Apparatus and method for profiling a beam

Claim 1

An apparatus for determining a cure parameter in a stereolithography device for producing a three-dimensional object from a medium solidifiable to varying depths upon varying exposure to a reaction means having portions of varying intensity, said reaction means operating and moving in a prescribed pattern onto the medium comprising: a sensor for sensing the intensity of a portion of the reaction means when that portion of the reaction means is incident on the sensor; means for relatively displacing the sensor and the reaction means such that substantially all portions of the reaction means may be sensed by the sensor; means for determining net exposure of the medium based on the sensing of intensity by the sensor and movement of the reaction means; and means for calculating the cure parameter of the medium based upon the determined net exposure and known properties of the medium.

Claim 2

An apparatus for determining a cure parameter in a stereolithography device for producing a three-dimensional object from a medium solidifiable to varying depths upon varying exposure to a reaction means having portions of varying intensity, said reaction means operating and moving in a prescribed pattern onto the medium comprising: a sensor for sensing the intensity of a portion of the reaction means when that portion of the reaction means is incident on the sensor; means for relatively displacing the sensor and the reaction means such that substantially all portions of the reaction means may be sensed by the sensor; means for determining net exposure of the medium based on the sensing of intensity by the sensor and movement of the reaction means; and means for calculating the cure parameter of the medium based upon the determined net exposure and known properties of the medium.

Claim 12

A method for calculating a cure parameter in a stereolithography apparatus for producing a three-dimensional object from a medium solidifiable to varying depths upon varying exposure to a reaction means having portions of varying intensity, said reaction means operating and moving in a prescribed pattern on the medium comprising the steps of: a) directing a portion of the reaction means onto a sensor and sensing the intensity of the portion of the reaction means; b) relatively displacing the reaction means and sensor such that a different portion of the reaction means impinges upon the sensor; c) repeating steps a) and b) until the intensity of substantially all portions of the reaction means have been sensed; d) calculating an exposure of the medium based on the sensed intensity of and movement of the reaction means; and e) calculating the cure parameter of the medium based upon the exposure of the medium by the reaction means and known characteristics of the medium.

Claim 13

A method for calculating a cure parameter in a stereolithography apparatus for producing a three-dimensional object from a medium solidifiable to varying depths upon varying exposure to a reaction means having portions of varying intensity, said reaction means operating and moving in a prescribed pattern on the medium comprising the steps of: a) directing a portion of the reaction means onto a sensor and sensing the intensity of the portion of the reaction means; b) relatively displacing the reaction means and sensor such that a different portion of the reaction means impinges upon the sensor; c) repeating steps a) and b) until the intensity of substantially all portions of the reaction means have been sensed; d) calculating an exposure of the medium based on the sensed intensity of and movement of the reaction means; and e) calculating the cure parameter of the medium based upon the exposure of the medium by the reaction means and known characteristics of the medium.

Claim 16

A method for determining a cure depth of an area element of a medium in a stereolithography device for producing a three-dimensional object on substantially a layer by layer basis, wherein the medium is solidifiable to a depth which is determined by exposure of the medium to a reaction means operating in a prescribed pattern at a working surface of the medium comprising the steps of: sensing an intensity of a portion of the reaction means when that portion of the reaction means is incident on a sensor; relatively displacing the sensor and the reaction means such that substantially all portions of the reaction means may be sensed by the sensor; calculating net exposure in the area element of the medium at approximately the working surface by summing the intensity of each portion of the reaction means that is passed over the area element, wherein the intensity of each portion is multiplied by a time over which each portion of the reaction means is incident on the area element; and calculating the cure depth of the area element of the medium provided by the exposure from the reaction means and known curing properties of the medium.

Claim 17

A method for determining a cure depth of an area element of a medium in a stereolithography device for producing a three-dimensional object on substantially a layer by layer basis, wherein the medium is solidifiable to a depth which is determined by exposure of the medium to a reaction means operating in a prescribed pattern at a working surface of the medium comprising the steps of: sensing an intensity of a portion of the reaction means when that portion of the reaction means is incident on a sensor; relatively displacing the sensor and the reaction means such that substantially all portions of the reaction means may be sensed by the sensor; calculating net exposure in the area element of the medium at approximately the working surface by summing the intensity of each portion of the reaction means that is passed over the area element, wherein the intensity of each portion is multiplied by a time over which each portion of the reaction means is incident on the area element; and calculating the cure depth of the area element of the medium provided by the exposure from the reaction means and known curing properties of the medium.

