# US 11,993,015 B2 · Build plate assemblies for continuous liquid interphase printing having lighting panels and related methods, systems and devices > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,993,015 B2 - Document ID: US11993015B2 - Status: Granted - Kind: B2 - Application number: 17/491,966 - Filed: 2021-10-01 - Published: 2022-01-20 - Granted: 2024-05-28 - Earliest claimed: 2015-12-03 - Assignees: Carbon, Inc. - Applicants: Carbon, Inc. - Inventors: Bob E. Feller; Ariel M. Hermann; John R. Tumbleston; David Moore; Gregory W. Dachs, II - Web page: https://patentgrep.com/patent/US11993015B2 ## CPC - B29C 64/245: Platforms or substrates (support structures intended to be sacrificed after manufacture B29C64/40) - B29C 64/255: Enclosures for the building material, e.g. powder containers - B29C 64/124: using layers of liquid which are selectively solidified - B29C 64/129: characterised by the energy source therefor, e.g. by global irradiation combined with a mask - B29C 64/135: the energy source being concentrated, e.g. scanning lasers or focused light sources - B29C 64/393: for controlling or regulating additive manufacturing processes - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 50/02: for controlling or regulating additive manufacturing processes - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING ## Abstract A build plate assembly for a three-dimensional printer includes: a lighting panel having individually addressable pixels configured to selectively emit light and/or transmit light from illumination below the pixels to a top surface top surface of the lighting panel; a rigid, optically transparent, gas-impermeable planar screen or base having an upper surface having an uneven surface topology and a lower surface that is affixed to the top surface of the lighting panel; and a flexible, optically transparent, gas-permeable sheet having upper and lower surfaces, the upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface positioned opposite the base, wherein the build plate is configured to permit gas flow to the build surface. ## Claims ### Claim 1 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, wherein said optically transparent member comprises a build plate comprising: a lighting panel having individually addressable pixels configured to selectively emit light and/or transmit light from illumination below the pixels to a top surface of the lighting panel; a planar screen or base having an upper surface and a lower surface that is affixed to the top surface of the lighting panel, wherein the base is rigid, optically transparent, gas-impermeable, and planar; a flexible, optically transparent, gas-permeable sheet having upper and lower surfaces, the upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface positioned opposite the base, wherein the build plate is configured to permit gas flow to the build surface, wherein said planar screen or base comprises a top portion and a bottom portion, wherein the top portion comprises a patterned rigid polymer and the bottom portion comprises a second material different than the first material, and the top portion is adhered to the bottom portion. ### Claim 2 (depends on 1) The method of claim 1, 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. ### Claim 3 (depends on 2) The method of claim 2, wherein said optically transparent member comprises a semipermeable member, and said continuously maintaining a dead zone is carried out by feeding an inhibitor of polymerization through said optically transparent member in an amount sufficient to maintain said dead zone and said gradient of polymerization. ### Claim 4 (depends on 3) The method of claim 3, wherein said gradient of polymerization zone is maintained for a time of at least 5 seconds. ### Claim 5 (depends on 1) The method of claim 1, wherein the carrier with said solid polymer adhered thereto is unidirectionally advanced away from said build surface on said build plate, and said build plate is stationary. ### Claim 6 (depends on 1) The method of claim 1, 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. ### Claim 7 (depends on 6) The method of claim 6, wherein said vertically reciprocating step comprises an upstroke and a downstroke, with the distance of said upstroke greater than the distance of said downstroke, to thereby concurrently carry out said advancing step in part or in whole. ### Claim 8 (depends on 6) The method of claim 6, wherein said vertically reciprocating step comprises an upstroke, and wherein the speed of said upstroke accelerates over a period of time during said upstroke. ### Claim 9 (depends on 6) The method of claim 6, wherein said vertically reciprocating step comprises a downstroke, and wherein the speed of said downstroke decelerates over a period of time during said downstroke. ### Claim 10 (depends on 1) The method of claim 1, wherein said vertically reciprocating step is carried out over a total time of from 0.01 seconds up to 10 seconds, and/or over an upstroke distance of travel of from 0.02 millimeters to 10 millimeters. ### Claim 11 (depends on 1) The method of claim 1, wherein said advancing is carried out intermittently at a rate of one individual advance per minute up to 1000 individual advances per minute, each followed by a pause during which an irradiating step is carried out. ### Claim 12 (depends on 11) The method of claim 11, wherein each of said individual advances is carried out over an average distance of travel for each advance of from 10 microns to 200 microns. ### Claim 13 (depends on 1) The method of claim 1, wherein said build surface is fixed and stationary in the lateral dimensions. ### Claim 14 (depends on 1) The method of claim 1, wherein said build surface is fixed and stationary in the vertical dimension. ### Claim 15 (depends on 1) The method of claim 1, wherein said build plate further comprises an adhesive layer between the gas-permeable sheet and the base, and a channel layer defining channels therein.