公开(公告)号：US12179435B2

公开(公告)日：2024-12-31

申请号：US17662706

申请日：2022-05-10

Applicant: Carbon, Inc.

Inventor： Jason P. Rolland ,  Kai Chen ,  Justin Poelma ,  James Goodrich ,  Robert Pinschmidt ,  Joseph M. DeSimone ,  Lloyd M. Robeson

IPC: B29C64/165 ,  B29C35/08 ,  B29C64/106 ,  B29C64/124 ,  B29C64/129 ,  B29C64/135 ,  B29C64/255 ,  B29C64/286 ,  B29C64/386 ,  B29C64/40 ,  B29C71/00 ,  B29D11/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y70/00 ,  B33Y80/00 ,  C08F220/34 ,  C08F283/00 ,  C08F290/06 ,  C08G18/10 ,  C08G18/24 ,  C08G18/40 ,  C08G18/42 ,  C08G18/48 ,  C08G18/69 ,  C08G18/73 ,  C08G18/75 ,  C08G18/76 ,  C08G18/81 ,  C08J5/00 ,  C08K3/01 ,  C08K3/013 ,  C08K5/00 ,  C08L75/04 ,  C08L75/14 ,  C09D135/02 ,  C09D175/04 ,  C09D175/08 ,  G03F7/00 ,  G03F7/027 ,  G03F7/038 ,  G03F7/075 ,  G03F7/38 ,  B29C33/00 ,  B29K75/00 ,  B29K105/00 ,  B29K105/04 ,  B29K105/16 ,  B29K509/00 ,  B29L11/00 ,  B29L31/00 ,  B29L31/10

Abstract: A method of forming a three-dimensional object is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid, the polymerizable liquid including a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from the first component; (c) irradiating the build region with light through the optically transparent member to form a solid polymer scaffold from the first component and also advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, and containing the second solidifiable component carried in the scaffold in unsolidified and/or uncured form; and (d) concurrently with or subsequent to the irradiating step, solidifying and/or curing the second solidifiable component in the three-dimensional intermediate to form the three-dimensional object.

公开(公告)号：US11850803B2

公开(公告)日：2023-12-26

申请号：US17655275

申请日：2022-03-17

Applicant: Carbon, Inc.

Inventor： Jason P. Rolland ,  Kai Chen ,  Justin Poelma ,  James Goodrich ,  Robert Pinschmidt ,  Joseph M. DeSimone ,  Lloyd M. Robeson

IPC: B29C71/02 ,  B29C71/04 ,  B29C64/40 ,  C08K3/013 ,  C08K3/01 ,  B29C64/129 ,  G03F7/00 ,  G03F7/027 ,  G03F7/038 ,  G03F7/075 ,  G03F7/38 ,  B29C64/124 ,  B29C64/135 ,  B29C64/386 ,  C08G18/81 ,  C08G18/10 ,  C08G18/76 ,  C08F220/34 ,  C08G18/42 ,  C08F290/06 ,  C08G18/73 ,  C08G18/48 ,  C08G18/24 ,  C08G18/69 ,  C08G18/75 ,  C08F283/00 ,  C08G18/40 ,  B29C71/00 ,  B29C64/286 ,  B33Y10/00 ,  B33Y70/00 ,  B29D11/00 ,  B29C35/08 ,  C08K5/00 ,  C08L75/04 ,  B33Y80/00 ,  C09D135/02 ,  C09D175/04 ,  C09D175/08 ,  B29C64/255 ,  B29C64/106 ,  B29C64/165 ,  B33Y30/00 ,  C08J5/00 ,  C08L75/14 ,  B33Y50/02 ,  B29C33/00 ,  B29K105/00 ,  B29K75/00 ,  B29K105/04 ,  B29L11/00 ,  B29L31/10 ,  B29K105/16 ,  B29K509/00 ,  B29L31/00

