U.S. patent application number 14/994853 was filed with the patent office on 2016-07-14 for three-dimensional printing with build plates having surface topologies for increasing permeability and related methods.
The applicant listed for this patent is Carbon3D, Inc.. Invention is credited to Alexander Ermoshkin, Bob E. Fellers, Ariel M. Herrmann, David Moore, Jason P. Rolland, Edward T. Samulski, John R. Tumbleston.
Application Number | 20160200052 14/994853 |
Document ID | / |
Family ID | 55315737 |
Filed Date | 2016-07-14 |
United States Patent
Application |
20160200052 |
Kind Code |
A1 |
Moore; David ; et
al. |
July 14, 2016 |
THREE-DIMENSIONAL PRINTING WITH BUILD PLATES HAVING SURFACE
TOPOLOGIES FOR INCREASING PERMEABILITY AND RELATED METHODS
Abstract
A build plate for a three-dimensional printer includes: a rigid,
optically transparent, gas-impermeable planar base having an upper
surface and a lower surface; and a flexible, optically transparent,
gas-permeable sheet having an upper and lower surface, the sheet
upper surface comprising a build surface for forming a
three-dimensional object, the sheet lower surface positioned on the
base upper surface. The build plate includes a gas flow enhancing
feature configured to increase gas flow to the build surface.
Inventors: |
Moore; David; (San Carlos,
CA) ; Tumbleston; John R.; (Menlo Park, CA) ;
Samulski; Edward T.; (Chapel Hill, NC) ; Ermoshkin;
Alexander; (Chapel Hill, NC) ; Rolland; Jason P.;
(San Carlos, CA) ; Herrmann; Ariel M.; (San
Francisco, CA) ; Fellers; Bob E.; (Mountain View,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Carbon3D, Inc. |
Redwood City |
CA |
US |
|
|
Family ID: |
55315737 |
Appl. No.: |
14/994853 |
Filed: |
January 13, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62102840 |
Jan 13, 2015 |
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62106421 |
Jan 22, 2015 |
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62109983 |
Jan 30, 2015 |
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62110014 |
Jan 30, 2015 |
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62205181 |
Aug 14, 2015 |
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62102861 |
Jan 13, 2015 |
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Current U.S.
Class: |
264/401 ;
425/174.4; 425/470 |
Current CPC
Class: |
G03F 7/70416 20130101;
B29C 71/0009 20130101; B29C 71/02 20130101; B29C 71/04 20130101;
B29C 2035/0855 20130101; B29C 64/124 20170801; B29C 64/245
20170801 |
International
Class: |
B29C 67/00 20060101
B29C067/00 |
Claims
1. A build plate for a three-dimensional printer comprising: a
rigid, optically transparent, gas-impermeable planar base having an
upper surface and a lower surface; a flexible, optically
transparent, gas-permeable sheet having an upper and lower surface,
the sheet upper surface comprising a build surface for forming a
three-dimensional object, the sheet lower surface positioned on the
base upper surface; wherein the build plate comprises a gas flow
enhancing feature configured to increase gas flow to the build
surface.
2. The build plate of claim 1, wherein the sheet is adhered to the
planar base by the adhesive layer.
3. The build plate of claim 2, wherein the gas flow enhancing
feature comprises a channel layer between the planar base and the
adhesive layer that defines channels therein.
4. The build plate of claim 3, wherein the channel layer is gas
permeable.
5. The build plate of claim 4 wherein the channel layer comprises a
permeable material such as a permeable polymer (e.g.,
poly(dimethylsiloxane) (PDMS).
6. The build plate of claim 3, wherein the channel layer defines
channels on a bottom surface opposite the adhesive.
7. The build plate of claim 3, wherein the channel layer is adhered
to the base by chemical bonding including oxidative treatments,
including oxygen plasma treatments, UV ozone treatments and/or wet
chemical treatments.
8. The build plate of claim 2, wherein the adhesive layer comprises
a gas-permeable adhesive.
9. The build plate of claim 2, wherein the adhesive layer comprises
a poly(dimethylsiloxane) (PDMS) film.
10. The build plate of claim 3, wherein the channel layer comprises
a first material and the base comprises a second material that is
different from the first material.
11. The build plate of claim 10, wherein the second material
comprises sapphire, glass and/or quartz.
12. The build plate of claim 3, further comprising an elastomeric
layer between the channel layer and the base configured to increase
an elasticity of the build surface.
13. The build plate of claim 3, wherein the permeable sheet and/or
channel layer comprises a PDMS composite comprising fluorescent,
oxygen-sensing particles for sensing oxygen.
14. The build plate of claim 12, wherein the permeable sheet,
elastomeric layer and/or channel layer comprises a PDMS composite
comprising electrically conductive particles for heating a portion
of the build plate.
15. The build plate of claim 1, wherein the gas-permeable sheet
lower surface has an uneven surface topology thereon.
16. The build plate of claim 2, wherein the gas flow enhancing
feature comprises the adhesive layer and the adhesive layer is a
patterned adhesive layer.
17. The build plate of claim 16, wherein the adhesive layer
comprises droplets deposited on the base upper surface.
18. The build plate of claim 16, wherein the adhesive layer
comprises a series of strips deposited on the base upper surface
that define channels between the base and the gas-permeable
sheet.
19. The build plate of claim 16, wherein the adhesive layer
comprises a random or non-random pattern of adhesive regions.
20. The build plate of claim 1, wherein the gas flow enhancing
feature comprises the sheet and the sheet has a plurality of
channels therein that increase gas flow to the build surface.
21. The build plate of claim 19, wherein the channels are formed by
laminating a first layer having a surface topology to a second
layer such that the first and second layers together form the
permeable sheet.
22. The build plate of claim 2, wherein the adhesive layer
comprises a first adhesive layer on the base upper surface, and the
gas flow enhancing feature comprises the channel layer, the channel
layer being a mesh layer on the adhesive layer opposite the base,
the build plate further comprising a second gas permeable adhesive
layer on the mesh layer opposite the base that adheres the sheet to
the mesh layer.
23. The build plate of claim 22, wherein the mesh layer comprises a
polyester screen mesh or a fiberglass fabric.
24. The build plate of claim 22, wherein the mesh layer is
optically transparent.
25. The build plate of claim 22, wherein the mesh layer comprises
fibers having a thickness of about 10-50 microns.
26. The build plate of claim 25, wherein a spacing or pitch between
the fibers is between about 50-500 microns.
27. The build plate of claim 1, wherein a thickness of the sheet is
less than about 150 .mu.m.
28. The build plate of claim 1, wherein the base comprises
sapphire, glass, quartz or polymer.
29. The build plate of claim 1, wherein the sheet comprises a
fluoropoloymer.
30. A method of forming a three-dimensional object, comprising:
providing a carrier and an optically transparent member having a
build surface, said carrier and said build surface defining a build
region therebetween; filling said build region with a polymerizable
liquid, continuously or intermittently irradiating said build
region with light through said optically transparent member to form
a solid polymer from said polymerizable liquid, continuously or
intermittently advancing (e.g., sequentially or concurrently with
said irradiating step) said carrier away from said build surface to
form said three-dimensional object from said solid polymer, wherein
said optically transparent member comprises a build plate for a
three-dimensional printer comprising: a rigid, optically
transparent, gas-impermeable planar base having an upper surface
and a lower surface; a flexible, optically transparent,
gas-permeable sheet having an upper and lower surface, the sheet
upper surface comprising a build surface for forming a
three-dimensional object, the sheet lower surface positioned on the
base upper surface; wherein the build plate comprises a gas flow
enhancing feature configured to increase gas flow to the build
surface.
31. The method of claim 30, wherein said filling, irradiating,
and/or advancing steps are 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.
32. The method of claim 30, wherein the carrier with said
polymerized region adhered thereto is unidirectionally advanced
away from said build surface on said stationary build plate.
33. The method of claim 30, said filling step further comprising
vertically reciprocating said carrier with respect to said build
surface; to enhance or speed the refilling of said build region
with said polymerizable liquid.
34. 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) an optically transparent
member having a build surface, with said build surface and said
carrier defining a build region therebetween; (d) a liquid polymer
supply (e.g., a well) operatively associated with said build
surface and configured to supply liquid polymer into said build
region for solidification or polymerization; (e) a radiation source
configured to irradiate said build region through said optically
transparent member to form a solid polymer from said polymerizable
liquid; (f) optionally at least one drive operatively associated
with either said transparent member or said carrier; (g) a
controller operatively associated with said carrier, and/or
optionally said at least one drive, and said radiation source for
advancing said carrier away from said build surface to form said
three-dimensional object from said solid polymer wherein said
optically transparent member comprises a build plate for a
three-dimensional printer comprising: a rigid, optically
transparent, gas-impermeable planar base having an upper surface
and a lower surface; a flexible, optically transparent,
gas-permeable sheet having an upper and lower surface, the sheet
upper surface comprising a build surface for forming a
three-dimensional object, the sheet lower surface positioned on the
base upper surface; wherein the build plate comprises a gas flow
enhancing feature configured to increase gas flow to the build
surface.
Description
RELATED APPLICATIONS
[0001] This application claims priority to United States
Provisional Patent Application Ser. Nos. 62/102,840 filed Jan. 13,
2015; 62/102,861 filed Jan. 13, 2015; 62/106,421 filed Jan. 22,
2015; 62/109,983 filed Jan. 30, 2015; 62/110,014 filed Jan. 30,
2015 and 62/205,181 filed Aug. 14, 2015, the disclosures of each of
which are incorporated by reference herein in their entireties.
FIELD OF THE INVENTION
[0002] The present invention concerns methods and apparatus for the
fabrication of solid three-dimensional objects from liquid
materials.
BACKGROUND OF THE INVENTION
[0003] In conventional additive or three-dimensional fabrication
techniques, construction of a three-dimensional object is performed
in a step-wise or layer-by-layer manner. In particular, layer
formation is performed through solidification of photo curable
resin under the action of visible or UV light irradiation. Two
techniques are known: one in which new layers are formed at the top
surface of the growing object; the other in which new layers are
formed at the bottom surface of the growing object.
[0004] If new layers are formed at the top surface of the growing
object, then after each irradiation step the object under
construction is lowered into the resin "pool," a new layer of resin
is coated on top, and a new irradiation step takes place. An early
example of such a technique is given in Hull, U.S. Pat. No.
5,236,637, at FIG. 3. A disadvantage of such "top down" techniques
is the need to submerge the growing object in a (potentially deep)
pool of liquid resin and reconstitute a precise overlayer of liquid
resin.
[0005] If new layers are formed at the bottom of the growing
object, then after each irradiation step the object under
construction must be separated from the bottom plate in the
fabrication well. An early example of such a technique is given in
Hull, U.S. Pat. No. 5,236,637, at FIG. 4. While such "bottom up"
techniques hold the potential to eliminate the need for a deep well
in which the object is submerged by instead lifting the object out
of a relatively shallow well or pool, a problem with such "bottom
up" fabrication techniques, as commercially implemented, is that
extreme care must be taken, and additional mechanical elements
employed, when separating the solidified layer from the bottom
plate due to physical and chemical interactions therebetween. For
example, in U.S. Pat. No. 7,438,846, an elastic separation layer is
used to achieve "non-destructive" separation of solidified material
at the bottom construction plane. Other approaches, such as the
B9Creator.TM. 3-dimensional printer marketed by B9Creations of
Deadwood, S. Dak., USA, employ a sliding build plate. See, e.g., M.
Joyce, US Patent App. 2013/0292862 and Y. Chen et al., US Patent
App. 2013/0295212 (both Nov. 7, 2013); see also Y. Pan et al., J.
Manufacturing Sci. and Eng. 134, 051011-1 (October 2012). Such
approaches introduce a mechanical step that may complicate the
apparatus, slow the method, and/or potentially distort the end
product.
[0006] Continuous processes for producing a three-dimensional
object are suggested at some length with respect to "top down"
techniques in U.S. Pat. No. 7,892,474, but this reference does not
explain how they may be implemented in "bottom up" systems in a
manner non-destructive to the article being produced. Accordingly,
there is a need for alternate methods and apparatus for
three-dimensional fabrication that can obviate the need for
mechanical separation steps in "bottom-up" fabrication.
