of polymer material that is inwardly directed.

2. The apparatus module according to item 1, wherein

the actuator is provided at one end portion of the trough and the hinging element is provided at an opposite end portion of the trough.

.e apparatus module according to item 1 or 2, wherein .e hinging element comprises a level adjustment mecha- sm, a spring element and a vertical slot.

The apparatus module according to one of the above- mentioned items, wherein

the actuator comprises an electric motor, a level adjustment mechanism, a spring element, and a nut being screwed onto a screw, the screw is attached to the electric motor The apparatus module according to one of the above- mentioned items, wherein

the stretchable transparent sheet comprises at least one material selected from a group consisting of Polytetra- fluoroethylene (PTFE) , polychlorotrifluoroethylene (PCT- FE) , perfluoroalkoxy polymer (PFA) , fluorinated ethylene- propylene (FEP) , polyethylenetetrafluoroethylene (ETFE) , and polyethylenechlorotrifluoroethylene (ECTFE) .

The apparatus module according to one of the above- mentioned items, wherein

the stretchable transparent sheet is connected to the trough by a clamping mechanism.

The apparatus module according to one of the above- mentioned items further comprising

a projecting platform for inwardly directing the stretchable transparent sheet.

The apparatus module according to one of the above- mentioned items, wherein

the projecting platform comprises a round portion for contacting the stretchable transparent sheet to stretch the stretchable transparent sheet.

The apparatus module according to item 8, wherein the stretchable transparent sheet comprises a round outline such that the projecting platform extends stretched parts of the stretchable transparent by essentially the same amount.

The apparatus module according to one of the above- mentioned items, wherein the stretchable transparent sheet is provided at a bottom portion of the trough. The apparatus module according to one of the above- mentioned items further comprising

a heater element for heating the liquid material. n apparatus for manufacturing a three-dimensional object, the apparatus comprising

a movable platform for attaching to a solidified layer of liquid material,

a positioning device for positioning the movable platform, and

an apparatus module according to one of the above- mentioned items comprising a tilting actuator. The apparatus according to item 12 further comprising a control unit being connected to the movable platform and to the tilting actuator. n apparatus for manufacturing a three-dimensional object, the apparatus comprising

an apparatus module according to one of items 1 to 11 comprising a tilting actuator and

a light source for transmitting a pattern of light to a stretchable transparent sheet of the apparatus module . The apparatus according to item 14 further comprising a control unit being connected to the light source and to the tilting actuator. n apparatus for manufacturing a three-dimensional object, the apparatus comprising a movable platform for attaching to a solidified layer of liquid material,

a positioning device for positioning the movable platform,

an apparatus module according to one of items 1 to 11 comprising a tilting actuator, and

a light source for transmitting a pattern of light to a stretchable transparent sheet of the apparatus module . The apparatus according to item 16 further comprising a control unit being connected to the light source, to the positioning device, and to the tilting actuator. The apparatus according to item 16 or 17, wherein the apparatus provides a forming position and a release position ,

in the forming position, the positioning device positions the movable platform such that a layer of the liquid material is provided between the movable platform and the stretchable transparent sheet, the light source transmits a pattern of light that corresponds to a layer of the three-dimensional object via the stretchable transparent sheet to the layer of liquid material,

in the release position, the tilting actuator tilts a trough of the apparatus module such that one portion of the stretchable transparent sheet separates from the layer of liquid material. A method for manufacturing a three-dimensional object comprising

providing a liquid material in a trough, wherein the liquid material solidifies under the influence of light, positioning a movable platform above a stretchable transparent sheet of the trough such that a layer of the liquid material is provided between the movable platform and the stretchable transparent sheet,

transmitting a pattern of light that corresponds to a layer of the three-dimensional object via the stretchable transparent sheet to the layer of liquid material, and

tilting the trough such that one portion of the stretchable transparent sheet separates from the layer of liquid material.

20. The method according to item 19 further comprising

heating the liquid material.

