Patent ID: 7758799

Claim:
A method for forming a three-dimensional object layer-by-layer comprising the steps of: a. receiving three-dimensional CAD data of an object to be built; b. processing the three-dimensional CAD data to receive slice data representative of cross-sectional layers of the object; c. converting the slice data into bit-map data; d. delivering a layer of photocurable solidifiable liquid medium to an imaging area via a radiation transparent carrier; e. projecting an image representative of cross-sectional image data from a radiation source through the radiation transparent carrier to selectively illuminate pixels in an image plane in a first exposure to selectively solidify the layer of photocurable solidifiable liquid medium; f. shifting the image by a subpixel amount to a new image position; g. adjusting the image to match the new image position to define an adjusted image; and h. projecting the adjusted image to selectively illuminate pixels in the image plane in a second exposure to selectively solidify the same layer of photocurable solidifiable liquid medium.