SUMMARY OF THE INVENTION
[0007] Described herein are methods, systems and apparatus
(including associated control methods, systems and apparatus), for
the production of a three-dimensional object by additive
manufacturing. In preferred (but not necessarily limiting)
embodiments, the method is carried out continuously. In preferred
(but not necessarily limiting) embodiments, the three-dimensional
object is produced from a liquid interface. Hence they are
sometimes referred to, for convenience and not for purposes of
limitation, as continuous liquid interface (or interphase)
production (or printing), that is, "CLIP" herein (the various
phrasings being used interchangeably). A schematic representation
of one embodiment thereof is given in FIG. 1 herein.
[0008] In some embodiments, a build plate for a three-dimensional
printer includes: a rigid, optically transparent, gas-impermeable
planar base having an upper surface and a lower surface; and a
flexible, optically transparent, gas-permeable sheet having an
upper and lower surface, the sheet upper surface comprising a build
surface for forming a three-dimensional object, the sheet lower
surface positioned on the base upper surface. The build plate
includes a gas flow enhancing feature configured to increase gas
flow to the build surface.
[0009] In some embodiments, the sheet is adhered to the planar base
by the adhesive layer.
[0010] In some embodiments, the gas flow enhancing feature
comprises the channel layer that defines channels therein. The
channel layer may be gas permeable.
[0011] In some embodiments, the channel layer comprises a permeable
material such as a permeable polymer (e.g., poly(dimethylsiloxane)
(PDMS).
[0012] In some embodiments, the channel layer defines channels on a
bottom surface opposite the adhesive.
[0013] In some embodiments, the channel layer is adhered to the
base by chemical bonding including oxidative treatments, including
oxygen plasma treatments, UV ozone treatments and/or wet chemical
treatments.
[0014] In some embodiments, the adhesive layer comprises a
gas-permeable adhesive.
[0015] In some embodiments, the adhesive layer comprises a
poly(dimethylsiloxane) (PDMS) film.
[0016] In some embodiments, the channel layer comprises a first
material and the base comprises a second material that is different
from the first material.
[0017] In some embodiments, the second material comprises sapphire,
glass and/or quartz.
[0018] In some embodiments, the build plate further comprising an
elastomeric layer between the channel layer and the base configured
to increase an elasticity of the build surface.
[0019] In some embodiments, the permeable sheet and/or channel
layer comprises a PDMS composite comprising fluorescent,
oxygen-sensing particles for sensing oxygen.
[0020] In some embodiments, the permeable sheet, elastomeric layer
and/or channel layer comprises a PDMS composite comprising
electrically conductive particles for heating a portion of the
build plate.
[0021] In some embodiments, the gas-permeable sheet lower surface
has an uneven surface topology thereon.
[0022] In some embodiments, the gas flow enhancing feature
comprises the adhesive layer and the adhesive layer is a patterned
adhesive layer.
[0023] In some embodiments, the adhesive layer comprises droplets
deposited on the base upper surface. The adhesive layer may include
a series of strips deposited on the base upper surface that define
channels between the base and the gas-permeable sheet. The adhesive
layer may include a random or non-random pattern of adhesive
regions.
[0024] In some embodiments, the gas flow enhancing feature
comprises the sheet and the sheet has a plurality of channels
therein that increase gas flow to the build surface.
[0025] In some embodiments, the channels are formed by laminating a
first layer having a surface topology to a second layer such that
the first and second layers together form the permeable sheet.
[0026] In some embodiments, the adhesive layer comprises a first
adhesive layer on the base upper surface, and the gas flow
enhancing feature comprises the channel layer. The channel layer is
a mesh layer on the adhesive layer opposite the base. The build
plate further includes a second gas permeable adhesive layer on the
mesh layer opposite the base that adheres the sheet to the mesh
layer.
[0027] In some embodiments, the mesh layer comprises a polyester
screen mesh or a fiberglass fabric.
[0028] In some embodiments, the mesh layer is optically
transparent.
[0029] In some embodiments, the mesh layer comprises fibers having
a thickness of about 10-50 microns.
[0030] In some embodiments, a spacing or pitch between the fibers
is between about 50-500 microns.
[0031] In some embodiments, a thickness of the sheet is less than
about 150 .mu.m.
[0032] In some embodiments, the base comprises sapphire, glass,
quartz or polymer.
[0033] In some embodiments, the sheet comprises a
fluoropoloymer.
[0034] In some embodiments, a method of forming a three-dimensional
object includes providing a carrier and an optically transparent
member having a build surface, said carrier and said build surface
defining a build region therebetween; filling said build region
with a polymerizable liquid, continuously or intermittently
irradiating said build region with light through said optically
transparent member to form a solid polymer from said polymerizable
liquid, continuously or intermittently advancing (e.g.,
sequentially or concurrently with said irradiating step) said
carrier away from said build surface to form said three-dimensional
object from said solid polymer, wherein said optically transparent
member comprises the build plate described above.
[0035] In some embodiments, the filling, irradiating, and/or
advancing steps are 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.
[0036] In some embodiments, the carrier with the polymerized region
adhered thereto is unidirectionally advanced away from said build
surface on said stationary build plate. In some embodiments,
filling step further comprising vertically reciprocating said
carrier with respect to said build surface to enhance or speed the
refilling of said build region with said polymerizable liquid.
[0037] In some embodiments, an apparatus for forming a
three-dimensional object from a polymerizable liquid, includes (a)
a support; (b) a carrier operatively associated with said support
on which carrier said three-dimensional object is formed; (c) an
optically transparent member having a build surface, with said
build surface and said carrier defining a build region
therebetween; (d) a liquid polymer supply (e.g., a well)
operatively associated with said build surface and configured to
supply liquid polymer into said build region for solidification or
polymerization; (e) a radiation source configured to irradiate said
build region through said optically transparent member to form a
solid polymer from said polymerizable liquid; (f) optionally at
least one drive operatively associated with either said transparent
member or said carrier; (g) a controller operatively associated
with said carrier, and/or optionally said at least one drive, and
said radiation source for advancing said carrier away from said
build surface to form said three-dimensional object from said solid
polymer
[0038] wherein said optically transparent member comprises the
build plate described above.
[0039] In some embodiments of the methods and compositions
described above and below, the polymerizable liquid (or "dual cure
resin") has a viscosity of 500 or 1,000 centipoise or more at room
temperature and/or under the operating conditions of the method, up
to a viscosity of 10,000, 20,000, or 50,000 centipoise or more, at
room temperature and/or under the operating conditions of the
method.
[0040] Non-limiting examples and specific embodiments of the
present invention are explained in greater detail in the drawings
herein and the specification set forth below. The disclosure of all
United States Patent references cited herein are to be incorporated
herein by reference in their entirety.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 is a schematic illustration of one embodiment of a
method of the present invention.
[0042] FIG. 2 is a perspective view of one embodiment of an
apparatus of the present invention.
[0043] FIGS. 3 to 5 are flow charts illustrating control systems
and methods for carrying out the present invention.
[0044] FIG. 6 is a top view of a 3 inch by 16 inch "high aspect"
rectangular build plate (or "window") assembly of the present
invention, where the film dimensions are 3.5 inch by 17 inch.
[0045] FIG. 7 is an exploded view of the build plate of FIG. 6,
showing the tension ring and tension ring spring plate.
[0046] FIG. 8 is a side sectional view of the build plates of FIGS.
6-9, showing how the tension member tensions and fixes or
rigidifies the polymer film.
[0047] FIG. 9 is a top view of a 2.88 inch diameter round build
plate of the invention, where the film dimension may be 4 inches in
diameter.
[0048] FIG. 10 is an exploded view of the build plate of FIG.
8.
[0049] FIG. 11 shows various alternate embodiments of the build
plates of FIGS. 7-10.
[0050] FIG. 12 is a front perspective view of an apparatus
according to an exemplary embodiment of the invention.
[0051] FIG. 13 is a side view of the apparatus of FIG. 12.
[0052] FIG. 14 is a rear perspective view of the apparatus of FIG.
12.
[0053] FIG. 15 is a perspective view of a light engine assembly
used with the apparatus of FIG. 12.
[0054] FIG. 16 is a front perspective view of an apparatus
according to another exemplary embodiment of the invention.
[0055] FIGS. 17A-17C are schematic diagrams illustrating tiled
images.
[0056] FIG. 18 is a front perspective view of an apparatus
according to another exemplary embodiment of the invention.
[0057] FIG. 19 is a side view of the apparatus of FIG. 18.
[0058] FIG. 20 is a perspective view of a light engine assembly
used with the apparatus of FIG. 18.
[0059] FIG. 21 is a graphic illustration of a process of the
invention indicating the position of the carrier in relation to the
build surface or plate, where both advancing of the carrier and
irradiation of the build region is carried out continuously.
Advancing of the carrier is illustrated on the vertical axis, and
time is illustrated on the horizontal axis.
[0060] FIG. 22 is a graphic illustration of another process of the
invention indicating the position of the carrier in relation to the
build surface or plate, where both advancing of the carrier and
irradiation of the build region is carried out stepwise, yet the
dead zone and gradient of polymerization are maintained. Advancing
of the carrier is again illustrated on the vertical axis, and time
is illustrated on the horizontal axis.
[0061] FIG. 23 is a graphic illustration of still another process
of the invention indicating the position of the carrier in relation
to the build surface or plate, where both advancing of the carrier
and irradiation of the build region is carried out stepwise, the
dead zone and gradient of polymerization are maintained, and a
reciprocating step is introduced between irradiation steps to
enhance the flow of polymerizable liquid into the build region.
Advancing of the carrier is again illustrated on the vertical axis,
and time is illustrated on the horizontal axis.
[0062] FIG. 24 is a detailed illustration of a reciprocation step
of FIG. 23, showing a period of acceleration occurring during the
upstroke (i.e., a gradual start of the upstroke) and a period of
deceleration occurring during the downstroke (i.e., a gradual end
to the downstroke).
[0063] FIG. 25 schematically illustrates the movement of the
carrier (z) over time (t) in the course of fabricating a
three-dimensional object by processes of the present invention
through a first base (or "adhesion") zone, a second transition
zone, and a third body zone.
[0064] FIG. 26A schematically illustrates the movement of the
carrier (z) over time (t) in the course of fabricating a
three-dimensional object by continuous advancing and continuous
exposure.
[0065] FIG. 26B illustrates the fabrication of a three-dimensional
object in a manner similar to FIG. 26 A, except that illumination
is now in an intermittent (or "strobe") pattern.
[0066] FIG. 27A schematically illustrates the movement of the
carrier (z) over time (t) in the course of fabricating a
three-dimensional object by intermittent (or "stepped") advancing
and intermittent exposure.
[0067] FIG. 27B illustrates the fabrication of a three-dimensional
object in a manner similar to FIG. 27A, except that illumination is
now in a shortened intermittent (or "strobe") pattern.
[0068] FIG. 28A schematically illustrates the movement of the
carrier (z) over time (t) in the course of fabricating a
three-dimensional object by oscillatory advancing and intermittent
exposure.
[0069] FIG. 28B illustrates the fabrication of a three-dimensional
object in a manner similar to FIG. 28A, except that illumination is
now in a shortened intermittent (or "strobe") pattern.
[0070] FIG. 29A schematically illustrates one segment of a "strobe"
pattern of fabrication, where the duration of the static portion of
the carrier has been shortened to near the duration of the "strobe"
exposure
[0071] FIG. 29B is a schematic illustration of a segment of a
strobe pattern of fabrication similar to FIG. 29A, except that the
carrier is now moving slowly upward during the period of strobe
illumination.
[0072] FIG. 30 is a cross sectional view of a laminated build
plate.
[0073] FIGS. 31 and 32 are cross sectional views of build plates
having a base with a surface topology and a permeable sheet thereon
that maintains a gap therebetween according to some
embodiments.
[0074] FIG. 33 is a cross sectional view of a build plate having a
base and a permeable sheet with a surface topology that maintains a
gap therebetween according to some embodiments.
[0075] FIGS. 34 and 35 are cross sectional views of a build plate
in a chamber according to some embodiments.
[0076] FIG. 36 is a cross sectional view of a build plate having a
base with a non-random pattern according to some embodiments.
[0077] FIGS. 37-40 are cross sectional side views of build plates
having an adhesive layer according to some embodiments.
[0078] FIGS. 41A-41C are cross sectional side views illustrating
methods of forming a build plate having a channel layer according
to some embodiments.
[0079] FIG. 42 is a cross sectional side view of a build plate
according to some embodiments.