Although the above description contains much specificity, this should not be construed as limiting the scope of the embodiments but merely providing illustration of the foreseeable embodiments. The above stated advantages of the embodiments should not be construed especially as limiting the scope of the embodiments but merely to explain possible achievements if the described embodiments are put into practice. Thus, the scope of the embodiments should be determined by the claims and their equivalents, rather than by the examples given.

Reference numbers

5 3D object

10 apparatus

12 trough module

13 carrier platform

14 light generation unit

15 polymerisation liquid material

17 height adjustment device

19 housing unit

21 top cover

22 aperture

25 exposure and projection unit

30 light source

33 mask production device

35 movable micro-mirror

37 reflector

38 light blocking unit

51 central computer unit

55 trough unit

57 movable upper plate

58 stationary lower plate

59 stationary bedding

61 sidewall

63 transparent sheet

68 clamp

70 first hollow centre

71 platform

72 transparent plate

75 heater element

76 light ray

77 second hollow centre

78 level adjustment stopper

78a level adjustment stopper

80 stopper screw 80a stopper screw

81 arm

81a arm

82 spring

82a spring

85 tilting module

87 tilting motor

86 actuating arm

88 shaft

90 nut

91 blocking plate

92 recess

93 blocking screw

95 aperture

X area surface d distance

Claims

1. An apparatus module for manufacturing a three-dimensional object, the apparatus module comprising

a stationary machine bed,

2. The apparatus module according to claim 1, wherein

3. The apparatus module according to claim 1, wherein

the hinging element comprises a level adjustment mechanism, a spring element and a vertical slot.

4. The apparatus module according to claim 1, wherein

the actuator comprises an electric motor, a level adjustment mechanism, a spring element, and a nut being screwed onto a screw, the screw is attached to the electric motor.

5. The apparatus module according to claim 1, wherein

The apparatus module according to claim 1, wherein the stretchable transparent sheet is connected to the trough by a clamping mechanism.

The apparatus module according to claim 1 further comprising

a projecting platform for inwardly directing the stretchable transparent sheet.

The apparatus module according to claim 1, wherein the projecting platform comprises a round portion for contacting the stretchable transparent sheet to stretch the stretchable transparent sheet.

The apparatus module according to claim 8, wherein the stretchable transparent sheet comprises a round outline such that the projecting platform extends stretched parts of the stretchable transparent by essentially the same amount.

The apparatus module according to claim 1, wherein the stretchable transparent sheet is provided at a bottom portion of the trough.

The apparatus module according to claim 1 further comprising

a heater element for heating the liquid material.

12. An apparatus for manufacturing a three-dimensional object, the apparatus comprising a movable platform for attaching to a solidified layer of liquid material,

a positioning device for positioning the movable platform, and

an apparatus module according to claim 1 comprising a tilting actuator.

The apparatus according to claim 12 further comprising a control unit being connected to the movable platform and to the tilting actuator.

An apparatus for manufacturing a three-dimensional object, the apparatus comprising

an apparatus module according to claim 1 comprising a tilting actuator and

a light source for transmitting a pattern of light to a stretchable transparent sheet of the apparatus module .

The apparatus according to claim 14 further comprising a control unit being connected to the light source and to the tilting actuator.

a movable platform for attaching to a solidified layer of liquid material,

a positioning device for positioning the movable platform,

an apparatus module according to claim 1 comprising a tilting actuator, and

a light source for transmitting a pattern of light to a stretchable transparent sheet of the apparatus module . The apparatus according to claim 16 further comprising a control unit being connected to the light source, to the positioning device, and to the tilting actuator.

The apparatus according to claim 16, wherein

the apparatus provides a forming position and a release position ,

in the release position, the tilting actuator tilts a trough of the apparatus module such that one portion of the stretchable transparent sheet separates from the layer of liquid material.

A method for manufacturing a three-dimensional object comprising

transmitting a pattern of light that corresponds to a layer of the three-dimensional object via the stretchable transparent sheet to the layer of liquid material, and tilting the trough such that one portion of the stretchable transparent sheet separates from the layer liquid material.

The method according to claim 19 further comprising heating the liquid material.