Method and apparatus for three-dimensional fabrication

• US 9,211,678 B2
• Filed: 12/16/2014
• Issued: 12/15/2015
• Est. Priority Date: 02/12/2013
• Status: Active Grant

• Current Assignee: Carbon, Inc.
• Original Assignee: Carbon3D, Inc.
• Inventors: DeSimone, Joseph M., Ermoshkin, Alexander, Samulski, Edward T.
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US14/572,128
• Publication Number:
  US 20150102532A1
• Time in Patent Office: 364 Days
• Field of Search: 264/37.18, 264/40.1, 264/338, 264/401, 264/497
• US Class Current: 1/1
• CPC Class Codes: A61F 2/82 Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents stent-grafts for tubular structures of the body other than blood vessels A61F2/04; stent-grafts for blood vessels A61F2/07; instruments specially adapted for placement or removal of stents or stent-grafts A61F2/95; for closing wounds, or holding wounds closed A61B17/04 - A61B17/115; dilators A61M29/00
• CPC Class Codes: A61F 2240/001 Designing or manufacturing processes
• CPC Class Codes: A61M 37/0015 by using microneedles
• CPC Class Codes: B29C 2033/0005 with transparent parts, e.g. permitting visual inspection of the interior of the cavity
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 33/0061 characterised by the configuration of the material feeding channel sprue channels for injection moulding B29C45/27
• CPC Class Codes: B29C 35/0888 using transparant moulds
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/02 Polyalkylene oxides, e.g. PEO, i.e. polyethylene oxide, or derivatives thereof
• CPC Class Codes: B29K 2105/0005 containing compounding ingredients releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26
• CPC Class Codes: B29K 2105/0058 Liquid or visquous
• CPC Class Codes: B29K 2827/12 containing fluorine
• CPC Class Codes: B29K 2883/005 LSR, i.e. liquid silicone rubbers, or derivatives thereof
• CPC Class Codes: B29K 2995/0026 Transparent
• CPC Class Codes: B29K 2995/006 Bio-degradable, e.g. bioabsorbable, bioresorbable or bioerodible
• CPC Class Codes: B29K 2995/0065 : Permeability to gases
• CPC Class Codes: B29L 2031/753 : Medical equipment; Accessories therefor bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008
• CPC Class Codes: B29L 2031/7534 : Cardiovascular protheses
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 : Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: G03F 7/0037 : Production of three-dimensional images
• CPC Class Codes: G05B 2219/00 : Program-control systems
• CPC Class Codes: G05B 2219/49016 : Desktop manufacturing [DTM]; Solid freeform machining [SFM]; Solid freeform fabrication [SFF]

Abstract

A method of forming a three-dimensional object, is carried out by (a) providing a carrier and a build plate, the build plate comprising a semipermeable member, the semipermeable member comprising a build surface with the build surface and the carrier defining a build region therebetween, and with the build surface in fluid communication by way of the semipermeable member with a source of polymerization inhibitor; (b) filling the build region with a polymerizable liquid, the polymerizable liquid contacting the build surface, (c) irradiating the build region through the build plate to produce a solid polymerized region in the build region, while forming or maintaining a liquid film release layer comprised of the polymerizable liquid formed between the solid polymerized region and the build surface, wherein the polymerization of which liquid film is inhibited by the polymerization inhibitor; and (d) advancing the carrier with the polymerized region adhered thereto away from the build surface on the build plate to create a subsequent build region between the polymerized region and the build surface while concurrently filling the subsequent build region with polymerizable liquid as in step (b). Apparatus for carrying out the method is also described.