[0080] FIGS. 43-45 are cross sectional side views of build plates
having an adhesive layer according to some embodiments.
[0081] FIGS. 46A-46C are top views of the base of a build plate
having an adhesive layer according to some embodiments illustrating
examples of adhesive patterns.
[0082] FIGS. 47-48 are cross sectional side views of build plates
having a permeable sheet having channels therein according to some
embodiments.
[0083] FIG. 49 is a cross sectional side view of a build plate
having a mesh layer according to some embodiments,
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0084] The present invention is now described more fully
hereinafter with reference to the accompanying drawings, in which
embodiments of the invention are shown. This invention may,
however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein; rather
these embodiments are provided so that this disclosure will be
thorough and complete and will fully convey the scope of the
invention to those skilled in the art.
[0085] Like numbers refer to like elements throughout. In the
figures, the thickness of certain lines, layers, components,
elements or features may be exaggerated for clarity. Where used,
broken lines illustrate optional features or operations unless
specified otherwise.
[0086] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a," "an" and
"the" are intended to include plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements components and/or groups or
combinations thereof, but do not preclude the presence or addition
of one or more other features, integers, steps, operations,
elements, components and/or groups or combinations thereof.
[0087] As used herein, the term "and/or" includes any and all
possible combinations or one or more of the associated listed
items, as well as the lack of combinations when interpreted in the
alternative ("or").
[0088] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the specification and claims and should
not be interpreted in an idealized or overly formal sense unless
expressly so defined herein. Well-known functions or constructions
may not be described in detail for brevity and/or clarity.
[0089] It will be understood that when an element is referred to as
being "on," "attached" to, "connected" to, "coupled" with,
"contacting," etc., another element, it can be directly on,
attached to, connected to, coupled with and/or contacting the other
element or intervening elements can also be present. In contrast,
when an element is referred to as being, for example, "directly
on," "directly attached" to, "directly connected" to, "directly
coupled" with or "directly contacting" another element, there are
no intervening elements present. It will also be appreciated by
those of skill in the art that references to a structure or feature
that is disposed "adjacent" another feature can have portions that
overlap or underlie the adjacent feature.
[0090] Spatially relative terms, such as "under," "below," "lower,"
"over," "upper" and the like, may be used herein for ease of
description to describe an element's or feature's relationship to
another element(s) or feature(s) as illustrated in the figures. It
will be understood that the spatially relative terms are intended
to encompass different orientations of the device in use or
operation in addition to the orientation depicted in the figures.
For example, if the device in the figures is inverted, elements
described as "under" or "beneath" other elements or features would
then be oriented "over" the other elements or features. Thus the
exemplary term "under" can encompass both an orientation of over
and under. The device may otherwise be oriented (rotated 90 degrees
or at other orientations) and the spatially relative descriptors
used herein interpreted accordingly. Similarly, the terms
"upwardly," "downwardly," "vertical," "horizontal" and the like are
used herein for the purpose of explanation only, unless
specifically indicated otherwise.
[0091] It will be understood that, although the terms first,
second, etc., may be used herein to describe various elements,
components, regions, layers and/or sections, these elements,
components, regions, layers and/or sections should not be limited
by these terms. Rather, these terms are only used to distinguish
one element, component, region, layer and/or section, from another
element, component, region, layer and/or section. Thus, a first
element, component, region, layer or section discussed herein could
be termed a second element, component, region, layer or section
without departing from the teachings of the present invention. The
sequence of operations (or steps) is not limited to the order
presented in the claims or figures unless specifically indicated
otherwise.
1. Polymerizable Liquids.
[0092] Any suitable polymerizable liquid can be used to enable the
present invention. The liquid (sometimes also referred to as
"liquid resin" "ink," or simply "resin" herein) can include a
monomer, particularly photopolymerizable and/or free radical
polymerizable monomers, and a suitable initiator such as a free
radical initiator, and combinations thereof. Examples include, but
are not limited to, acrylics, methacrylics, acrylamides, styrenics,
olefins, halogenated olefins, cyclic alkenes, maleic anhydride,
alkenes, alkynes, carbon monoxide, functionalized oligomers,
multifunctional cure site monomers, functionalized PEGs, etc.,
including combinations thereof. Examples of liquid resins, monomers
and initiators include but are not limited to those set forth in
U.S. Pat. Nos. 8,232,043; 8,119,214; 7,935,476; 7,767,728;
7,649,029; WO 2012129968 A1; CN 102715751 A; JP 2012210408 A.
[0093] Acid Catalyzed Polymerizable Liquids.
[0094] While in some embodiments as noted above the polymerizable
liquid comprises a free radical polymerizable liquid (in which case
an inhibitor may be oxygen as described below), in other
embodiments the polymerizable liquid comprises an acid catalyzed,
or cationically polymerized, polymerizable liquid. In such
embodiments the polymerizable liquid comprises monomers contain
groups suitable for acid catalysis, such as epoxide groups, vinyl
ether groups, etc. Thus suitable monomers include olefins such as
methoxyethene, 4-methoxystyrene, styrene, 2-methylprop-1-ene,
butadiene, etc.; heterocycloic monomers (including lactones,
lactams, and cyclic amines) such as oxirane, thietane,
tetrahydrofuran, oxazoline, 1,3, dioxepane, oxetan-2-one, etc., and
combinations thereof. A suitable (generally ionic or non-ionic)
photoacid generator (PAG) is included in the acid catalyzed
polymerizable liquid, examples of which include, but are not
limited to onium salts, sulfonium and iodonium salts, etc., such as
diphenyl iodide hexafluorophosphate, diphenyl iodide
hexafluoroarsenate, diphenyl iodide hexafluoroantimonate, diphenyl
p-methoxyphenyl triflate, diphenyl p-toluenyl triflate, diphenyl
p-isobutylphenyl triflate, diphenyl p-tert-butylphenyl triflate,
triphenylsulfonium hexafluororphosphate, triphenylsulfonium
hexafluoroarsenate, triphenylsulfonium hexafluoroantimonate,
triphenylsulfonium triflate, dibutylnaphthylsulfonium triflate,
etc., including mixtures thereof. See, e.g., U.S. Pat. Nos.
7,824,839; 7,550,246; 7,534,844; 6,692,891; 5,374,500; and
5,017,461; see also Photoacid Generator Selection Guide for the
electronics industry and energy curable coatings (BASF 2010).
[0095] Hydrogels.
[0096] In some embodiments suitable resins includes photocurable
hydrogels like poly(ethylene glycols) (PEG) and gelatins. PEG
hydrogels have been used to deliver a variety of biologicals,
including Growth factors; however, a great challenge facing PEG
hydrogels crosslinked by chain growth polymerizations is the
potential for irreversible protein damage. Conditions to maximize
release of the biologicals from photopolymerized PEG diacrylate
hydrogels can be enhanced by inclusion of affinity binding peptide
sequences in the monomer resin solutions, prior to
photopolymerization allowing sustained delivery. Gelatin is a
biopolymer frequently used in food, cosmetic, pharmaceutical and
photographic industries. It is obtained by thermal denaturation or
chemical and physical degradation of collagen. There are three
kinds of gelatin, including those found in animals, fish and
humans. Gelatin from the skin of cold water fish is considered safe
to use in pharmaceutical applications. UV or visible light can be
used to crosslink appropriately modified gelatin. Methods for
crosslinking gelatin include cure derivatives from dyes such as
Rose Bengal.
[0097] Photocurable Silicone Resins.
[0098] A suitable resin includes photocurable silicones. UV cure
silicone rubber, such as Silopren.TM. UV Cure Silicone Rubber can
be used as can LOCTITE.TM. Cure Silicone adhesives sealants.
Applications include optical instruments, medical and surgical
equipment, exterior lighting and enclosures, electrical
connectors/sensors, fiber optics and gaskets.
[0099] Biodegradable Resins.
[0100] Biodegradable resins are particularly important for
implantable devices to deliver drugs or for temporary performance
applications, like biodegradable screws and stents (U.S. Pat. Nos.
7,919,162; 6,932,930). Biodegradable copolymers of lactic acid and
glycolic acid (PLGA) can be dissolved in PEG dimethacrylate to
yield a transparent resin suitable for use. Polycaprolactone and
PLGA oligomers can be functionalized with acrylic or methacrylic
groups to allow them to be effective resins for use.
[0101] Photocurable Polyurethanes.
[0102] A particularly useful resin is photocurable polyurethanes. A
photopolymerizable polyurethane composition comprising (1) a
polyurethane based on an aliphatic diisocyanate, poly(hexamethylene
isophthalate glycol) and, optionally, 1,4-butanediol; (2) a
polyfunctional acrylic ester; (3) a photoinitiator; and (4) an
anti-oxidant, can be formulated so that it provides a hard,
abrasion-resistant, and stain-resistant material (U.S. Pat. No.
4,337,130). Photocurable thermoplastic polyurethane elastomers
incorporate photoreactive diacetylene diols as chain extenders.
[0103] High Performance Resins.
[0104] In some embodiments, high performance resins are used. Such
high performance resins may sometimes require the use of heating to
melt and/or reduce the viscosity thereof, as noted above and
discussed further below. Examples of such resins include, but are
not limited to, resins for those materials sometimes referred to as
liquid crystalline polymers of esters, ester-imide, and ester-amide
oligomers, as described in U.S. Pat. Nos. 7,507,784; 6,939,940.
Since such resins are sometimes employed as high-temperature
thermoset resins, in the present invention they further comprise a
suitable photoinitiator such as benzophenone, anthraquinone, and
fluoroenone initiators (including derivatives thereof), to initiate
cross-linking on irradiation, as discussed further below.
[0105] Additional Example Resins.
[0106] Particularly useful resins for dental applications include
EnvisionTEC's Clear Guide, EnvisionTEC's E-Denstone Material.
Particularly useful resins for hearing aid industries include
EnvisionTEC's e-Shell 300 Series of resins. Particularly useful
resins include EnvisionTEC's HTM140IV High Temperature Mold
Material for use directly with vulcanized rubber in molding/casting
applications. A particularly useful material for making tough and
stiff parts includes EnvisionTEC's RC31 resin. A particulary useful
resin for investment casting applications includes EnvisionTEC's
Easy Cast EC500.
[0107] Additional Resin Ingredients.
[0108] The liquid resin or polymerizable material can have solid
particles suspended or dispersed therein. Any suitable solid
particle can be used, depending upon the end product being
fabricated. The particles can be metallic, organic/polymeric,
inorganic, or composites or mixtures thereof. The particles can be
nonconductive, semi-conductive, or conductive (including metallic
and non-metallic or polymer conductors); and the particles can be
magnetic, ferromagnetic, paramagnetic, or nonmagnetic. The
particles can be of any suitable shape, including spherical,
elliptical, cylindrical, etc. The particles can comprise an active
agent or detectable compound as described below, though these may
also be provided dissolved solubilized in the liquid resin as also
discussed below. For example, magnetic or paramagnetic particles or
nanoparticles can be employed. The resin or polymerizable material
may contain a dispersing agent, such as an ionic surfactant, a
non-ionic surfactant, a block copolymer, or the like.
[0109] The liquid resin can have additional ingredients solubilized
therein, including pigments, dyes, active compounds or
pharmaceutical compounds, detectable compounds (e.g., fluorescent,
phosphorescent, radioactive), etc., again depending upon the
particular purpose of the product being fabricated. Examples of
such additional ingredients include, but are not limited to,
proteins, peptides, nucleic acids (DNA, RNA) such as siRNA, sugars,
small organic compounds (drugs and drug-like compounds), etc.,
including combinations thereof.
[0110] Inhibitors of Polymerization.
[0111] Inhibitors or polymerization inhibitors for use in the
present invention may be in the form of a liquid or a gas. In some
embodiments, gas inhibitors are preferred. The specific inhibitor
will depend upon the monomer being polymerized and the
polymerization reaction. For free radical polymerization monomers,
the inhibitor can conveniently be oxygen, which can be provided in
the form of a gas such as air, a gas enriched in oxygen (optionally
but in some embodiments preferably containing additional inert
gases to reduce combustibility thereof), or in some embodiments
pure oxygen gas. In alternate embodiments, such as where the
monomer is polymerized by photoacid generator initiator, the
inhibitor can be a base such as ammonia, trace amines (e.g. methyl
amine, ethyl amine, di and trialkyl amines such as dimethyl amine,
diethyl amine, trimethyl amine, triethyl amine, etc.), or carbon
dioxide, including mixtures or combinations thereof.
