SLA PATENT SUMMARY

PATENT NO: 4,575,330

INVENTOR: Charles W. Hall

INTRODUCTION
In today’s landscape of innovation, the primary focus revolves around enhancing
the tools used to craft three-dimensional objects from liquid mediums.
Stereolithography, in particular, stands out as it applies lithographic techniques to
efficiently produce three-dimensional objects in a rapid, reliable, precise, and cost-
effective manner. This process involves continuous evaluation and iterative
refinement until the desired outcome is achieved. Traditional plastic manufacturing
primarily relies on injection molding, reserved for high-volume production due to
its intricate setup and high tooling expenses. Recent developments have introduced
highly advanced methods for constructing three-dimensional objects within a liquid
medium, utilizing controlled light emissions focused within the medium’s three-
dimensional volume. The present invention combines stereolithography, the art of
crafting three-dimensional objects through lithographic techniques, with
computer-generated graphics – a widely used approach. This fusion occurs
alongside computer-assisted design and assembly, enabling the direct
transformation of computer instructions into three-dimensional objects. This
technology serves as an assembly line, suitable for molding prototypes and models
during product development or as a medium for artistic expression. Essentially, this
innovation facilitates the creation of a diverse range of structural forms.

SUMMARY
The creation of intricate structures is now significantly simplified through the
utilization of computer assistance to generate customized commands and transmit
them to the stereolithographic object-forming subsystem. It’s essential to note that
various forms of compatible stimuli can be employed for a treatable liquid medium,
including particle bombardment, chemical reactions facilitated by material spraying
through a mask or via inkjet technology, or radiation beyond ultraviolet light,
without deviating from the innovation’s core principles. For instance, within this
invention, a body of liquid medium capable of solidifying upon prescribed
stimulation is initially placed within a suitable container to define a designated
working surface. On this working surface, successive cross-sectional layers can be
systematically produced. This defined working surface is then subjected to a
suitable form of stimulating influence, such as a pinpoint of UV light or equivalent,
to concretely shape sparse yet robust individual layers, with each layer representing
an adjacent cross-section of the desired three-dimensional object. Consequently,
the solid material formed at the working surface is separated, allowing fresh liquid
to flow in, and a portion of this fresh liquid is transformed into solid material by the
modified UV light point. This process defines another layer, firmly adhering to the
surrounding material, especially the preceding layer. The prolonged gap between
design and production is eliminated once the design is finalized, enabling
immediate part production. Overall production and part costs should align with
existing injection molding costs for short runs, if not lower, including labor
expenses. Thanks to the ease of part creation, stereolithography can expand the
use of plastic components into many areas traditionally dominated by metal or
alternative materials. It also allows for the cost-effective production of plastic
prototypes before committing to the production of more expensive metal or
alternative material parts.