CPC classification number: B29C64/40 ,  B29C35/0805 ,  B29C64/106 ,  B29C64/124 ,  B29C64/129 ,  B29C64/135 ,  B29C64/165 ,  B29C64/255 ,  B29C64/286 ,  B29C64/386 ,  B29C71/0009 ,  B29D11/00009 ,  B29D11/00663 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B33Y70/00 ,  B33Y80/00 ,  C08F220/34 ,  C08F283/006 ,  C08F290/067 ,  C08G18/10 ,  C08G18/244 ,  C08G18/40 ,  C08G18/42 ,  C08G18/4825 ,  C08G18/4854 ,  C08G18/69 ,  C08G18/73 ,  C08G18/755 ,  C08G18/758 ,  C08G18/7671 ,  C08G18/81 ,  C08G18/8175 ,  C08J5/00 ,  C08K3/01 ,  C08K3/013 ,  C08K5/0008 ,  C08K5/0041 ,  C08L75/04 ,  C08L75/14 ,  C09D135/02 ,  C09D175/04 ,  C09D175/08 ,  G03F7/00 ,  G03F7/0037 ,  G03F7/027 ,  G03F7/038 ,  G03F7/0757 ,  G03F7/38 ,  B29C2033/0005 ,  B29C2035/0827 ,  B29C2035/0855 ,  B29K2075/00 ,  B29K2075/02 ,  B29K2105/0002 ,  B29K2105/0058 ,  B29K2105/0073 ,  B29K2105/0091 ,  B29K2105/043 ,  B29K2105/16 ,  B29K2105/251 ,  B29K2509/00 ,  B29K2995/0026 ,  B29L2011/00 ,  B29L2011/0016 ,  B29L2011/0075 ,  B29L2031/001 ,  B29L2031/10 ,  C08J2375/14 ,  C08F283/006 ,  C08F222/102 ,  C08F222/1063 ,  C08F290/067 ,  C08F222/102 ,  C08F222/1063 ,  C08F220/1808 ,  C08F290/067 ,  C08F222/102 ,  C08F220/1811 ,  C08G18/672 ,  C08G18/48 ,  C08F290/067 ,  C08F222/102 ,  C08F222/1063

Abstract: A method of forming a three-dimensional object (e.g. comprised of polyurethane, polyurea, or copolymer thereof) is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid, the polymerizable liquid comprising a mixture of: (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from the first component; (c) irradiating the build region with light through the optically transparent member to form a solid blocked polymer scaffold and advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, with the intermediate containing the second solidifiable component; and then (d) contacting the three-dimensional intermediate to water to form the three-dimensional object.

公开(公告)号：US20230373156A9

公开(公告)日：2023-11-23

申请号：US17513312

申请日：2021-10-28

Applicant: Carbon, Inc.

Inventor： Joseph M. DeSimone ,  Alexander Ermoshkin ,  Edward T. Samulski

IPC: B29C64/135 ,  B29C35/08 ,  B29C64/393 ,  B29C64/129 ,  G03F7/00 ,  B29C64/40 ,  A61M37/00 ,  A61F2/82 ,  B33Y80/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B29C64/124

CPC classification number: B29C64/135 ,  B29C35/0888 ,  B29C64/393 ,  B29C64/129 ,  G03F7/0037 ,  B29C64/40 ,  A61M37/0015 ,  A61F2/82 ,  B33Y80/00 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y50/02 ,  B29C64/124 ,  B29C2033/0005

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.

公开(公告)号：US11786711B2

公开(公告)日：2023-10-17

申请号：US17155349

申请日：2021-01-22

Applicant: Carbon, Inc.

Inventor： Joseph M. DeSimone ,  Alexander Ermoshkin ,  Nikita Ermoshkin ,  Edward T. Samulski

IPC: B29C33/58 ,  B29C33/62 ,  A61M25/00 ,  A61M29/02 ,  A61B17/24 ,  A61B17/34 ,  A61M25/10 ,  A61B90/00

CPC classification number: A61M29/02 ,  A61B17/24 ,  A61B17/3415 ,  A61M25/1002 ,  A61M25/1025 ,  A61B2090/062 ,  A61M2025/1054 ,  A61M2025/1061 ,  A61M2029/025 ,  A61M2210/0675 ,  A61M2210/0681

Abstract: A method of forming a three-dimensional object is carried out by providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; filling the build region with a polymerizable liquid; irradiating the build region through the optically transparent member to form a solid polymer from the polymerizable liquid and advancing the carrier away from the build surface to form the three-dimensional object from the solid polymer, while also concurrently with the irradiating and/or advancing steps: (i) continuously maintaining a dead zone of polymerizable liquid in contact with the build surface, and (ii) continuously maintaining a gradient of polymerization zone between the dead zone and the solid polymer and in contact with each thereof. The gradient of polymerization zone comprises the polymerizable liquid in partially cured form (e.g., so that the formation of fault or cleavage lines between layers of solid polymer in the three-dimensional object is reduced). Apparatus for carrying out the method is also described.

