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US 10,471,699 B2Granted
Three-dimensional printing with reciprocal feeding of polymerizable liquid
AssigneeCarbon, Inc.
InventorsAlexander Ermoshkin, David Shirvanyants, Nordstrom Kirk Phelps, Nikita Ermoshkin, Edward T. Samulski, Joseph M. DeSimone
Life of this patent
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Abstract
Described herein are methods and apparatus for the production of a three-dimensional object by “bottom up” additive manufacturing, in which a carrier (112) is vertically reciprocated with respect to a build surface, to enhance or speed the refilling of the build region with a solidifiable liquid. In preferred embodiments, the three-dimensional object is produced from a liquid interface by continuous liquid interface production (i.e., “CLIP”).
Claims34
A method of forming a three-dimensional object, comprising:
- providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween,
- filling said build region with a polymerizable liquid,
- continuously or intermittently irradiating said build region with light through said optically transparent member to form a solid polymer from said polymerizable liquid,
- continuously or intermittently advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer,
- said filling step further comprising vertically reciprocating said carrier with respect to said build surface to enhance or speed the refilling of said build region with said polymerizable liquid,
- wherein said filling, irradiating, and/or advancing steps are carried out while also concurrently:
- (i) continuously maintaining a dead zone of polymerizable liquid in contact with said build surface, and
- (ii) continuously maintaining a gradient of polymerization zone between said dead zone and said solid polymer and in contact with each thereof, said gradient of polymerization zone comprising said polymerizable liquid in partially cured form.
5 more elements
A method of forming a three-dimensional object, comprising:
- providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween,
- filling said build region with a polymerizable liquid,
- continuously or intermittently irradiating said build region with light through said optically transparent member to form a solid polymer from said polymerizable liquid,
- continuously or intermittently advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer,
- said filling step further comprising vertically reciprocating said carrier with respect to said build surface to enhance or speed the refilling of said build region with said polymerizable liquid,
- wherein said filling, irradiating, and/or advancing steps are carried out while also concurrently:
- (i) continuously maintaining a dead zone of polymerizable liquid in contact with said build surface, and
- (ii) continuously maintaining a gradient of polymerization zone between said dead zone and said solid polymer and in contact with each thereof, said gradient of polymerization zone comprising said polymerizable liquid in partially cured form,
- wherein said build surface is fixed and stationary in the lateral (X and Y) dimensions.
6 more elements
An apparatus for forming a three-dimensional object from a polymerizable liquid, comprising:
- (a) a support;
- (b) a carrier operatively associated with said support on which carrier said three-dimensional object is formed;
- (c) an optically transparent member having a build surface, with said build surface and said carrier defining a build region therebetween;
- (d) a liquid polymer supply operatively associated with said build surface and configured to supply liquid polymer into said build region for solidification or polymerization;
- (e) a radiation source configured to irradiate said build region through said optically transparent member to form a solid polymer from said polymerizable liquid;
- (f) optionally at least one drive operatively associated with either said transparent member or said carrier;
- (g) a controller operatively associated with said carrier, and optionally said at least one drive, and said radiation source for advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer,
- said controller further configured to reciprocate said carrier vertically with respect to said build surface to enhance or speed the refilling of said build region with said polymerizable liquid,
- wherein said controller is further configured to form said three-dimensional object from said solid polymer while also concurrently with supplying liquid polymer, advancing the carrier, and/or irradiating the build region:
- (i) continuously maintaining a dead zone of polymerizable liquid in contact with said build surface, and (ii) continuously maintaining a gradient of polymerization zone between said dead zone and said solid polymer and in contact with each thereof, said gradient of polymerization zone comprising said polymerizable liquid in partially cured form.
7 more elements
An apparatus for forming a three-dimensional object from a polymerizable liquid, comprising:
- (a) a support;
- (b) a carrier operatively associated with said support on which carrier said three-dimensional object is formed;
- (c) an optically transparent member having a build surface, with said build surface and said carrier defining a build region therebetween;
- (d) a liquid polymer supply operatively associated with said build surface and configured to supply liquid polymer into said build region for solidification or polymerization;
- (e) a radiation source configured to irradiate said build region through said optically transparent member to form a solid polymer from said polymerizable liquid;
- (f) optionally at least one drive operatively associated with either said transparent member or said carrier;
- (g) a controller operatively associated with said carrier, and optionally said at least one drive, and said radiation source for advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer,
- said controller further configured to reciprocate said carrier vertically with respect to said build surface to enhance or speed the refilling of said build region with said polymerizable liquid,
- wherein said controller is further configured to form said three-dimensional object from said solid polymer while also concurrently with supplying liquid polymer, advancing the carrier, and/or irradiating the build region:
- (i) continuously maintaining a dead zone of polymerizable liquid in contact with said build surface, and (ii) continuously maintaining a gradient of polymerization zone between said dead zone and said solid polymer and in contact with each thereof, said gradient of polymerization zone comprising said polymerizable liquid in partially cured form,
- wherein said build surface is fixed and stationary in the lateral (X and Y) dimensions.
8 more elements
Dependencies are inferred from the claim text.