Method and apparatus for three-dimensional fabrication

• US 9,498,920 B2
• Filed: 01/14/2014
• Issued: 11/22/2016
• 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): Del Sole, Joseph S
• Assistant Examiner(s): Nguyen, Thukhanh T
• Application Number:
  US14/154,700
• Publication Number:
  US 20140361463A1
• Time in Patent Office: 1,043 Days
• Field of Search: 425/174.4, 425/375, 264/308, 264/401
• US Class Current: 1/1
• 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 64/20 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• 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 2105/0058 Liquid or visquous
• 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

Abstract

The present invention relates to methods and an apparatus for the fabrication of solid three-dimensional objects from liquid polymerizable materials.

Claims

1. An apparatus for forming a three-dimensional object from a polymerizable liquid, comprising:

(a) a support;

(b) a carrier operatively associated with said support on which carrier said three-dimensional object is formed;

(c) a stationary rigid build plate connected to said support, said build plate comprising a fixed semipermeable member, said semipermeable member comprising a build surface and a feed surface separate from said build surface, with said build surface and said carrier defining a build region therebetween;

(d) a polymerization inhibitor source in fluid communication with said feed surface;

(e) a liquid polymer supply operatively associated with said build plate and configured to supply liquid polymer into said build region for solidification polymerization;

(f) a radiation source operatively associated with said build plate and configured to irradiate said build region through said build plate and form a solid polymerized region therein from said liquid polymer; and

(g) a controller operatively associated with said carrier and said light source for advancing said carrier and said build plate away from one another solely in the X and Y (horizontal) directions during or after polymerization of liquid in said build zone.

2. The apparatus of claim 1, wherein:

said semipermeable member comprises a top surface portion, a bottom surface portion, and an edge surface portion;

said build surface is on said top surface portion; and

said feed surface is on at least one of said top surface portion, said bottom surface portion, and said edge surface portion.

3. The apparatus of claim 1, further comprising a pressure source operatively associated with said liquid polymer supply.

4. The apparatus of claim 1, wherein said radiation source comprises a light source.

5. The apparatus of claim 1, further comprising a pattern forming element operatively associated with said radiation source and said controller.

6. The apparatus of claim 1, wherein said carrier comprises a plate, post, web, film, reel, or combination thereof operatively associated with at least one actuator.

7. A build plate useful in an apparatus for forming a three-dimensional object from a polymerizable liquid, said build plate comprising:

(a) a fluoropolymer semipermeable member, said semipermeable member comprising a build surface and a feed surface separate from said build surface; and

(b) a transparent lower supporting member to which said fluoropolymer semipermeable member is fixed.

8. The build plate of claim 7, wherein said build surface is convexly or concavely curved.

9. The build plate of claim 7, wherein said supporting member comprises porous or microporous glass.