公开(公告)号：US20230001634A1

公开(公告)日：2023-01-05

申请号：US17662706

申请日：2022-05-10

Applicant: Carbon, Inc.

Inventor： Jason P. Rolland ,  Kai Chen ,  Justin Poelma ,  James Goodrich ,  Robert Pinschmidt ,  Joseph M. DeSimone ,  Lloyd M. Robeson

IPC: B29C64/165 ,  B29C64/286 ,  B33Y10/00 ,  B33Y70/00

Abstract: A method of forming a three-dimensional object is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid, the polymerizable liquid including a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from the first component; (c) irradiating the build region with light through the optically transparent member to form a solid polymer scaffold from the first component and also advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, and containing the second solidifiable component carried in the scaffold in unsolidified and/or uncured form; and (d) concurrently with or subsequent to the irradiating step, solidifying and/or curing the second solidifiable component in the three-dimensional intermediate to form the three-dimensional object.

公开(公告)号：US11376786B2

公开(公告)日：2022-07-05

申请号：US15934301

申请日：2018-03-23

Applicant: Carbon, Inc.

Inventor： Bob E. Feller ,  Jason P. Rolland ,  Joseph M. DeSimone

IPC: B29C64/135 ,  B29C64/188 ,  B33Y10/00 ,  B29C64/255 ,  B29C64/245 ,  B29C64/232 ,  B29C64/264 ,  B29C64/321 ,  B33Y40/00 ,  B33Y70/00 ,  B29C64/379 ,  B29C64/129 ,  B29K75/00 ,  B29K105/00 ,  B29K105/16 ,  B29C64/35 ,  B33Y30/00

Abstract: Provided herein is an apparatus for producing three-dimensional objects by additive manufacturing, which may include: (a) optionally a window permeable to an inhibitor of polymerization; (b) a window mount to which the window is secured when the window is present; (c) optionally a carrier platform on which the three-dimensional object can be produced; (d) a carrier platform mount operatively associated with the window mount; (e) a drive assembly operatively associated with the window mount and the carrier platform mount; (f) a light source operatively associated with the window mount operatively associated with a patterning array; (g) an inhibitor of polymerization supply configured for operative association with the feed surface when present; and (h) at least one or two reactant supplies configured for operative association with the feed surface when present. Methods of making a three-dimensional object from a polymerization liquid that may use such apparatus are also provided.

公开(公告)号：US11000992B2

公开(公告)日：2021-05-11

申请号：US15547326

申请日：2016-02-10

Applicant: Carbon, Inc. ,  The University of North Carolina at Chapel Hill

Inventor： Ian Craven ,  Joseph M. DeSimone ,  Rima Janusziewicz

IPC: B29C64/135 ,  B29C64/129 ,  B29C64/245 ,  B29C64/255 ,  B29C64/227

Abstract: A method of forming a three-dimensional object is carried out by: providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; filling the build region with a polymerizable liquid; irradiating the build region through the optically transparent member to form a solid polymer from the polymerizable liquid while concurrently advancing the carrier away from the build surface to form the three-dimensional object from the solid polymer, while also concurrently: (i) continuously maintaining a dead zone of polymerizable liquid in contact with the build surface by electrochemically generating a polymerization inhibitor therein from a precursor of the polymerization inhibitor, and (ii) continuously maintaining a gradient of polymerization zone (e.g., an active surface) between the dead zone and the solid polymer and in contact with each thereof, the gradient of polymerization zone comprising the polymerizable liquid in partially cured form. Apparatus for carrying out the method is also described.

公开(公告)号：US10647880B2

公开(公告)日：2020-05-12

申请号：US16269710

申请日：2019-02-07

Applicant: Carbon, Inc.