Claim 18

A method for determining a scanning speed necessary to achieve a desired cure parameter in a stereolithography device for producing a three-dimensional object from a medium solidifiable to varying depths upon varying exposure to a reaction means operating in a prescribed pattern onto a surface of the medium, comprising the steps of: determining a required exposure to obtain the desired cure parameter in an area element of the medium, based on characteristics of the medium; generating a profile of an intensity of the reaction means; specifying a scanning direction and path of the reaction means as it crosses the area element of the medium; calculating an integrated intensity profile of the reaction means in a direction parallel to the scanning direction by utilizing the profile of the intensity of the reaction means and the known scanning direction; and calculating the scanning speed at which the reaction means must move across the area element, such that the integrated intensity profile of the reaction means appropriately exposes the area element, by utilizing the integrated intensity profile of the reaction means, the path of the reaction means, and the required exposure.

Claim 19

A method for determining a scanning speed necessary to achieve a desired cure parameter in a stereolithography device for producing a three-dimensional object from a medium solidifiable to varying depths upon varying exposure to a reaction means operating in a prescribed pattern onto a surface of the medium, comprising the steps of: determining a required exposure to obtain the desired cure parameter in an area element of the medium, based on characteristics of the medium; generating a profile of an intensity of the reaction means; specifying a scanning direction and path of the reaction means as it crosses the area element of the medium; calculating an integrated intensity profile of the reaction means in a direction parallel to the scanning direction by utilizing the profile of the intensity of the reaction means and the known scanning direction; and calculating the scanning speed at which the reaction means must move across the area element, such that the integrated intensity profile of the reaction means appropriately exposes the area element, by utilizing the integrated intensity profile of the reaction means, the path of the reaction means, and the required exposure.

Claim 23

An apparatus for determining an intensity profile of a reaction means in a stereolithography system for producing a three-dimensional object substantially on a layer by layer basis at a surface of a building medium, comprising: a sensor for sensing the intensity of part of the reaction means when that part of the reaction means is incident on the sensor; and a single directing means for directing each part of the reaction means onto the sensor to determine the intensity of each part of the reaction means, thereby determining the intensity profile for the reaction means and for directing the reaction means onto the surface of the medium for producing the object.

Claim 24

An apparatus for determining an intensity profile of a reaction means in a stereolithography system for producing a three-dimensional object substantially on a layer by layer basis at a surface of a building medium, comprising: a sensor for sensing the intensity of part of the reaction means when that part of the reaction means is incident on the sensor; and a single directing means for directing each part of the reaction means onto the sensor to determine the intensity of each part of the reaction means, thereby determining the intensity profile for the reaction means and for directing the reaction means onto the surface of the medium for producing the object.

Claim 25

An apparatus for determining a scanning speed necessary to achieve a desired cure parameter in a stereolithography device for producing a three-dimensional object from a medium solidifiable to varying depths upon varying exposure to a reaction means operating in a prescribed pattern onto a surface of the medium comprising: means for determining a required exposure to obtain the desired cure parameter in a area element of the medium, based on curing characteristics of the medium; means for generating a profile of an intensity of the reaction means; means for specifying a scanning path and direction of the reaction means as it crosses the area element of the medium; means for calculating an integrated intensity profile of the reaction means in a direction parallel to the scanning direction by utilizing the profile of the intensity of the reaction means and the scanning direction; and means for calculating the scanning speed at which the reaction means must move across the area element, such that the integrated intensity profile of the reaction means appropriately exposes the area element, by utilizing the integrated intensity profile of the reaction means, the scanning path and the required exposure.

Claim 26

An apparatus for determining a scanning speed necessary to achieve a desired cure parameter in a stereolithography device for producing a three-dimensional object from a medium solidifiable to varying depths upon varying exposure to a reaction means operating in a prescribed pattern onto a surface of the medium comprising: means for determining a required exposure to obtain the desired cure parameter in a area element of the medium, based on curing characteristics of the medium; means for generating a profile of an intensity of the reaction means; means for specifying a scanning path and direction of the reaction means as it crosses the area element of the medium; means for calculating an integrated intensity profile of the reaction means in a direction parallel to the scanning direction by utilizing the profile of the intensity of the reaction means and the scanning direction; and means for calculating the scanning speed at which the reaction means must move across the area element, such that the integrated intensity profile of the reaction means appropriately exposes the area element, by utilizing the integrated intensity profile of the reaction means, the scanning path and the required exposure.