Methods and apparatus for rolling film additive manufacturing using light scattering film
AssigneeCarbon, Inc.
InventorBernard Carreon
Life of this patent
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Abstract
An apparatus for forming a three-dimensional object includes: (a) at least one radiation source; (b) a build platform on which a three-dimensional object is formed; (c) an optically transparent film and a film transport assembly for moving the optically transparent film between the at least one radiation source and the build platform; (d) an applicator for coating polymerizable material onto the optically transparent film; (e) at least one controller and/or drive assembly; and (f) optionally a housing and/or frame, wherein the optically transparent film (i) comprises light scattering particles therein and/or thereon; and/or (ii) has an optical profile that varies along the length, and optionally the width, of the film.
Claims16
A method of making a three-dimensional object, comprising:
- (a) coating polymerizable material onto an optically transparent film;
- (b) positioning a first portion of the film having polymerizable material thereon between a radiation source and a build platform such that the polymerizable material contacts the build platform;
- (c) irradiating the polymerizable material through the first portion of the film with the radiation source to solidify and laminate the polymerizable material onto the build platform, thereby forming an object attached to the build platform;
- (d) positioning an additional portion of the film having additional polymerizable material thereon between the radiation source and the build platform such that the additional polymerizable material contacts the object;
- (e) irradiating the additional polymerizable material through the additional portion of the film with the radiation source to solidify and laminate the additional polymerizable material onto the object, thereby adding a layer to the object;
- (f) repeating steps (d) and (e) until the object attached to the build platform forms the three-dimensional object or an intermediate having the same shape, or the shape to be imparted to, the three-dimensional object, wherein:
- (i) each portion of the optically transparent film has an optical profile and at least one portion of the film that is irradiated in step (c) or step (e) has a different optical profile from at least one other portion of the film irradiated in step (c) or step (e);
- and/or
- (ii) the optically transparent film comprises scattering particles dispersed therein.
An apparatus for forming a three-dimensional object, comprising
- (a) at least one radiation source;
- (b) a build platform on which a three-dimensional object is formed;
- (c) an optically transparent film and a film transport assembly for moving the optically transparent film between the at least one radiation source and the build platform;
- (d) an applicator for coating polymerizable material onto the optically transparent film;
- (e) at least one controller and/or drive assembly;
- and
- (f) optionally a housing and/or frame,
- wherein the optically transparent film (i) comprises light scattering particles therein and/or thereon;
- and/or (ii) has an optical profile that varies along the length, and optionally the width, of the film.
Dependencies are inferred from the claim text.