Inventor： Jason P. Rolland ,  Kai Chen ,  Justin Poelma ,  James Goodrich ,  Robert Pinschmidt ,  Joseph M. DeSimone ,  Lloyd M. Robeson

IPC: B29C71/02 ,  B29C71/04 ,  C09D175/08 ,  C08K3/013 ,  C08K3/01 ,  B29C64/129 ,  G03F7/00 ,  G03F7/038 ,  G03F7/027 ,  G03F7/075 ,  G03F7/38 ,  B29C64/124 ,  B29C64/135 ,  B29C64/386 ,  C08G18/81 ,  C08G18/10 ,  C08G18/76 ,  C08F220/34 ,  C08G18/42 ,  C08F290/06 ,  C08G18/73 ,  C08G18/48 ,  C08G18/24 ,  C08G18/69 ,  C08G18/75 ,  C08F283/00 ,  C08G18/40 ,  B33Y10/00 ,  B33Y70/00 ,  B29D11/00 ,  B29C35/08 ,  C08K5/00 ,  C08L75/04 ,  B33Y80/00 ,  C09D135/02 ,  C09D175/04 ,  B29C64/255 ,  B29C64/106 ,  B29C64/165 ,  B33Y30/00 ,  C08J5/00 ,  C08L75/14 ,  B33Y50/02 ,  B29C33/00 ,  B29K75/00 ,  B29K105/04 ,  B29L11/00 ,  B29L31/10 ,  B29K105/00 ,  B29K105/16 ,  B29K509/00 ,  B29L31/00

Abstract: A method of forming a three-dimensional object of polyurethane, polyurea, or copolymer thereof is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid, the polymerizable liquid including at least one of: (i) a blocked or reactive blocked prepolymer, (ii) a blocked or reactive blocked diisocyanate, or (iii) a blocked or reactive blocked diisocyanate chain extender; (c) irradiating the build region with light through the optically transparent member to form a solid blocked polymer scaffold and advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, with the intermediate containing the chain extender; and then (d) heating or microwave irradiating the three-dimensional intermediate sufficiently to form from the three-dimensional intermediate the three-dimensional object of polyurethane, polyurea, or copolymer thereof.

公开(公告)号：US10471699B2

公开(公告)日：2019-11-12

申请号：US15314332

申请日：2015-06-18

Applicant: Carbon, Inc.

Inventor： Alexander Ermoshkin ,  David Shirvanyants ,  Nordstrom Kirk Phelps ,  Nikita Ermoshkin ,  Edward T. Samulski ,  Joseph M. DeSimone

IPC: B29C64/124 ,  B33Y50/02 ,  B33Y10/00 ,  B33Y30/00 ,  B29K105/00

Abstract: Described herein are methods and apparatus for the production of a three-dimensional object by “bottom up” additive manufacturing, in which a carrier (112) is vertically reciprocated with respect to a build surface, to enhance or speed the refilling of the build region with a solidifiable liquid. In preferred embodiments, the three-dimensional object is produced from a liquid interface by continuous liquid interface production (i.e., “CLIP”).

公开(公告)号：US20190112499A1

公开(公告)日：2019-04-18

申请号：US16204141

申请日：2018-11-29

Applicant: Carbon, Inc.

Inventor： Jason P. Rolland ,  Kai Chen ,  Justin Poelma ,  James Goodrich ,  Robert Pinschmidt ,  Joseph M. DeSimone ,  Lloyd M. Robeson

IPC: C09D175/08 ,  C08K3/013 ,  C09D135/02 ,  C09D175/04 ,  C08K5/00 ,  B29C35/08 ,  B29D11/00 ,  G03F7/38 ,  G03F7/075 ,  G03F7/038 ,  G03F7/027 ,  G03F7/00 ,  B29C64/135 ,  B29C64/124 ,  C08K3/01 ,  B33Y10/00 ,  B33Y70/00 ,  C08L75/04 ,  B33Y80/00 ,  B29C64/255 ,  B29C64/106 ,  B29C64/165 ,  B33Y30/00 ,  C08J5/00 ,  C08L75/14 ,  B33Y50/02

Abstract: A method of forming a three-dimensional object is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid, the polymerizable liquid including a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from the first component; (c) irradiating the build region with light through the optically transparent member to form a solid polymer scaffold from the first component and also advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, and containing the second solidifiable component carried in the scaffold in unsolidified and/or uncured form; and (d) concurrently with or subsequent to the irradiating step, solidifying and/or curing the second solidifiable component in the three-dimensional intermediate to form the three-dimensional object.