Functionally-graded three-dimensional ordered open-cellular microstructure and method of making same
First Claim
1. A method for forming a functionally-graded three-dimensional ordered open-cellular microstructure, the method comprising:
- securing a volume of photo-monomer;
exposing the volume of photo-monomer to a first three-dimensional light pattern and a second three-dimensional light pattern differing from the first three-dimensional light pattern, wherein the first three-dimensional light pattern and the second three-dimensional light pattern are exposed on opposite exposure surfaces of the volume of photo-monomer, wherein the first three-dimensional light pattern creates a first three-dimensional interconnected pattern of polymer waveguides in the volume of photo-monomer, wherein the second three-dimensional light pattern creates a second three-dimensional interconnected pattern of polymer waveguides in the volume of photo-monomer, and wherein an exposure energy of each of the light patterns is sufficient to at least connect the first three-dimensional interconnected pattern of polymer waveguides to the second three-dimensional interconnected pattern of polymer waveguides; and
removing any uncured photo-monomer to leave behind the functionally-graded three-dimensional ordered open-cellular microstructure.
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Abstract
A method for creating or forming a functionally graded 3D ordered open-cellular microstructure, and a functionally graded 3D ordered open-cellular microstructure. In one embodiment, the functionally-graded three-dimensional ordered open-cellular microstructure includes a first three-dimensional interconnected pattern of polymer waveguides having a first three-dimensional pattern; a second three-dimensional interconnected pattern of polymer waveguides having a second three-dimensional pattern differing from the first three-dimensional pattern; and an interface connected with the first three-dimensional interconnected pattern of polymer waveguides and the second three-dimensional interconnected pattern of polymer waveguides. Here, the term “functionally graded” refers to a spatial variation in the physical microstructure—and thus the properties—through the thickness of the material.
33 Citations
16 Claims
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1. A method for forming a functionally-graded three-dimensional ordered open-cellular microstructure, the method comprising:
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securing a volume of photo-monomer; exposing the volume of photo-monomer to a first three-dimensional light pattern and a second three-dimensional light pattern differing from the first three-dimensional light pattern, wherein the first three-dimensional light pattern and the second three-dimensional light pattern are exposed on opposite exposure surfaces of the volume of photo-monomer, wherein the first three-dimensional light pattern creates a first three-dimensional interconnected pattern of polymer waveguides in the volume of photo-monomer, wherein the second three-dimensional light pattern creates a second three-dimensional interconnected pattern of polymer waveguides in the volume of photo-monomer, and wherein an exposure energy of each of the light patterns is sufficient to at least connect the first three-dimensional interconnected pattern of polymer waveguides to the second three-dimensional interconnected pattern of polymer waveguides; and removing any uncured photo-monomer to leave behind the functionally-graded three-dimensional ordered open-cellular microstructure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A system for forming a functionally-graded three-dimensional ordered open-cellular microstructure, the system comprising:
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a reservoir having a volume of photo-monomer adapted to polymerize by collimated light beams; and a first patterning apparatus adapted to expose the volume of photo-monomer to a first three-dimensional light pattern; a second patterning apparatus adapted to expose the volume of photo-monomer to a second three-dimensional light pattern, wherein the first three-dimensional light pattern and the second three-dimensional light pattern are exposed on opposite exposure surfaces of the volume of photo-monomer, wherein the first three-dimensional light pattern creates a first three-dimensional interconnected pattern of polymer waveguides, wherein the second three-dimensional light pattern creates a second three-dimensional interconnected pattern of polymer waveguides, and wherein an exposure energy of each of the light patterns is sufficient to at least connect the first three-dimensional interconnected pattern of polymer waveguides to the second three-dimensional interconnected pattern of polymer waveguides.
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Specification