[0112] Polymerizable Liquids Carrying Live Cells.
[0113] In some embodiments, the polymerizable liquid may carry live
cells as "particles" therein. Such polymerizable liquids are
generally aqueous, and may be oxygenated, and may be considered as
"emulsions" where the live cells are the discrete phase. Suitable
live cells may be plant cells (e.g., monocot, dicot), animal cells
(e.g., mammalian, avian, amphibian, reptile cells), microbial cells
(e.g., prokaryote, eukaryote, protozoal, etc.), etc. The cells may
be of differentiated cells from or corresponding to any type of
tissue (e.g., blood, cartilage, bone, muscle, endocrine gland,
exocrine gland, epithelial, endothelial, etc.), or may be
undifferentiated cells such as stem cells or progenitor cells. In
such embodiments the polymerizable liquid can be one that forms a
hydrogel, including but not limited to those described in U.S. Pat.
Nos. 7,651,683; 7,651,682; 7,556,490; 6,602,975; 5,836,313;
etc.
2. Apparatus.
[0114] A non-limiting embodiment of an apparatus of the invention
is shown in FIG. 2. It comprises a radiation source 11 such as a
digital light processor (DLP) providing electromagnetic radiation
12 which though reflective mirror 13 illuminates a build chamber
defined by wall 14 and a rigid build plate 15 forming the bottom of
the build chamber, which build chamber is filled with liquid resin
16. The bottom of the chamber 15 is constructed of build plate
comprising a semipermeable member as discussed further below. The
top of the object under construction 17 is attached to a carrier
18. The carrier is driven in the vertical direction by linear stage
19, although alternate structures can be used as discussed
below.
[0115] A liquid resin reservoir, tubing, pumps liquid level sensors
and/or valves can be included to replenish the pool of liquid resin
in the build chamber (not shown for clarity) though in some
embodiments a simple gravity feed may be employed. Drives/actuators
for the carrier or linear stage, along with associated wiring, can
be included in accordance with known techniques (again not shown
for clarity). The drives/actuators, radiation source, and in some
embodiments pumps and liquid level sensors can all be operatively
associated with a suitable controller, again in accordance with
known techniques.
[0116] Build plates 15 used to carry out the present invention
generally comprise or consist of a (typically rigid or solid,
stationary, and/or fixed, but may also be flexible) semipermeable
(or gas permeable) member, alone or in combination with one or more
additional supporting substrates (e.g., clamps and tensioning
members to rigidify an otherwise flexible semipermeable material).
Additional build plate configurations are described with respect to
FIGS. 30-49. The semipermeable member can be made of any suitable
material that is optically transparent at the relevant wavelengths
(or otherwise transparent to the radiation source, whether or not
it is visually transparent as perceived by the human eye--i.e., an
optically transparent window may in some embodiments be visually
opaque), including but not limited to porous or microporous glass,
and the rigid gas permeable polymers used for the manufacture of
rigid gas permeable contact lenses. See, e.g., Norman G. Gaylord,
U.S. Pat. No. RE31,406; see also U.S. Pat. Nos. 7,862,176;
7,344,731; 7,097,302; 5,349,394; 5,310,571; 5,162,469; 5,141,665;
5,070,170; 4,923,906; and 4,845,089. Other suitable
oxygen-permeable materials may be used, including polyester, e.g.,
Mylar.RTM. from Dupont Tejjin Films, Chester, V.A., polyurethane,
polyethelene, polychlorophene, mercapto ester-based resins, e.g.,
Norland 60, from Norland Optical Products, Inc., New Brunswich,
N.J., porous Tygon.RTM. tubing from Saint-Gobain Performance
Plastics, Mickleton, N.J., or other materials. Still other
Exemplary oxygen-permeable materials are described in U.S. Pat. No.
7,709,544, the disclosure of which is incorporated herein by
reference.
[0117] In some embodiments, suitable oxygen-permeable materials are
characterized as glassy and/or amorphous polymers and/or
substantially crosslinked that they are essentially non-swellable.
Preferably the semipermeable member is formed of a material that
does not swell when contacted to the liquid resin or material to be
polymerized (i.e., is "non-swellable"). Suitable materials for the
semipermeable member include amorphous fluoropolymers, such as
those described in U.S. Pat. Nos. 5,308,685 and 5,051,115. For
example, such fluoropolymers are particularly useful over silicones
that would potentially swell when used in conjunction with organic
liquid resin inks to be polymerized. For some liquid resin inks,
such as more aqueous-based monomeric systems and/or some polymeric
resin ink systems that have low swelling tendencies, silicone based
window materials maybe suitable. The solubility or permeability of
organic liquid resin inks can be dramatically decreased by a number
of known parameters including increasing the crosslink density of
the window material or increasing the molecular weight of the
liquid resin ink. In some embodiments the build plate may be formed
from a thin film or sheet of material which is flexible when
separated from the apparatus of the invention, but which is clamped
and tensioned when installed in the apparatus (e.g., with a
tensioning ring) so that it is rendered fixed or rigid in the
apparatus. Particular materials include TEFLON AF.RTM.
fluoropolymers, commercially available from DuPont. Additional
materials include perfluoropolyether polymers such as described in
U.S. Pat. Nos. 8,268,446; 8,263,129; 8,158,728; and 7,435,495.
[0118] It will be appreciated that essentially all solid materials,
and most of those described above, have some inherent "flex" even
though they may be considered "rigid," depending on factors such as
the shape and thickness thereof and environmental factors such as
the pressure and temperature to which they are subjected. In
addition, the terms "stationary" or "fixed" with respect to the
build plate is intended to mean that no mechanical interruption of
the process occurs, or no mechanism or structure for mechanical
interruption of the process (as in a layer-by-layer method or
apparatus) is provided, even if a mechanism for incremental
adjustment of the build plate (for example, adjustment that does
not lead to or cause collapse of the gradient of polymerization
zone) is provided), or if the build surface contributes to
reciprocation to aid feeding of the polymerizable liquid, as
described further below.
[0119] The semipermeable member typically comprises a top surface
portion, a bottom surface portion, and an edge surface portion. The
build surface is on the top surface portion; and the feed surface
may be on one, two, or all three of the top surface portion, the
bottom surface portion, and/or the edge surface portion. In the
embodiment illustrated in FIG. 2 the feed surface is on the bottom
surface portion, but alternate configurations where the feed
surface is provided on an edge, and/or on the top surface portion
(close to but separate or spaced away from the build surface) can
be implemented with routine skill.
[0120] The semipermeable member has, in some embodiments, a
thickness of from 0.01, 0.1 or 1 millimeters to 10 or 100
millimeters, or more (depending upon the size of the item being
fabricated, whether or not it is laminated to or in contact with an
additional supporting plate such as glass, etc., as discussed
further below.
[0121] The permeability of the semipermeable member to the
polymerization inhibitor will depend upon conditions such as the
pressure of the atmosphere and/or inhibitor, the choice of
inhibitor, the rate or speed of fabrication, etc. In general, when
the inhibitor is oxygen, the permeability of the semipermeable
member to oxygen may be from 10 or 20 Barrers, up to 1000 or 2000
Barrers, or more. For example, a semipermeable member with a
permeability of 10 Barrers used with a pure oxygen, or highly
enriched oxygen, atmosphere under a pressure of 150 PSI may perform
substantially the same as a semipermeable member with a
permeability of 500 Barrers when the oxygen is supplied from the
ambient atmosphere under atmospheric conditions.
[0122] Thus, the semipermeable member may comprise a flexible
polymer film (having any suitable thickness, e.g., from 0.001,
0.01, 0.05, 0.1 or 1 millimeters to 1, 5, 10, or 100 millimeters,
or more), and the build plate may further comprise a tensioning
member (e.g., a peripheral clamp and an operatively associated
strain member or stretching member, as in a "drum head"; a
plurality of peripheral clamps, etc., including combinations
thereof) connected to the polymer film and to fix and rigidify the
film (e.g., at least sufficiently so that the film does not stick
to the object as the object is advanced and resiliently or
elastically rebound therefrom). The film has a top surface and a
bottom surface, with the build surface on the top surface and the
feed surface preferably on the bottom surface. In other
embodiments, the semipermeable member comprises: (i) a polymer film
layer (having any suitable thickness, e.g., from 0.001, 0.01, 0.1
or 1 millimeters to 5, 10 or 100 millimeters, or more), having a
top surface positioned for contacting said polymerizable liquid and
a bottom surface, and (ii) a rigid, gas permeable, optically
transparent supporting member (having any suitable thickness, e.g.,
from 0.01, 0.1 or 1 millimeters to 10, 100, or 200 millimeters, or
more), contacting said film layer bottom surface. The supporting
member has a top surface contacting the film layer bottom surface,
and the supporting member has a bottom surface which may serve as
the feed surface for the polymerization inhibitor. Any suitable
materials that permit the polymerization inhibitor to pass to the
build surface may be used, including materials that are
semipermeable (that is, permeable to the polymerization inhibitor).
For example, the polymer film or polymer film layer may, for
example, be a fluoropolymer film, such as an amorphous
thermoplastic fluoropolymer like TEFLON AF 1600.TM. or TEFLON AF
2400.TM. fluoropolymer films, or perfluoropolyether (PFPE),
particularly a crosslinked PFPE film, or a crosslinked silicone
polymer film. The supporting member comprises a silicone or
crosslinked silicone polymer member such as a polydmiethylxiloxane
member, a rigid gas permeable polymer member, or glass member,
including porous or microporous glass. Films can be laminated or
clamped directly to the rigid supporting member without adhesive
(e.g., using PFPE and PDMS materials), or silane coupling agents
that react with the upper surface of a PDMS layer can be utilized
to adhere to the first polymer film layer. UV-curable,
acrylate-functional silicones can also be used as a tie layer
between UV-curable PFPEs and rigid PDMS supporting layers.
[0123] When configured for placement in the apparatus, the carrier
defines a "build region" on the build surface, within the total
area of the build surface. Because lateral "throw" (e.g., in the X
and/or Y directions) is not required in the present invention to
break adhesion between successive layers, as in the Joyce and Chen
devices noted previously, the area of the build region within the
build surface may be maximized (or conversely, the area of the
build surface not devoted to the build region may be minimized).
Hence in some embodiments, the total surface area of the build
region can occupy at least fifty, sixty, seventy, eighty, or ninety
percent of the total surface area of the build surface.
[0124] As shown in FIG. 2, the various components are mounted on a
support or frame assembly 20. While the particular design of the
support or frame assembly is not critical and can assume numerous
configurations, in the illustrated embodiment it is comprised of a
base 21 to which the radiation source 11 is securely or rigidly
attached, a vertical member 22 to which the linear stage is
operatively associated, and a horizontal table 23 to which wall 14
is removably or securely attached (or on which the wall is placed),
and with the build plate rigidly fixed, either permanently or
removably, to form the build chamber as described above.
[0125] As noted above, the build plate can consist of a single
unitary and integral piece of a rigid semipermeable member, or can
comprise additional materials. For example, glass can be laminated
or fixed to a rigid semipermeable material. Or, a semipermeable
member as an upper portion can be fixed to a transparent lower
member having purging channels formed therein for feeding gas
carrying the polymerization inhibitor to the semipermeable member
(through which it passes to the build surface to facilitate the
formation of a release layer of unpolymerized liquid material, as
noted above and below). Such purge channels may extend fully or
partially through the base plate: For example, the purge channels
may extend partially into the base plate, but then end in the
region directly underlying the build surface to avoid introduction
of distortion. Specific geometries will depend upon whether the
feed surface for the inhibitor into the semipermeable member is
located on the same side or opposite side as the build surface, on
an edge portion thereof, or a combination of several thereof.
Additional build plate configurations are described with respect to
FIGS. 30-49.