Claims

1. A method of forming a three-dimensional object, comprising the steps of:

(a) providing a carrier and a build plate, said build plate comprising a semipermeable member, said semipermeable member comprising a build surface with said build surface and said carrier defining a build region therebetween, and with said build surface in fluid communication by way of the semipermeable member with a source of polymerization inhibitor;

(b) filling said build region with a polymerizable liquid, said polymerizable liquid contacting said build surface,

(c) irradiating said build region through said build plate to produce a solid polymerized region in said build region, while forming or maintaining a liquid film release layer comprised of said polymerizable liquid between said solid polymerized region and said build surface, the polymerization of which liquid film is inhibited by said polymerization inhibitor; and

(d) advancing said carrier with said polymerized region adhered thereto away from said build surface on said build plate to create a subsequent build region between said polymerized region and said build surface while concurrently filling said subsequent build region with polymerizable liquid as in step (b),

(e) continuing and/or repeating steps (c) and (d) to continuously produce in a layerless manner a subsequent polymerized region adhered to a previous polymerized region until the continued or repeated deposition of polymerized regions adhered to one another forms said three-dimensional object;

wherein said build plate is stationary.

2. The method of claim 1, wherein steps (c) and (d) are carried out concurrently.

3. The method of claim 1, wherein the source of polymerization inhibitor is a reservoir of polymerization inhibitor within the semipermeable member.

6. The method of claim 1, further comprising heating said polymerizable liquid to reduce the viscosity thereof in said build region.

7. The method of claim 1, further comprising cooling said polymerizable liquid in said build region to dissipate heat generated by polymerization reactions.

8. The method of claim 1, wherein said advancing step or steps is/are carried out at a cumulative rate of at least 10 microns per second.

9. The method of claim 8, wherein excess polymerizable liquid is supplied to said build region, removed or drained therefrom to cool said build region, and then optionally recirculated back to said build region.

10. The method of claim 1, wherein said carrier has a soluble sacrificial layer thereon, and said three-dimensional object is formed on said soluble sacrificial layer.

11. The method of claim 1, wherein:

a total surface area of the build region occupies at least seventy percent of a total surface area of the build surface; and

/or

wherein lateral movement of the carrier and object in any direction is not more than thirty percent of a width of said build region in the corresponding direction.

12. The method of claim 1, wherein (a) said polymerizable liquid comprises a free radical polymerizable liquid and said inhibitor comprises oxygen, or (b) said polymerizable liquid comprises an acid-catalyzed or cationically polymerizable liquid, and said inhibitor comprises a base.

14. The method of claim 1, wherein the carrier with said polymerized region adhered thereto is unidirectionally advanced away from said build surface on said stationary build plate.

15. The method of claim 1, wherein said semipermeable member comprises a flexible polymer film, and said build plate further comprises a tensioning member connected to said polymer film and to fix and rigidify the film.

16. The method of claim 1, wherein said semipermeable member comprises:

(i) a polymer film layer having a top surface positioned for contacting said polymerizable liquid and a bottom surface, and

(ii) a rigid, gas permeable, optically transparent supporting member contacting said film layer bottom surface.

17. The method of claim 16, wherein said polymer film layer comprises a fluoropolymer film.

18. The method of claim 16, wherein the supporting member comprises a silicone polymer member, a rigid gas permeable polymer member, or a porous or microporous glass member.

25. The method of claim 1, wherein said semipermeable member comprises a fluoropolymer film.

4. A method of forming a three-dimensional object, comprising the steps of:

(a) providing a carrier and a build plate, said build plate comprising a semipermeable member, said semipermeable member comprising a build surface with said build surface and said carrier defining a build region therebetween, and with said build surface in fluid communication by way of the semipermeable member with a source of polymerization inhibitor;

(b) filling said build region with a polymerizable liquid, said polymerizable liquid contacting said build surface,

(c) irradiating said build region through said build plate to produce a solid polymerized region in said build region, while forming or maintaining a liquid film release layer comprised of said polymerizable liquid between said solid polymerized region and said build surface, the polymerization of which liquid film is inhibited by said polymerization inhibitor; and

(d) advancing said carrier with said polymerized region adhered thereto away from said build surface on said build plate to create a subsequent build region between said polymerized region and said build surface while concurrently filling said subsequent build region with polymerizable liquid as in step (b),

(e) continuing and/or repeating steps (c) and (d) to continuously produce in a layerless manner a subsequent polymerized region adhered to a previous polymerized region until the continued or repeated deposition of polymerized regions adhered to one another forms said three-dimensional object;

wherein said build plate is stationary, and wherein the semipermeable member further comprises a feed surface separate from said build surface.

