Abstract:
A method of forming a three-dimensional object 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; (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 comprised of polyurethane, polyurea, or copolymer thereof.
Abstract:
A method of forming a three-dimensional object (17) includes: providing a carrier (18) and an optically transparent member (15) having a build surface, the carrier (18) and the build surface defining a build region therebetween; filling the build region with a polymerizable liquid (16); irradiating the build region with light (12) through the optically transparent member (15) to form a solid polymer from the polymerizable liquid; and advancing the carrier (18) away from the build surface to form the three-dimensional object (17) from the solid polymer. The carrier (18) includes at least one retain and release (34) feature that is configured to: i) retain the three- dimensional object (17) formed from the solid polymer on the carrier (18) in a first state; and ii) facilitate release of the three-dimensional object (17) formed from the solid polymer from the carrier (18) in a second state.
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").
Abstract:
A build plate for a three dimensional printer comprising: a rigid, optically transparent, gas-impermeable planar base having upper and lower surfaces (710); and a flexible, optically transparent, gas-permeable sheet (720) having upper and lower surfaces, the upper surface comprising a build surface for forming a three dimensional object, the sheet lower surface being positioned on the base upper surface, wherein at least one of the base upper surface and the sheet lower surface has an uneven surface topology (712) that increases gas flow to the build surface.
Abstract:
A method of forming a three-dimensional object includes: 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 with light through the optically transparent member to form a solid polymer from the polymerizable liquid, and advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer. The irradiating step includes projecting focused light at the build region, and the advancing step is carried out at a rate that is dependent on an average light intensity of the focused light. An apparatus to perform the method is also disclosed.
Abstract:
A method of forming a three-dimensional object includes: 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 with light 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. The irradiating step is carried out with a plurality of tiled images projected into the build region, and each tiled image includes an array of projected pixels. An apparatus to perform the method is also discloses.
Abstract:
A method of forming a three-dimensional object includes: (a) providing a carrier and a build plate, with the build plate including an optically transparent member, with the optically transparent member including a build surface, and with the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid; (c) irradiating the build region with light through the optically transparent member to form a solid polymer from the polymerizable liquid; (d) advancing the carrier away from the build surface to form the three-dimensional object from the solid polymer; (e) wherein the carrier has a plurality of channels formed therein, and the filling step includes concurrently forcing different polymerizable liquids through different ones of the plurality of channels.
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.
Abstract:
Provided herein are microfluidic devices having seamless channels with curved cross-section segments extending in a non-linear direction and/or having a tapering cross-section. Methods, systems and apparatus for the production of the same by three dimensional additive manufacturing is also provided.
Abstract:
A polymerizable liquid useful for the production of a three-dimensional object comprised of polyurethane, polyurea, or a copolymer thereof by additive manufacturing, is described. The polymerizable liquid comprises a mixture of: (a) at least one constitutent selected from the group consisting of (i) a blocked or reactive blocked prepolymer, (ii) a blocked or reactive blocked diisocyanate, and (iii) a blocked or reactive blocked diisocyanate chain extender, (b) optionally at least one additional chain extender, (c) a photoinitiator, (d) optionally a polyol and/or a polyamine, (e) optionally a reactive diluent, (f) optionally at least one non-reactive light absorbing pigment or dye which when present is included in an amount of from 0.001 or 0.01 to 10 percent by weight, and (g) optionally a filler (e.g. silica).