[0126] Any suitable radiation source (or combination of sources)
can be used, depending upon the particular resin employed,
including electron beam and ionizing radiation sources. In a
preferred embodiment the radiation source is an actinic radiation
source, such as one or more light sources, and in particular one or
more ultraviolet light sources. Any suitable light source can be
used, such as incandescent lights, fluorescent lights,
phosphorescent or luminescent lights, a laser, light-emitting
diode, etc., including arrays thereof. The light source preferably
includes a pattern-forming element operatively associated with a
controller, as noted above. In some embodiments, the light source
or pattern forming element comprises a digital (or deformable)
micromirror device (DMD) with digital light processing (DLP), a
spatial modulator (SLM), or a microelectromechanical system (MEMS)
mirror array, a mask (aka a reticle), a silhouette, or a
combination thereof. See, U.S. Pat. No. 7,902,526. Preferably the
light source comprises a spatial light modulation array such as a
liquid crystal light valve array or micromirror array or DMD (e.g.,
with an operatively associated digital light processor, typically
in turn under the control of a suitable controller), configured to
carry out exposure or irradiation of the polymerizable liquid
without a mask, e.g., by maskless photolithography. See, e.g., U.S.
Pat. Nos. 6,312,134; 6,248,509; 6,238,852; and 5,691,541.
[0127] In some embodiments, as discussed further below, there may
be movement in the X and/or Y directions concurrently with movement
in the Z direction, with the movement in the X and/or Y direction
hence occurring during polymerization of the polymerizable liquid
(this is in contrast to the movement described in Y. Chen et al.,
or M. Joyce, supra, which is movement between prior and subsequent
polymerization steps for the purpose of replenishing polymerizable
liquid). In the present invention such movement may be carried out
for purposes such as reducing "burn in" or fouling in a particular
zone of the build surface.
[0128] Because an advantage of some embodiments of the present
invention is that the size of the build surface on the
semipermeable member (i.e., the build plate or window) may be
reduced due to the absence of a requirement for extensive lateral
"throw" as in the Joyce or Chen devices noted above, in the
methods, systems and apparatus of the present invention lateral
movement (including movement in the X and/or Y direction or
combination thereof) of the carrier and object (if such lateral
movement is present) is preferably not more than, or less than, 80,
70, 60, 50, 40, 30, 20, or even 10 percent of the width (in the
direction of that lateral movement) of the build region.
[0129] While in some embodiments the carrier is mounted on an
elevator to advance up and away from a stationary build plate, on
other embodiments the converse arrangement may be used: That is,
the carrier may be fixed and the build plate lowered to thereby
advance the carrier away therefrom. Numerous different mechanical
configurations will be apparent to those skilled in the art to
achieve the same result.
[0130] Depending on the choice of material from which the carrier
is fabricated, and the choice of polymer or resin from which the
article is made, adhesion of the article to the carrier may
sometimes be insufficient to retain the article on the carrier
through to completion of the finished article or "build." For
example, an aluminum carrier may have lower adhesion than a
poly(vinyl chloride) (or "PVC") carrier. Hence one solution is to
employ a carrier comprising a PVC on the surface to which the
article being fabricated is polymerized. If this promotes too great
an adhesion to conveniently separate the finished part from the
carrier, then any of a variety of techniques can be used to further
secure the article to a less adhesive carrier, including but not
limited to the application of adhesive tape such as "Greener
Masking Tape for Basic Painting #2025 High adhesion" to further
secure the article to the carrier during fabrication.
3. Controller and Process Control.
[0131] The methods and apparatus of the invention can include
process steps and apparatus features to implement process control,
including feedback and feed-forward control, to, for example,
enhance the speed and/or reliability of the method.
[0132] A controller for use in carrying out the present invention
may be implemented as hardware circuitry, software, or a
combination thereof. In one embodiment, the controller is a general
purpose computer that runs software, operatively associated with
monitors, drives, pumps, and other components through suitable
interface hardware and/or software. Suitable software for the
control of a three-dimensional printing or fabrication method and
apparatus as described herein includes, but is not limited to, the
ReplicatorG open source 3d printing program, 3DPrint.TM. controller
software from 3D systems, Slic3r, Skeinforge, KISSlicer,
Repetier-Host, PrintRun, Cura, etc., including combinations
thereof.
[0133] Process parameters to directly or indirectly monitor,
continuously or intermittently, during the process (e.g., during
one, some or all of said filling, irradiating and advancing steps)
include, but are not limited to, irradiation intensity, temperature
of carrier, polymerizable liquid in the build zone, temperature of
growing product, temperature of build plate, pressure, speed of
advance, pressure, force (e.g., exerted on the build plate through
the carrier and product being fabricated), strain (e.g., exerted on
the carrier by the growing product being fabricated), thickness of
release layer, etc.
[0134] Known parameters that may be used in feedback and/or
feed-forward control systems include, but are not limited to,
expected consumption of polymerizable liquid (e.g., from the known
geometry or volume of the article being fabricated), degradation
temperature of the polymer being formed from the polymerizable
liquid, etc.
[0135] Process conditions to directly or indirectly control,
continuously or step-wise, in response to a monitored parameter,
and/or known parameters (e.g., during any or all of the process
steps noted above), include, but are not limited to, rate of supply
of polymerizable liquid, temperature, pressure, rate or speed of
advance of carrier, intensity of irradiation, duration of
irradiation (e.g. for each "slice"), etc.
[0136] For example, the temperature of the polymerizable liquid in
the build zone, or the temperature of the build plate, can be
monitored, directly or indirectly with an appropriate thermocouple,
non-contact temperature sensor (e.g., an infrared temperature
sensor), or other suitable temperature sensor, to determine whether
the temperature exceeds the degradation temperature of the
polymerized product. If so, a process parameter may be adjusted
through a controller to reduce the temperature in the build zone
and/or of the build plate. Suitable process parameters for such
adjustment may include: decreasing temperature with a cooler,
decreasing the rate of advance of the carrier, decreasing intensity
of the irradiation, decreasing duration of radiation exposure,
etc.
[0137] In addition, the intensity of the irradiation source (e.g.,
an ultraviolet light source such as a mercury lamp) may be
monitored with a photodetector to detect a decrease of intensity
from the irradiation source (e.g., through routine degredation
thereof during use). If detected, a process parameter may be
adjusted through a controller to accommodate the loss of intensity.
Suitable process parameters for such adjustment may include:
increasing temperature with a heater, decreasing the rate of
advance of the carrier, increasing power to the light source,
etc.
[0138] As another example, control of temperature and/or pressure
to enhance fabrication time may be achieved with heaters and
coolers (individually, or in combination with one another and
separately responsive to a controller), and/or with a pressure
supply (e.g., pump, pressure vessel, valves and combinations
thereof) and/or a pressure release mechanism such as a controllable
valve (individually, or in combination with one another and
separately responsive to a controller).
[0139] In some embodiments the controller is configured to maintain
the gradient of polymerization zone described herein (see, e.g.,
FIG. 1) throughout the fabrication of some or all of the final
product. The specific configuration (e.g., times, rate or speed of
advancing, radiation intensity, temperature, etc.) will depend upon
factors such as the nature of the specific polymerizable liquid and
the product being created. Configuration to maintain the gradient
of polymerization zone may be carried out empirically, by entering
a set of process parameters or instructions previously determined,
or determined through a series of test runs or "trial and error";
configuration may be provided through pre-determined instructions;
configuration may be achieved by suitable monitoring and feedback
(as discussed above), combinations thereof, or in any other
suitable manner.
[0140] In some embodiments, a method and apparatus as described
above may be controlled by a software program running in a general
purpose computer with suitable interface hardware between that
computer and the apparatus described above. Numerous alternatives
are commercially available. Non-limiting examples of one
combination of components is shown in FIGS. 3 to 5, where
"Microcontroller" is Parallax Propeller, the Stepper Motor Driver
is Sparkfun EasyDriver, the LED Driver is a Luxeon Single LED
Driver, the USB to Serial is a Parallax USB to Serial converter,
and the DLP System is a Texas Instruments LightCrafter system.
4. General Methods.
[0141] As noted above, the present invention provides 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 and a feed surface separate from said build surface,
with said build surface and said carrier defining a build region
therebetween, and with said feed surface in fluid contact with a
polymerization inhibitor; then (concurrently and/or sequentially)
(b) filing said build region with a polymerizable liquid, said
polymerizable liquid contacting said build segment, (c) irradiating
said build region through said build plate to produce a solid
polymerized region in said build region, with a liquid film release
layer comprised of said polymerizable liquid formed 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 stationary build plate
to create a subsequent build region between said polymerized region
and said top zone. In general the method includes (e) continuing
and/or repeating steps (b) through (d) to produce 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.
[0142] Since no mechanical release of a release layer is required,
or no mechanical movement of a build surface to replenish oxygen is
required, the method can be carried out in a continuous fashion,
though it will be appreciated that the individual steps noted above
may be carried out sequentially, concurrently, or a combination
thereof. Indeed, the rate of steps can be varied over time
depending upon factors such as the density and/or complexity of the
region under fabrication.
[0143] Also, since mechanical release from a window or from a
release layer generally requires that the carrier be advanced a
greater distance from the build plate than desired for the next
irradiation step, which enables the window to be recoated, and then
return of the carrier back closer to the build plate (e.g., a "two
steps forward one step back" operation), the present invention in
some embodiments permits elimination of this "back-up" step and
allows the carrier to be advanced unidirectionally, or in a single
direction, without intervening movement of the window for
re-coating, or "snapping" of a pre-formed elastic release-layer.
However, in other embodiments of the invention, reciprocation is
utilized not for the purpose of obtaining release, but for the
purpose of more rapidly filling or pumping polymerizable liquid
into the build region.
[0144] In some embodiments, the advancing step is carried out
sequentially in uniform increments (e.g., of from 0.1 or 1 microns,
up to 10 or 100 microns, or more) for each step or increment. In
some embodiments, the advancing step is carried out sequentially in
variable increments (e.g., each increment ranging from 0.1 or 1
microns, up to 10 or 100 microns, or more) for each step or
increment. The size of the increment, along with the rate of
advancing, will depend in part upon factors such as temperature,
pressure, structure of the article being produced (e.g., size,
density, complexity, configuration, etc.)
[0145] In other embodiments of the invention, the advancing step is
carried out continuously, at a uniform or variable rate.
[0146] In some embodiments, the rate of advance (whether carried
out sequentially or continuously) is from about 0.1 l, or 10
microns per second, up to about to 100, 1,000, or 10,000 microns
per second, again depending again depending on factors such as
temperature, pressure, structure of the article being produced,
intensity of radiation, etc
[0147] As described further below, in some embodiments the filling
step is carried out by forcing said polymerizable liquid into said
build region under pressure. In such a case, the advancing step or
steps may be carried out at a rate or cumulative or average rate of
at least 0.1, 1, 10, 50, 100, 500 or 1000 microns per second, or
more. In general, the pressure may be whatever is sufficient to
increase the rate of said advancing step(s) at least 2, 4, 6, 8 or
10 times as compared to the maximum rate of repetition of said
advancing steps in the absence of said pressure. Where the pressure
is provided by enclosing an apparatus such as described above in a
pressure vessel and carrying the process out in a pressurized
atmosphere (e.g., of air, air enriched with oxygen, a blend of
gasses, pure oxygen, etc.) a pressure of 10, 20, 30 or 40 pounds
per square inch (PSI) up to, 200, 300, 400 or 500 PSI or more, may
be used. For fabrication of large irregular objects higher
pressures may be less preferred as compared to slower fabrication
times due to the cost of a large high pressure vessel. In such an
embodiment, both the feed surface and the polymerizable liquid can
be in fluid contact with the same compressed gas (e.g., one
comprising from 20 to 95 percent by volume of oxygen, the oxygen
serving as the polymerization inhibitor.
[0148] On the other hand, when smaller items are fabricated, or a
rod or fiber is fabricated that can be removed or exited from the
pressure vessel as it is produced through a port or orifice
therein, then the size of the pressure vessel can be kept smaller
relative to the size of the product being fabricated and higher
pressures can (if desired) be more readily utilized.
[0149] As noted above, the irradiating step is in some embodiments
carried out with patterned irradiation. The patterned irradiation
may be a fixed pattern or may be a variable pattern created by a
pattern generator (e.g., a DLP) as discussed above, depending upon
the particular item being fabricated.
[0150] When the patterned irradiation is a variable pattern rather
than a pattern that is held constant over time, then each
irradiating step may be any suitable time or duration depending on
factors such as the intensity of the irradiation, the presence or
absence of dyes in the polymerizable material, the rate of growth,
etc. Thus in some embodiments each irradiating step can be from
0.001, 0.01, 0.1, 1 or 10 microseconds, up to 1, 10, or 100
minutes, or more, in duration. The interval between each
irradiating step is in some embodiments preferably as brief as
possible, e.g., from 0.001, 0.01, 0.1, or 1 microseconds up to 0.1,
1, or 10 seconds.