5. The method of claim 4, wherein the feed surface is in fluid contact with a polymerization inhibitor so as to provide said source of polymerization inhibitor.

26. The method of claim 4, wherein said semipermeable member comprises a fluoropolymer film.

13. A method of forming a three-dimensional object, comprising the steps of:

(a) providing a carrier and a build plate, said build plate comprising a semipermeable member, said semipermeable member comprising a build surface with said build surface and said carrier defining a build region therebetween, and with said build surface in fluid communication by way of the semipermeable member with a source of polymerization inhibitor;

(b) filling said build region with a polymerizable liquid, said polymerizable liquid contacting said build surface,

(c) irradiating said build region through said build plate to produce a solid polymerized region in said build region, while forming or maintaining a liquid film release layer comprised of said polymerizable liquid between said solid polymerized region and said build surface, the polymerization of which liquid film is inhibited by said polymerization inhibitor; and

(d) advancing said carrier with said polymerized region adhered thereto away from said build surface on said build plate to create a subsequent build region between said polymerized region and said build surface while concurrently filling said subsequent build region with polymerizable liquid as in step (b),

wherein said build plate is stationary,

said method further comprising the steps of;

(i) monitoring or detecting at least one process parameter and/or providing at least one known or predetermined process parameter; and

then

(ii) altering at least one process condition in response to said monitored process parameter or known or predetermined process parameter.

24. The method of claim 13, wherein:

said process parameter is expected consumption of polymerizable liquid; and

said process condition is rate of supply of polymerizable liquid.

27. The method of claim 13, wherein said semipermeable member comprises a fluoropolymer film.

29. The method of claim 13, wherein said process condition is rate of supply of polymerizable liquid, temperature, pressure, rate or speed of advance of carrier, intensity of irradiation, or duration of irradiation.

19. A method of forming a three-dimensional object, comprising the steps of:

(a) providing a carrier and a build plate, said build plate comprising a semipermeable member, said semipermeable member comprising a build surface with said build surface and said carrier defining a build region therebetween, and with said build surface in fluid communication by way of the semipermeable member with a source of polymerization inhibitor;

(b) filling said build region with a polymerizable liquid, said polymerizable liquid contacting said build surface,

(c) irradiating said build region through said build plate to produce a solid polymerized region in said build region, while forming or maintaining a liquid film release layer comprised of said polymerizable liquid between said solid polymerized region and said build surface, the polymerization of which liquid film is inhibited by said polymerization inhibitor; and

(d) advancing said carrier with said polymerized region adhered thereto away from said build surface on said build plate to create a subsequent build region between said polymerized region and said build surface while concurrently filling said subsequent build region with polymerizable liquid as in step (b),

wherein said build plate is stationary;

and wherein said advancing step is carried out while also concurrently (i) continuously maintaining a dead zone of polymerizable liquid in contact with said build surface, and (ii) continuously maintaining a gradient of polymerization zone between said dead zone and said solid polymer and in contact with each thereof, said gradient of polymerization zone comprising said polymerizable liquid in partially cured form.

20. The method of claim 19, wherein said semipermeable member comprises a flexible polymer film, and said build plate further comprises a tensioning member connected to said polymer film to fix and rigidify the film.

21. The method of claim 20, wherein said flexible polymer film comprises a fluoropolymer film.

22. The method of claim 21, wherein the carrier with said polymerized region adhered thereto is unidirectionally advanced away from said build surface on said stationary build plate.

23. The method of claim 22, wherein (a) said polymerizable liquid comprises a free radical polymerizable liquid and said inhibitor comprises oxygen, or (b) said polymerizable liquid comprises an acid-catalyzed or cationically polymerizable liquid, and said inhibitor comprises a base.

28. The method of claim 19, wherein said semipermeable member comprises a fluoropolymer film.