US 10,350,823 B2Granted

Dual precursor resin systems for additive manufacturing with dual cure resins

AssigneeCarbon, Inc.

InventorsJason P. Rolland, Julia D. Cushen

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Abstract

A method of forming a dual cure three-dimensional object by additive manufacturing may be carried out by mixing a first precursor liquid and a second precursor liquid to produce a polymerizable liquid comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component (e.g., a second reactive component) that is different from the first component (e.g., that does not contain a cationic photoinitiator, or is further solidified by a different physical mechanism, or further reacted, polymerized or chain extended by a different chemical reaction). In the foregoing: (i′) at least one reactant of the second solidifiable component is contained in the first precursor liquid, and (ii′) at least one reactant or catalyst of the second solidifiable component is contained in the second precursor liquid. Once mixed, the three-dimensional object may be formed from the resin by a dual cure additive manufacturing process.

Claims27

Dependent claims

A method of forming a three-dimensional object, comprising:

(a) providing a carrier and a fill level, and optionally an optically transparent member having a build surface defining said fill level, said carrier and said fill level having a build region therebetween;
(b) mixing a first precursor liquid and a second precursor liquid to produce a polymerizable liquid comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from said first component,
and wherein:
(i′) at least one reactant of said second solidifiable component is contained in said first precursor liquid, and (ii′) at least one reactant or catalyst of said second solidifiable component is contained in said second precursor liquid;
then
(c) filling said build region with said polymerizable liquid;
(d) irradiating said build region with light (through said optically transparent member when present) to form a solid polymer scaffold from said first component and also advancing said carrier away from said build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, said three-dimensional object and containing said second solidifiable component carried in said scaffold in unsolidified and/or uncured form;
(e) optionally washing said three-dimensional intermediate;
and
(f) concurrently with or subsequent to said irradiating step, solidifying and/or curing, said second solidifiable component in said three-dimensional intermediate to form said three-dimensional object,
wherein said second solidifiable component comprises a polymerizable liquid solubilized in or suspended in said first component.

8 more elements

A method of forming a three-dimensional object comprised of polyurethane, polyurea, or copolymer thereof, said method comprising:

(a) providing a carrier and a fill level, and optionally an optically transparent member having a build surface defining said fill level, said carrier and said fill level having a build region therebetween;
(b) mixing a first precursor liquid and a second precursor liquid to produce a polymerizable liquid comprising at least one of:
(i) a blocked or reactive blocked prepolymer, a blocked or reactive blocked isocyanate, or (iii) a blocked or reactive blocked diisocyanate chain extender;
(c) filling said build region with said polymerizable liquid;
then;
(d) irradiating said build region with light (through said optically transparent member when present) to form by a first reaction a solid blocked polymer scaffold and advancing said carrier away from said build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, said three-dimensional object, with said intermediate containing said (i) blocked or reactive blocked prepolymer, (ii) blocked or reactive blocked isocyanate, or (iii) blocked or reactive blocked diisocyanate chain extender;
(e) optionally washing said intermediate, and then
(f) heating or microwave irradiating said three-dimensional intermediate sufficiently to form, by a second reaction, from said three-dimensional intermediate said three-dimensional object comprised of polyurethane, polyurea, or copolymer thereof;
and wherein:
(i′) at least one reactant of said second reaction is contained in said first precursor liquid, and (ii′) at least one reactant or catalyst of said second reaction is contained in said second precursor liquid.

7 more elements

Dependencies are inferred from the claim text.

Facts

Application: 15/755,385Filed 20 Dec 2016
Published: US 2018/0264719 A120 Sep 2018
Granted: 16 Jul 2019
Term ends: Not estimatedThe source records don’t support an estimate.

Classification25 codes

A43B 13/181
Resilient soles: resiliency achieved by the structure of the sole
B29C 64/129
Using layers of liquid which are selectively solidified: characterised by the energy source therefor, e.g. by global irradiation combined with a mask
A42C 2/00
Manufacturing helmets by processes not otherwise provided for
A43B 13/14
Soles; Sole-and-heel integral units: characterised by the constructive form