[0151] While the dead zone and the gradient of polymerization zone
do not have a strict boundary therebetween (in those locations
where the two meet), the thickness of the gradient of
polymerization zone is in some embodiments at least as great as the
thickness of the dead zone. Thus, in some embodiments, the dead
zone has a thickness of from 0.01, 0.1, 1, 2, or 10 microns up to
100, 200 or 400 microns, or more, and/or said gradient of
polymerization zone and said dead zone together have a thickness of
from 1 or 2 microns up to 400, 600, or 1000 microns, or more. Thus
the gradient of polymerization zone may be thick or thin depending
on the particular process conditions at that time. Where the
gradient of polymerization zone is thin, it may also be described
as an active surface on the bottom of the growing three-dimensional
object, with which monomers can react and continue to form growing
polymer chains therewith. In some embodiments, the gradient of
polymerization zone, or active surface, is maintained (while
polymerizing steps continue) for a time of at least 5, 10, 15, 20
or 30 seconds, up to 5, 10, 15 or 20 minutes or more, or until
completion of the three-dimensional product.
[0152] The method may further comprise the step of disrupting said
gradient of polymerization zone for a time sufficient to form a
cleavage line in said three-dimensional object (e.g., at a
predetermined desired location for intentional cleavage, or at a
location in said object where prevention of cleavage or reduction
of cleavage is non-critical), and then reinstating said gradient of
polymerization zone (e.g. by pausing, and resuming, the advancing
step, increasing, then decreasing, the intensity of irradiation,
and combinations thereof
[0153] In some embodiments the build surface is flat; in other the
build surface is irregular such as convexly or concavely curved, or
has walls or trenches formed therein. In either case the build
surface may be smooth or textured.
[0154] Curved and/or irregular build plates or build surfaces can
be used in fiber or rod formation, to provide different materials
to a single object being fabricated (that is, different
polymerizable liquids to the same build surface through channels or
trenches formed in the build surface, each associated with a
separate liquid supply, etc.
[0155] Carrier Feed Channels for Polymerizable Liquid.
[0156] While polymerizable liquid may be provided directly to the
build plate from a liquid conduit and reservoir system, in some
embodiments the carrier include one or more feed channels therein.
The carrier feed channels are in fluid communication with the
polymerizable liquid supply, for example a reservoir and associated
pump. Different carrier feed channels may be in fluid communication
with the same supply and operate simultaneously with one another,
or different carrier feed channels may be separately controllable
from one another (for example, through the provision of a pump
and/or valve for each). Separately controllable feed channels may
be in fluid communication with a reservoir containing the same
polymerizable liquid, or may be in fluid communication with a
reservoir containing different polymerizable liquids. Through the
use of valve assemblies, different polymerizable liquids may in
some embodiments be alternately fed through the same feed channel,
if desired.
[0157] Three-dimensional products produced by the methods and
processes of the present invention may be final, finished or
substantially finished products, or may be intermediate products
subject to further manufacturing steps such as surface treatment,
laser cutting, electric discharge machining, etc., is intended.
Intermediate products include products for which further additive
manufacturing, in the same or a different apparatus, may be carried
out). The three dimensional intermediate is preferably formed from
resins as described above by additive manufacturing, typically
bottom-up or top-down additive manufacturing. Such methods are
known and described in, for example, U.S. Pat. No. 5,236,637 to
Hull, U.S. Pat. Nos. 5,391,072 and 5,529,473 to Lawton, U.S. Pat.
No. 7,438,846 to John, U.S. Pat. No. 7,892,474 to Shkolnik, U.S.
Pat. No. 8,110,135 to El-Siblani, U.S. Patent Application
Publication Nos. 2013/0292862 to Joyce and 2013/0295212 to Chen et
al., and PCT Application Publicaiton No. WO 2015/164234 to Robeson
et al. The disclosures of these patents and applications are
incorporated by reference herein in their entirety.
[0158] In general, top-down three-dimensional fabrication is
carried out by:
[0159] (a) providing a polymerizable liquid reservoir having a
polymerizable liquid fill level and a carrier positioned in the
reservoir, the carrier and the fill level defining a build region
therebetween;
[0160] (b) filling the build region with a polymerizable liquid
(i.e., the resin), said polymerizable liquid comprising a mixture
of (i) a light (typically ultraviolet light) polymerizable liquid
first component, and (ii) a second solidifiable component of the
dual cure system; and then
[0161] (c) irradiating the build region with light to form a solid
polymer scaffold from the first component and also advancing
(typically lowering) 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 said second solidifiable component (e.g., a second
reactive component) carried in the scaffold in unsolidified and/or
uncured form.
[0162] A wiper blade, doctor blade, or optically transparent (rigid
or flexible) window, may optionally be provided at the fill level
to facilitate leveling of the polymerizable liquid, in accordance
with known techniques. In the case of an optically transparent
window, the window provides a build surface against which the three
dimensional intermediate is formed, analogous to the build surface
in bottom-up three dimensional fabrication as discussed below.
[0163] In general, bottom-up three dimensional fabrication is
carried out by:
[0164] (a) providing a carrier and an optically transparent member
having a build surface, the carrier and the build surface defining
a build region therebetween;
[0165] (b) filling the build region with a polymerizable liquid
(i.e., the resin), said polymerizable liquid comprising a mixture
of (i) a light (typically ultraviolet light) polymerizable liquid
first component, and (ii) a second solidifiable component of the
dual cure system; and then
[0166] (c) irradiating the build region with light through said
optically transparent member to form a solid polymer scaffold from
the first component and also advancing (typically raising) 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 said second
solidifiable component (e.g., a second reactive component) carried
in the scaffold in unsolidified and/or uncured form.
[0167] In some embodiments of bottom up or top down three
dimensional fabrication as implemented in the context of the
present invention, the build surface is stationary during the
formation of the three dimensional intermediate; in other
embodiments of bottom-up three dimensional fabrication as
implemented in the context of the present invention, the build
surface is tilted, slid, flexed and/or peeled, and/or otherwise
translocated or released from the growing three dimensional
intermediate, usually repeatedly, during formation of the three
dimensional intermediate.
[0168] In some embodiments of bottom up or top down three
dimensional fabrication as carried out in the context of the
present invention, the polymerizable liquid (or resin) is
maintained in liquid contact with both the growing thee dimensional
intermediate and the build surface during both the filling and
irradiating steps, during fabrication of some of, a major portion
of, or all of the three dimensional intermediate.
[0169] In some embodiments of bottom-up or top down three
dimensional fabrication as carried out in the context of the
present invention, the growing three dimensional intermediate is
fabricated in a layerless manner (e.g., through multiple exposures
or "slices" of patterned actinic radiation or light) during at
least a portion of the formation of the three dimensional
intermediate.
[0170] In some embodiments of bottom up or top down three
dimensional fabrication as carried out in the context of the
present invention, the growing three dimensional intermediate is
fabricated in a layer-by-layer manner (e.g., through multiple
exposures or "slices" of patterned actinic radiation or light),
during at least a portion of the formation of the three dimensional
intermediate.
[0171] In some embodiments of bottom up or top down three
dimensional fabrication employing a rigid or flexible optically
transparent window, a lubricant or immiscible liquid may be
provided between the window and the polymerizable liquid (e.g., a
fluorinated fluid or oil such as a perfluoropolyether oil).
[0172] From the foregoing it will be appreciated that, in some
embodiments of bottom-up or top down three dimensional fabrication
as carried out in the context of the present invention, the growing
three dimensional intermediate is fabricated in a layerless manner
during the formation of at least one portion thereof, and that same
growing three dimensional intermediate is fabricated in a
layer-by-layer manner during the formation of at least one other
portion thereof. Thus, operating mode may be changed once, or on
multiple occasions, between layerless fabrication and
layer-by-layer fabrication, as desired by operating conditions such
as part geometry.
[0173] In preferred embodiments, the intermediate is formed by
continuous liquid interface production (CLIP). CLIP is known and
described in, for example, PCT Applications Nos. PCT/US2014/015486
(published as U.S. Pat. No. 9,211,678 on Dec. 15, 2015);
PCT/US2014/015506 (also published as U.S. Pat. No. 9,205,601 on
Dec. 8, 2015), PCT/US2014/015497 (also published as US
2015/0097316, and to publish as U.S. Pat. No. 9,216,546 on Dec. 22,
2015), and in J. Tumbleston, D. Shirvanyants, N. Ermoshkin et al.,
Continuous liquid interface production of 3D Objects, Science 347,
1349-1352 (published online 16 Mar. 2015). In some embodiments,
CLIP employs features of a bottom-up three dimensional fabrication
as described above, but the irradiating and/or said advancing steps
are carried out while also concurrently maintaining a stable or
persistent liquid interface between the growing object and the
build surface or window, such as by: (i) continuously maintaining a
dead zone of polymerizable liquid in contact with said build
surface, and (ii) continuously maintaining a gradient of
polymerization zone (such as an active surface) between the dead
zone and the solid polymer and in contact with each thereof, the
gradient of polymerization zone comprising the first component in
partially cured form. In some embodiments of CLIP, the optically
transparent member comprises a semipermeable member (e.g., a
fluoropolymer), and the continuously maintaining a dead zone is
carried out by feeding an inhibitor of polymerization through the
optically transparent member, thereby creating a gradient of
inhibitor in the dead zone and optionally in at least a portion of
the gradient of polymerization zone.
[0174] In some embodiments, the stable liquid interface may be
achieved by other techniques, such as by providing an immiscible
liquid as the build surface between the polymerizable liquid and
the optically transparent member, by feeding a lubricant to the
build surface (e.g., through an optically transparent member which
is semipermeable thereto, and/or serves as a reservoir thereof),
etc.
[0175] While the dead zone and the gradient of polymerization zone
do not have a strict boundary therebetween (in those locations
where the two meet), the thickness of the gradient of
polymerization zone is in some embodiments at least as great as the
thickness of the dead zone. Thus, in some embodiments, the dead
zone has a thickness of from 0.01, 0.1, 1, 2, or 10 microns up to
100, 200 or 400 microns, or more, and/or the gradient of
polymerization zone and the dead zone together have a thickness of
from 1 or 2 microns up to 400, 600, or 1000 microns, or more. Thus
the gradient of polymerization zone may be thick or thin depending
on the particular process conditions at that time. Where the
gradient of polymerization zone is thin, it may also be described
as an active surface on the bottom of the growing three-dimensional
object, with which monomers can react and continue to form growing
polymer chains therewith. In some embodiments, the gradient of
polymerization zone, or active surface, is maintained (while
polymerizing steps continue) for a time of at least 5, 10, 15, 20
or 30 seconds, up to 5, 10, 15 or 20 minutes or more, or until
completion of the three-dimensional product.
[0176] Inhibitors, or polymerization inhibitors, for use in the
present invention may be in the form of a liquid or a gas. In some
embodiments, gas inhibitors are preferred. In some embodiments,
liquid inhibitors such as oils or lubricants may be employed. In
further embodiments, gas inhibitors which are dissolved in liquids
(e.g. oils or lubricants) may be employed. For example, oxygen
dissolved in a fluorinated fluid. The specific inhibitor will
depend upon the monomer being polymerized and the polymerization
reaction. For free radical polymerization monomers, the inhibitor
can conveniently be oxygen, which can be provided in the form of a
gas such as air, a gas enriched in oxygen (optionally but in some
embodiments preferably containing additional inert gases to reduce
combustibility thereof), or in some embodiments pure oxygen gas. In
alternate embodiments, such as where the monomer is polymerized by
photoacid generator initiator, the inhibitor can be a base such as
ammonia, trace amines (e.g. methyl amine, ethyl amine, di and
trialkyl amines such as dimethyl amine, diethyl amine, trimethyl
amine, triethyl amine, etc.), or carbon dioxide, including mixtures
or combinations thereof.
[0177] The method may further comprise the step of disrupting the
gradient of polymerization zone for a time sufficient to form a
cleavage line in the three-dimensional object (e.g., at a
predetermined desired location for intentional cleavage, or at a
location in the object where prevention of cleavage or reduction of
cleavage is non-critical), and then reinstating the gradient of
polymerization zone (e.g. by pausing, and resuming, the advancing
step, increasing, then decreasing, the intensity of irradiation,
and combinations thereof).
