Patent ID: 6893804

Claim:
A method for stereolithographically fabricating a structure having at least one sidewall, comprising: submerging a base having an upper surface in liquid photopolymer material curable in response to exposure to electromagnetic radiation of a selected wavelength to a first depth over the upper surface; applying a beam of precisely focused coherent electromagnetic radiation in the form of an ultraviolet (UV) wavelength laser to selected regions of the curable liquid photopolymer material over the upper surface to at least partially consolidate the curable liquid photopolymer material in the selected regions over the upper surface and form a first layer of at least semisolid material defining at least a portion of a sidewall of a height substantially the same as the first depth on the upper surface, the first layer extending substantially parallel to the upper surface and having a greater lateral extent above the upper surface than adjacent thereto, wherein a crevice is defined between at least one side of the first layer and the upper surface and the crevice contains the curable liquid photopolymer material; removing the base from the curable liquid photopolymer material, leaving a quantity of the curable liquid photopolymer material in the crevice; orienting the base to permit access to the quantity of the curable liquid photopolymer material by the electromagnetic radiation in the form of an ultraviolet (UV) wavelength laser; and exposing the quantity of the curable liquid photopolymer material to the electromagnetic radiation in the form of an ultraviolet (UV) wavelength laser to at least partially consolidate at least an outer portion of the quantity of the curable liquid photopolymer material.