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METHOD OF ADDITIVE MANUFACTURING BY FABRICATION THROUGH MULTIPLE ZONES

  • US 20160303793A1
  • Filed: 06/29/2016
  • Published: 10/20/2016
  • Est. Priority Date: 02/05/2015
  • Status: Active Grant
First Claim
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1. A method of forming a three-dimensional object, comprising:

  • (a) providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween, with said carrier positioned adjacent and spaced apart from said build surface at a start position;

    then(b) forming an adhesion segment of said three-dimensional object by;

    (i) filling said build region with a polymerizable liquid,(ii) irradiating said build region with light through said optically transparent member (e.g., by a single exposure), while(iii) maintaining said carrier stationary or advancing said carrier away from said build surface at a first cumulative rate of advance, to thereby form from said polymerizable liquid a solid polymer adhesion segment of said object adhered to said carrier;

    then(c) optionally but preferably forming a transition segment of said three dimensional object by(i) filling said build region with a polymerizable liquid,(ii) continuously or intermittently irradiating said build region with light through said optically transparent member, and(iii) continuously or intermittently advancing said carrier away from said build surface at a second cumulative rate of advance to thereby form from said polymerizable liquid a transition segment of said object between said adhesion segment and said build surface;

    wherein said second cumulative rate of advance is greater than said first cumulative rate of advance; and

    then(d) forming a body segment of said three dimensional object by;

    (i) filling said build region with a polymerizable liquid,(ii) continuously or intermittently irradiating said build region with light through said optically transparent, and(iii) continuously or intermittently advancing said carrier away from said build surface at a third cumulative rate of advance, to thereby form from said polymerizable liquid a body segment of said object between said transition segment and said build surface;

    wherein said third cumulative rate of advance is greater than said first and/or said second cumulative rate of advance.

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