[0178] CLIP may be carried out in different operating modes
operating modes (that is, different manners of advancing the
carrier and build surface away from one another), including
continuous, intermittent, reciprocal, and combinations thereof.
[0179] Thus in some embodiments, the advancing step is carried out
continuously, at a uniform or variable rate, with either constant
or intermittent illumination or exposure of the build area to the
light source.
[0180] In other embodiments, the advancing step is carried out
sequentially in uniform increments (e.g., of from 0.1 or 1 microns,
up to 10 or 100 microns, or more) for each step or increment. In
some embodiments, the advancing step is carried out sequentially in
variable increments (e.g., each increment ranging from 0.1 or 1
microns, up to 10 or 100 microns, or more) for each step or
increment. The size of the increment, along with the rate of
advancing, will depend in part upon factors such as temperature,
pressure, structure of the article being produced (e.g., size,
density, complexity, configuration, etc.).
[0181] In some embodiments, the rate of advance (whether carried
out sequentially or continuously) is from about 0.1 l, or 10
microns per second, up to about to 100, 1,000, or 10,000 microns
per second, again depending again depending on factors such as
temperature, pressure, structure of the article being produced,
intensity of radiation, etc.
[0182] In still other embodiments, the carrier is vertically
reciprocated with respect to the build surface to enhance or speed
the refilling of the build region with the polymerizable liquid. In
some embodiments, the vertically reciprocating step, which
comprises an upstroke and a downstroke, is carried out with the
distance of travel of the upstroke being greater than the distance
of travel of the downstroke, to thereby concurrently carry out the
advancing step (that is, driving the carrier away from the build
plate in the Z dimension) in part or in whole.
[0183] In some embodiments, the solidifiable or polymerizable
liquid is changed at least once during the method with a subsequent
solidifiable or polymerizable liquid (e.g., by switching a "window"
or "build surface" and associated reservoir of polymerizable liquid
in the apparatus); optionally where the subsequent solidifiable or
polymerizable liquid is cross-reactive with each previous
solidifiable or polymerizable liquid during the subsequent curing,
to form an object having a plurality of structural segments
covalently coupled to one another, each structural segment having
different structural (e.g., tensile) properties (e.g., a rigid
funnel or liquid connector segment, covalently coupled to a
flexible pipe or tube segment).
[0184] Once the three-dimensional intermediate is formed, it may be
removed from the carrier, optionally washed, any supports
optionally removed, any other modifications optionally made
(cutting, welding, adhesively bonding, joining, grinding, drilling,
etc.), and then heated and/or microwave irradiated sufficiently to
further cure the resin and form the three dimensional object. Of
course, additional modifications may also be made following the
heating and/or microwave irradiating step.
[0185] Washing may be carried out with any suitable organic or
aqueous wash liquid, or combination thereof, including solutions,
suspensions, emulsions, microemulsions, etc. Examples of suitable
wash liquids include, but are not limited to water, alcohols (e.g.,
methanol, ethanol, isopropanol, etc.), benzene, toluene, etc. Such
wash solutions may optionally contain additional constituents such
as surfactants, etc. A currently preferred wash liquid is a 50:50
(volume:volume) solution of water and isopropanol. Wash methods
such as those described in U.S. Pat. No. 5,248,456 may be employed
and are included therein.
[0186] After the intermediate is formed, optionally washed, etc.,
as described above, it is then heated and/or microwave irradiated
to further cure the same. Heating may be active heating (e.g., in
an oven, such as an electric, gas, or solar oven), or passive
heating (e.g., at ambient temperature). Active heating will
generally be more rapid than passive heating and in some
embodiments is preferred, but passive heating--such as simply
maintaining the intermediate at ambient temperature for a
sufficient time to effect further cure--is in some embodiments
preferred.
[0187] In some embodiments, the heating step is carried out at at
least a first temperature and a second temperature, with the first
temperature greater than ambient temperature, the second
temperature greater than the first temperature, and the second
temperature less than 300.degree. C. (e.g., with ramped or
step-wise increases between ambient temperature and the first
temperature, and/or between the first temperature and the second
temperature).
[0188] For example, the intermediate may be heated in a stepwise
manner at a first oven temperature of about 70.degree. C. to about
150.degree. C., and then at a second temperature of about
150.degree. C. to 200 or 250.degree. C., with the duration of each
heating depending on the size, shape, and/or thickness of the
intermediate. In another embodiment, the intermediate may be cured
by a ramped heating schedule, with the temperature ramped from
ambient temperature through a temperature of 70 to 150.degree. C.,
and up to a final oven temperature of 250 or 300.degree. C., at a
change in heating rate of 0.5.degree. C. per minute, to 5.degree.
C. per minute. (See, e.g., U.S. Pat. No. 4,785,075).
[0189] It will be clear to those skilled in the art that the
materials described in the current invention will be useful in
other additive manufacturing techniques, including ink-jet
printer-based methods.
5. Reciprocating Feed of Polymerizable Liquid.
[0190] In an embodiment of the present invention, the carrier is
vertically reciprocated with respect to the build surface (that is,
the two are vertically reciprocated with respect to one another) to
enhance or speed the refilling of the build region with the
polymerizable liquid.
[0191] In some embodiments, the vertically reciprocating step,
which comprises an upstroke and a downstroke, is carried out with
the distance of travel of the upstroke being greater than the
distance of travel of the downstroke, to thereby concurrently carry
out the advancing step (that is, driving the carrier away from the
build plate in the Z dimension) in part or in whole.
[0192] In some embodiments, the speed of the upstroke gradually
accelerates (that is, there is provided a gradual start and/or
gradual acceleration of the upstroke, over a period of at least 20,
30, 40, or 50 percent of the total time of the upstroke, until the
conclusion of the upstroke, or the change of direction which
represents the beginning of the downstroke. Stated differently, the
upstroke begins, or starts, gently or gradually.
[0193] In some embodiments, the speed of the downstroke gradually
decelerates (that is, there is provided a gradual termination
and/or gradual deceleration of the downstroke, over a period of at
least 20, 30, 40, or 50 percent of the total time of the
downstroke. Stated differently, the downstroke concludes, or ends,
gently or gradually.
[0194] While in some embodiments there is an abrupt end, or abrupt
deceleration, of the upstroke, and an abrupt beginning or
deceleration of the downstroke (e.g., a rapid change in vector or
direction of travel from upstroke to downstroke), it will be
appreciated that gradual transitions may be introduced here as well
(e.g., through introduction of a "plateau" or pause in travel
between the upstroke and downstroke). It will also be appreciated
that, while each reciprocating step may be consist of a single
upstroke and downstroke, the reciprocation step may comprise a
plurality of 2, 3, 4 or 5 or more linked set of reciprocations,
which may e the same or different in frequent and/or amplitude
[0195] In some embodiments, the vertically reciprocating step is
carried out over a total time of from 0.01 or 0.1 seconds up to 1
or 10 seconds (e.g., per cycle of an upstroke and a
downstroke).
[0196] In some embodiments, the upstroke distance of travel is from
0.02 or 0.2 millimeters (or 20 or 200 microns) to 1 or 10
millimeters (or 1000 to 10,000 microns). The distance of travel of
the downstroke may be the same as, or less than, the distance of
travel of the upstroke, where a lesser distance of travel for the
downstroke serves to achieve the advancing of the carrier away from
the build surface as the three-dimensional object is gradually
formed. Where a reciprocation step comprises multiple linked
reciprocations, the sum distance of travel of all upstrokes in that
set is preferably greater than the sum distance of travel of all
downstrokes in that set, to achieve the advancing of the carrier
away from the build surface as the three-dimensional object is
gradually formed.
[0197] Preferably the vertically reciprocating step, and
particularly the upstroke thereof, does not cause the formation of
gas bubbles or a gas pocket in the build region, but instead the
build region remains filled with the polymerizable liquid
throughout the reciprocation steps, and the gradient of
polymerization zone or region remains in contact with the "dead
zone" and with the growing object being fabricated throughout the
reciprocation steps. As will be appreciated, a purpose of the
reciprocation is to speed or enhance the refilling of the build
region, particularly where larger build regions are to be refilled
with polymerizable liquid, as compared to the speed at which the
build region could be refilled without the reciprocation step.
[0198] In some embodiments, the advancing step is carried out
intermittently at a rate of 1, 2, 5 or 10 individual advances per
minute up to 300, 600, or 1000 individual advances per minute, each
followed by a pause during which an irradiating step is carried
out. It will be appreciated that one or more reciprocation steps
(e.g., upstroke plus downstroke) may be carried out within each
advancing step. Stated differently, the reciprocating steps may be
nested within the advancing steps.
[0199] In some embodiments, the individual advances are carried out
over an average distance of travel for each advance of from 10 or
50 microns to 100 or 200 microns (optionally including the total
distance of travel for each vertically reciprocating step, e.g.,
the sum of the upstroke distance minus the downstroke
distance).
[0200] Apparatus for carrying out the invention in which the
reciprocation steps described herein are implemented substantially
as described above, with the drive associated with the carrier,
and/or with an additional drive operatively associated with the
transparent member, and with the controller operatively associated
with either or both thereof and configured to reciprocate the
carrier and transparent member with respect to one another as
described above.
[0201] In the alternative, vertical reciprocation may be carried
out by configuring the build surface (and corresponding build
plate) so that it may have a limited range of movement up and down
in the vertical or "Z" dimension, while the carrier advances (e.g.,
continuously or step-wise) away from the build plate in the
vertical or "Z" dimension. In some embodiments, such limited range
of movement may be passively imparted, such as with upward motion
achieved by partial adhesion of the build plate to the growing
object through a viscous polymerizable liquid, followed by downward
motion achieved by the weight, resiliency, etc. of the build plate
(optionally including springs, buffers, shock absorbers or the
like, configured to influence either upward or downward motion of
the build plate and build surface). In another embodiment, such
motion of the build surface may be actively achieved, by
operatively associating a separate drive system with the build
plate, which drive system is also operatively associated with the
controller, to separately achieve vertical reciprocation. In still
another embodiment, vertical reciprocation may be carried out by
configuring the build plate, and/or the build surface, so that it
flexes upward and downward, with the upward motion thereof being
achieved by partial adhesion of the build surface to the growing
object through a viscous polymerizable liquid, followed by downward
motion achieved by the inherent stiffness of the build surface
biasing it or causing it to return to a prior position.
[0202] It will be appreciated that illumination or irradiation
steps, when intermittent, may be carried out in a manner
synchronized with vertical reciprocation, or not synchronized with
vertical reciprocation, depending on factors such as whether the
reciprocation is achieved actively or passively.
[0203] It will also be appreciated that vertical reciprocation may
be carried out between the carrier and all regions of the build
surface simultaneously (e.g., where the build surface is rigid), or
may be carried out between the carrier and different regions of the
build surface at different times (e.g., where the build surface is
of a flexible material, such as a tensioned polymer film).
6. Increased Speed of Fabrication by Increasing Light
Intensity.
[0204] In general, it has been observed that speed of fabrication
can increase with increased light intensity. In some embodiments,
the light is concentrated or "focused" at the build region to
increase the speed of fabrication. This may be accomplished using
an optical device such as an objective lens.
[0205] The speed of fabrication may be generally proportional to
the light intensity. For example, the build speed in millimeters
per hour may be calculated by multiplying the light intensity in
milliWatts per square centimeter and a multiplier. The multiplier
may depend on a variety of factors, including those discussed
below. A range of multipliers, from low to high, may be employed.
On the low end of the range, the multiplier may be about 10, 15, 20
or 30. On the high end of the multiplier range, the multiplier may
be about 150, 300, 400 or more.
[0206] The relationships described above are, in general,
contemplated for light intensities of from 1, 5 or 10 milliWatts
per square centimeter, up to 20 or 50 milliWatts per square
centimeter.
[0207] Certain optical characteristics of the light may be selected
to facilitate increased speed of fabrication. By way of example, a
band pass filter may be used with a mercury bulb light source to
provide 365.+-.10 nm light measured at Full Width Half Maximum
(FWHM). By way of further example, a band pass filter may be used
with an LED light source to provide 375.+-.15 nm light measured at
FWHM.
[0208] As noted above, poymerizable liquids used in such processes
are, in general, free radical polymerizable liquids with oxygen as
the inhibitor, or acid-catalyzed or cationically polymerizable
liquids with a base as the inhibitor. Some specific polymerizable
liquids will of course cure more rapidly or efficiently than others
and hence be more amenable to higher speeds, though this may be
offset at least in part by further increasing light intensity.
