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Three-dimensional printing systems for rapidly producing objects

  • US 10,639,877 B2
  • Filed: 05/16/2016
  • Issued: 05/05/2020
  • Est. Priority Date: 05/15/2015
  • Status: Active Grant
First Claim
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1. A method for making a three-dimensional object comprising the steps ofa. loading a polymerizable liquid resin material or heated resin material as a liquid into a resin bath (vat) of a 3D printer;

  • b. positioning one or more mechanical arms on top of a clear and/or transparent window proximate to a bottom surface of the resin bath to maintain a liquid interface between a build surface and the clear and/or transparent window proximate to the bottom of the resin bath;

    wherein the one or more mechanical arms include an edge that is in contact with the clear and/or transparent window;

    c. applying sequential voxel planes into the liquid resin or the heated resin to form a first layer of material, which polymerizes into a first solid layer;

    d. moving the one or more mechanical arms at a speed so that the edge removes at least a portion of the liquid resin or heated resin from pre-matured polymerization while separating and removing a portion of the first solid layer from the clear and/or transparent window using the edge of the one or more mechanical arms to clean the clear and/or transparent window;

    e. supplying additional liquid resin or heated resin to the cleaned clear and/or transparent window;

    f. applying sequential voxel planes into the additional liquid resin or the heated resin to form a second layer of material, which polymerizes into a second solid layer;

    g. adjusting the speed of the one or more arms based on curing rate, curing area, curing volume, moving of building platform, and/or rheological behavior of the polymerizable liquid resin material or heated resin material so that the edge separates and removes a portion of the additional liquid resin or heated resin and a portion of the second solid layer from the clear and/or transparent window; and

    h. applying one or more successive layers of the polymerized material continuously until a predetermined shape is formed.

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