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US 2019/0160733 A1Published application
Method for the fabrication of three-dimensional objects and apparatus for same
AssigneeNorthwestern University
InventorsChad A. Mirkin, David A. Walker, James L. Hedrick, III
Life of this patent
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Abstract
Methods and apparatus comprising a dewetting phase and a polymerization liquid that are immiscible, and can be used for the formation of three-dimensional objects, wherein the method does not require a dead zone. Additionally, methods and apparatus that employ an optically transparent cooling apparatus to mitigate heat generated during the fabrication process, and the use of a mobile phase to provide a shearing interface to reduce interfacial adhesive forces.
Claims156
A method of forming a three-dimensional object, comprising:
- providing an adhesion stage and a member, the member having a dewetting phase thereon, the dewetting phase having a build surface, the adhesion stage and the build surface defining a build region therebetween;
- providing a polymerizable liquid in the build region, wherein the polymerizable liquid is immiscible with the dewetting phase;
- and
- undergoing polymerization of the polymerizable liquid by exposing the build region to energy through at least a portion of the dewetting phase to form a solid polymer from the polymerizable liquid and advancing the adhesion stage away from the build surface to form the three-dimensional object comprised of the solid polymer,
- wherein
- the dewetting phase is not a liquid.
3 more elements
A method of forming a three-dimensional object, comprising
- providing an adhesion stage, a member, and a cooling apparatus, the member having a dewetting phase thereon, the member between the cooling apparatus and the dewetting phase, the dewetting phase having a build surface, the adhesion stage and the build surface defining a build region therebetween;
- providing a polymerizable liquid in the build region, wherein the polymerizable liquid is immiscible with the dewetting phase;
- and
- undergoing polymerization of the polymerizable liquid by exposing the build region to energy through at least a portion of the cooling apparatus and through at least a portion of the dewetting phase to form a solid polymer from the polymerizable liquid and advancing the adhesion stage away from the build surface to form the three-dimensional object comprised of the solid polymer.
1 more element
An apparatus for forming a three-dimensional object from a polymerizable liquid, comprising:
- a support;
- an adhesion stage operatively associated with the support on which adhesion stage the three-dimensional object is formed;
- a member having a layer of a dewetting phase thereon, the dewetting phase having a build surface, wherein the dewetting phase is not a liquid, with the build surface and adhesion stage defining a build region therebetween;
- a polymerizable liquid supply operatively associated with the build surface and configured to supply polymerizable liquid into the build region for solidification or polymerization;
- an energy source configured to deliver energy to the build region through the member to form a solid polymer from the polymerizable liquid;
- at least one controller operatively associated with the energy source for delivering energy to the build region, the at least one controller also operatively associated with the adhesion stage for advancing the adhesion stage away from the build surface at a rate that is dependent on energy intensity to form the three-dimensional object from the solid polymer.
3 more elements
An apparatus for forming a three-dimensional object from a polymerizable liquid, comprising:
- a support;
- an adhesion stage operatively associated with the support on which adhesion stage the three-dimensional object is formed;
- a member having a layer of a dewetting phase thereon, the dewetting phase having a build surface, with the build surface and adhesion stage defining a build region therebetween;
- an optically transparent cooling apparatus;
- a polymerizable liquid supply operatively associated with the build surface and configured to supply polymerizable liquid into the build region for solidification or polymerization;
- an energy source configured to deliver energy to the build region through the member to form a solid polymer from the polymerizable liquid;
- and
- at least one controller operatively associated with the energy source for delivering energy to the build region, the at least one controller also operatively associated with the cooling apparatus for cooling the build region, the at least one controller also operatively associated with the adhesion stage for advancing the adhesion stage away from the build surface at a rate that is dependent on energy intensity to form the three-dimensional object from the solid polymer.
5 more elements
A method of forming a three-dimensional object, comprising:
- providing an adhesion stage and a member, the member having a mobile phase thereon, the mobile phase having a build surface, the adhesion stage and the build surface defining a build region therebetween;
- providing a polymerizable liquid in the build region, wherein the polymerizable liquid is immiscible with the mobile phase;
- and
- undergoing polymerization of the polymerizable liquid by exposing the build region to energy through at least a portion of the mobile phase to form a solid polymer from the polymerizable liquid and advancing the adhesion stage away from the build surface to form the three-dimensional object comprised of the solid polymer.
1 more element
An apparatus for forming a three-dimensional object from a polymerizable liquid, comprising:
- a support;
- an adhesion stage operatively associated with the support on which adhesion stage the three-dimensional object is formed;
- a member having a layer of a mobile phase thereon, the mobile phase having a build surface, with the build surface and adhesion stage defining a build region therebetween;
- a polymerizable liquid supply operatively associated with the build surface and configured to supply polymerizable liquid into the build region for solidification or polymerization;
- an energy source configured to deliver energy to the build region through the member to form a solid polymer from the polymerizable liquid;
- at least one controller operatively associated with the energy source for delivering energy to the build region, the at least one controller also operatively associated with the adhesion stage for advancing the adhesion stage away from the build surface at a rate that is dependent on energy intensity to form the three-dimensional object from the solid polymer.
3 more elements
Dependencies are inferred from the claim text.