CONTINUOUS LIQUID INTERFACE PRODUCTION SYSTEM WITH VISCOSITY PUMP
First Claim
1. A continuous liquid interface production system for building a three dimensional part, the system comprising:
- a source of optical stimulation, the source configured to form a planar programmably structured image;
a vessel configured to retain a pool or film of an optically sensitive monomer within the vessel;
a substantially optically transparent plate retained by the vessel wherein the substantially optically transparent plate is configured to be positioned below the pool or a film of optically sensitive monomer, wherein the optical stimulation is configured to be directed through the plate and into the pool or film of the optically sensitive monomer;
a source of reaction inhibitor proximate to the substantially optically transparent plate, wherein the substantially optically transparent plate is configured to allow the reaction inhibitor to permeate through the plate and into the pool or the film such that when the system is in use a sufficient concentration of the reaction inhibitor is in the pool or the film proximate the plate to create a zone that prevents polymerization therein;
a build platen configured to be at least partially immersed into the pool or the film and above the zone at least at a beginning of a building process of the three dimensional part;
a build platen actuator configured to move the build platen in a direction substantially normal to a top surface of the plate;
a relative movement actuator configured to provide relative movement between the plate and the part being built in a direction substantially parallel to the top surface of the plate such that a viscosity pump effect is created that forces monomer between the part being built and the top surface of the plate; and
a controller configured to cause the source to project the optical stimulation based upon a sliced 3D model of the part based upon sensed variables comprising at least a height of the build platen.
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Accused Products
Abstract
A continuous liquid interface production system includes a source of optical stimulation. The system includes a vessel configured to retain a pool or film of optically sensitive monomer and a substantially optically transparent plate retained by the vessel. The optical stimulation is directed through the plate and into the pool or the film based upon a sliced 3D model of the part. The system includes source of reaction inhibitor wherein the substantially optically transparent plate allows the reaction inhibitor to permeate through the plate and into the pool or the film such that a sufficient amount of reaction inhibitor is within the pool or the film to create a zone proximate the plate that prevents polymerization therein. A build platen is configured to be at least partially immersed into the pool or the film and above the zone as a part is initially being built, wherein a build platen actuator moves the build platen away from the pool or the film in a direction substantially normal to a top surface of the plate. A relative movement actuator provides relative movement between the plate and the part in a direction substantially parallel to the top surface of the plate such that a viscosity pump effect is created that forces monomer between the part being built and the plate.
91 Citations
22 Claims
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1. A continuous liquid interface production system for building a three dimensional part, the system comprising:
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a source of optical stimulation, the source configured to form a planar programmably structured image; a vessel configured to retain a pool or film of an optically sensitive monomer within the vessel; a substantially optically transparent plate retained by the vessel wherein the substantially optically transparent plate is configured to be positioned below the pool or a film of optically sensitive monomer, wherein the optical stimulation is configured to be directed through the plate and into the pool or film of the optically sensitive monomer; a source of reaction inhibitor proximate to the substantially optically transparent plate, wherein the substantially optically transparent plate is configured to allow the reaction inhibitor to permeate through the plate and into the pool or the film such that when the system is in use a sufficient concentration of the reaction inhibitor is in the pool or the film proximate the plate to create a zone that prevents polymerization therein; a build platen configured to be at least partially immersed into the pool or the film and above the zone at least at a beginning of a building process of the three dimensional part; a build platen actuator configured to move the build platen in a direction substantially normal to a top surface of the plate; a relative movement actuator configured to provide relative movement between the plate and the part being built in a direction substantially parallel to the top surface of the plate such that a viscosity pump effect is created that forces monomer between the part being built and the top surface of the plate; and a controller configured to cause the source to project the optical stimulation based upon a sliced 3D model of the part based upon sensed variables comprising at least a height of the build platen. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A method of manufacturing a part with an additive manufacturing process, the method comprising:
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providing a continuous liquid interface production system comprising a substantially optically transparent plate within a vessel containing a pool or film of optically sensitive monomer, a source of optical stimulation configured to direct the optical stimulation through the optically transparent plate, a build platen configured to provide a bonding surface for the part being built, an actuator configured to raise the build platen and a controller configured to monitor a height of the build platen and to send a signal to cause the source to send optical stimulation through the plate and into the pool or the film to cause a layer of the part to be polymerized; raising the build platen and the part being built in a direction substantially normal to a top surface of the plate while causing successive patterns of optical stimulation to be sent through the plate and into the pool or the film to build a portion of the part; causing relative movement between the part and the plate in a direction substantially parallel to the top surface of the plate while raising the build platen, such that a viscosity pump effect is created between the part and the plate; and causing a series of optical stimulations from the source to be emitted into the pool or the film through the plate to form additional layers of the part until the part is built. - View Dependent Claims (21, 22)
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Specification