[0209] At higher light intensities and speeds, the "dead zone" may
become thinner as inhibitor is consumed. If the dead zone is lost
then the process will be disrupted. In such case, the supply of
inhibitor may be enhanced by any suitable means, including
providing an enriched and/or pressurized atmosphere of inhibitor, a
more porous semipermeable member, a stronger or more powerful
inhibitor (particularly where a base is employed), etc.
[0210] In general, lower viscosity polymerizable liquids are more
amenable to higher speeds, particularly for fabrication of articles
with a large and/or dense cross section (although this can be
offset at least in part by increasing light intensity).
Polymerizable liquids with viscosities in the range of 50 or 100
centipoise, up to 600, 800 or 1000 centipoise or more (as measured
at room temperature and atmospheric pressure with a suitable device
such as a HYDRAMOTION REACTAVISC.TM. Viscometer (available from
Hydramotion Ltd, 1 York Road Business Park, Malton, York YO17 6YA
England). In some embodiments, where necessary, the viscosity of
the polymerizable liquid can advantageously be reduced by heating
the polymerizable liquid, as described above.
[0211] In some embodiments, such as fabrication of articles with a
large and/or dense cross-section, speed of fabrication can be
enhanced by introducing reciprocation to "pump" the polymerizable
liquid, as described above, and/or the use of feeding the
polymerizable liquid through the carrier, as also described above,
and/or heating and/or pressurizing the polymerizable liquid, as
also described above.
7. Tiling.
[0212] It may be desirable to use more than one light engine to
preserve resolution and light intensity for larger build sizes.
Each light engine may be configured to project an image (e.g., an
array of pixels) into the build region such that a plurality of
"tiled" images are projected into the build region. As used herein,
the term "light engine" can mean an assembly including a light
source, a DLP device such as a digital micromirror device and/or an
optical device such as an objective lens. The "light engine" may
also include electronics such as a controller that is operatively
associated with one or more of the other components.
[0213] This is shown schematically in FIGS. 17A-17C. The light
engine assemblies 130A, 130B produce adjacent or "tiled" images
140A, 140B. In FIG. 17A, the images are slightly misaligned; that
is, there is a gap between them. In FIG. 17B, the images are
aligned; there is no gap and no overlap between them. In FIG. 17C,
there is a slight overlap of the images 140A and 140B.
[0214] In some embodiments, the configuration with the overlapped
images shown in FIG. 17C is employed with some form of "blending"
or "smoothing" of the overlapped regions as generally discussed in,
for example, U.S. Pat. Nos. 7,292,207, 8,102,332, 8,427,391,
8,446,431 and U.S. Patent Application Publication Nos.
2013/0269882, 2013/0278840 and 2013/0321475, the disclosures of
which are incorporated herein in their entireties. The tiled images
can allow for larger build areas without sacrificing light
intensity, and therefore can facilitate faster build speeds for
larger objects. It will be understood that more than two light
engine assemblies (and corresponding tiled images) may be employed.
Various embodiments of the invention employ at least 4, 8, 16, 32,
64, 128 or more tiled images.
8. Fabrication in Multiple Zones.
[0215] As noted above, embodiments of the invention may carry out
the formation of the three-dimensional object through multiple
zones or segments of operation. Such a method generally
comprises:
[0216] (a) providing a carrier and an optically transparent member
having a build surface, the carrier and the build surface defining
a build region therebetween, with the carrier positioned adjacent
and spaced apart from the build surface at a start position;
then
[0217] (b) forming an adhesion segment of the three-dimensional
object by: [0218] (i) filling the build region with a polymerizable
liquid, [0219] (ii) irradiating the build region with light through
the optically transparent member (e.g., by a single exposure),
while [0220] (iii) maintaining the carrier stationary or advancing
the carrier away from the build surface at a first cumulative rate
of advance, to thereby form from the polymerizable liquid a solid
polymer adhesion segment of the object adhered to the carrier;
then
[0221] (c) optionally but preferably forming a transition segment
of the three dimensional object by [0222] (i) filling the build
region with a polymerizable liquid, [0223] (ii) continuously or
intermittently irradiating the build region with light through the
optically transparent member, and [0224] (iii) continuously or
intermittently advancing (e.g., sequentially or concurrently with
the irradiating step) the carrier away from the build surface at a
second cumulative rate of advance to thereby form from the
polymerizable liquid a transition segment of the object between the
adhesion segment and the build surface; [0225] wherein the second
cumulative rate of advance is greater than the first cumulative
rate of advance; and then
[0226] (d) forming a body segment of the three dimensional object
by: [0227] (i) filling the build region with a polymerizable
liquid, [0228] (ii) continuously or intermittently irradiating the
build region with light through the optically transparent, and
[0229] (iii) continuously or intermittently advancing (e.g.,
sequentially or concurrently with the irradiating step) the carrier
away from the build surface at a third cumulative rate of advance,
to thereby form from the polymerizable liquid a body segment of the
object between the transition segment and the build surface; [0230]
wherein the third cumulative rate of advance is greater than the
first and/or the second cumulative rate of advance.
[0231] Note that the start position can be any position among a
range of positions (e.g., a range of up to 5 or 10 millimeters or
more), and the irradiating step (b)(ii) is carried out at an
intensity sufficient to adhere the solid polymer to the carrier
when the carrier is at any position within that range of positions.
This advantageously reduces the possibility of failure of adhesion
of the three-dimensional object to the carrier due to variations in
uniformity of the carrier and/or build surfaces, variations
inherent in drive systems in positioning the carrier adjacent the
build surface, etc.
9. Fabrication with Intermittent (or Strobe") Illumination.
[0232] As noted above, in some embodiments the invention may be
carried out with the illumination in intermittent periods or burst.
In one embodiment, such a method comprises:
[0233] providing a carrier and an optically transparent member
having a build surface, the carrier and the build surface defining
a build region therebetween;
[0234] filling the build region with a polymerizable liquid,
[0235] intermittently irradiating the build region with light
through the optically transparent member to form a solid polymer
from the polymerizable liquid,
[0236] continuously advancing the carrier away from the build
surface to form the three-dimensional object from the solid
polymer.
[0237] Another embodiment of such a mode of operation
comprises:
[0238] providing a carrier and an optically transparent member
having a build surface, the carrier and the build surface defining
a build region therebetween;
[0239] filling the build region with a polymerizable liquid,
[0240] intermittently irradiating the build region with light
through the optically transparent member to form a solid polymer
from the polymerizable liquid,
[0241] continuously or intermittently advancing (e.g., sequentially
or concurrently with the irradiating step) the carrier away from
the build surface to form the three-dimensional object from the
solid polymer.
[0242] In some embodiments, the intermittently irradiating
comprises alternating periods of active and inactive illumination,
where the average duration of the periods of active illumination is
less than the average duration of the periods of inactive
illumination (e.g., is not more than 50, 60, or 80 percent
thereof).
[0243] In other embodiments, the intermittently irradiating
comprises alternating periods of active and inactive illumination,
where the average duration of the periods of active illumination is
the same as or greater than the average duration of the periods of
inactive illumination (e.g., is at least 100, 120, 160, or 180
percent thereof).
[0244] Examples of such modes of operation are given further below.
These features may be combined with any of the other features and
operating steps or parameters described herein.
10. Fabrication Products.
[0245] Three-dimensional products produced by the methods and
processes of the present invention may be final, finished or
substantially finished products, or may be intermediate products
subject to further manufacturing steps such as surface treatment,
laser cutting, electric discharge machining, etc., is intended.
Intermediate products include products for which further additive
manufacturing, in the same or a different apparatus, may be carried
out). For example, a fault or cleavage line may be introduced
deliberately into an ongoing "build" by disrupting, and then
reinstating, the gradient of polymerization zone, to terminate one
region of the finished product, or simply because a particular
region of the finished product or "build" is less fragile than
others.
[0246] Numerous different products can be made by the methods and
apparatus of the present invention, including both large-scale
models or prototypes, small custom products, miniature or
microminiature products or devices, etc. Examples include, but are
not limited to, medical devices and implantable medical devices
such as stents, drug delivery depots, functional structures,
microneedle arrays, fibers and rods such as waveguides,
micromechanical devices, microfluidic devices, etc.
[0247] Thus in some embodiments the product can have a height of
from 0.1 or 1 millimeters up to 10 or 100 millimeters, or more,
and/or a maximum width of from 0.1 or 1 millimeters up to 10 or 100
millimeters, or more. In other embodiments, the product can have a
height of from 10 or 100 nanometers up to 10 or 100 microns, or
more, and/or a maximum width of from 10 or 100 nanometers up to 10
or 100 microns, or more. These are examples only: Maximum size and
width depends on the architecture of the particular device and the
resolution of the light source and can be adjusted depending upon
the particular goal of the embodiment or article being
fabricated.
[0248] In some embodiments, the ratio of height to width of the
product is at least 2:1, 10:1, 50:1, or 100:1, or more, or a width
to height ratio of 1:1, 10:1, 50:1, or 100:1, or more.
[0249] In some embodiments, the product has at least one, or a
plurality of, pores or channels formed therein, as discussed
further below.
[0250] The processes described herein can produce products with a
variety of different properties. Hence in some embodiments the
products are rigid; in other embodiments the products are flexible
or resilient. In some embodiments, the products are a solid; in
other embodiments, the products are a gel such as a hydrogel. In
some embodiments, the products have a shape memory (that is, return
substantially to a previous shape after being deformed, so long as
they are not deformed to the point of structural failure). In some
embodiments, the products are unitary (that is, formed of a single
polymerizable liquid); in some embodiments, the products are
composites (that is, formed of two or more different polymerizable
liquids). Particular properties will be determined by factors such
as the choice of polymerizable liquid(s) employed.
[0251] In some embodiments, the product or article made has at
least one overhanging feature (or "overhang"), such as a bridging
element between two supporting bodies, or a cantilevered element
projecting from one substantially vertical support body. Because of
the unidirectional, continuous nature of some embodiments of the
present processes, the problem of fault or cleavage lines that form
between layers when each layer is polymerized to substantial
completion and a substantial time interval occurs before the next
pattern is exposed, is substantially reduced. Hence, in some
embodiments the methods are particularly advantageous in reducing,
or eliminating, the number of support structures for such overhangs
that are fabricated concurrently with the article.
11. Build Plates with Surface Topology
[0252] According to some embodiments, the build plate may be
configured to allow a polymerization inhibitor to reach the build
surface. In particular, the build plate includes a rigid, optically
transparent, gas-impermeable planar base having upper and lower
surfaces, and an optically transparent sheet having upper and lower
surfaces such that the sheet lower surface is positioned on the
base upper surface. The base upper surface and/or the sheet lower
surface have a surface topology that increases gas flow to the gas
permeable sheet. For example, the surface topology may include a
surface roughness that maintains a sufficient gap between the base
and the sheet such that a polymerization inhibitor may flow through
the gap through the permeable sheet and to the build surface. In
some embodiments, the surface topology may reduce or prevent
surface wetting or sticking between the base and the sheet. In this
configuration, a relatively thin, flexible permeable sheet may be
used. The rigid base may serve to stabilize the flexible sheet
and/or reduce or prevent warping or bowing, particularly in the
lower direction, during three-dimensional object fabrication. The
surface topology may be configured to sufficiently maintain an
optical pathway of radiation passing through the window (e.g., by
limiting any optical blocking or scattering) so as to minimize any
effects on the resolution of the three-dimensional object
fabrication. The sheet may be held against the plate by one or more
clamps along the periphery or a "drum head" configuration.
[0253] As illustrated in FIG. 30, a configuration of a build plate
600 with generally smooth surfaces, i.e., without a surface
topology that increases gas flow, is shown. The build plate 600 has
a rigid support base 610 with a planar surface topology 612 and a
permeable or semipermeable sheet 620 thereon is shown.
Electromagnetic radiation 640 (e.g., from the radiation source 12
of FIG. 2) passes through the base 610 and the sheet 620 to define
a build region 650, which is filled with liquid resin that is cured
in a continuous liquid interface printing process to form a
three-dimensional object as described herein. As shown in FIG. 6,
the radiation 640 maintains substantially the same optical path as
it passes through the build plate 600.
[0254] As illustrated in FIG. 31, a build plate 700 having a rigid
support base 710 with a rough surface topology 712 and a permeable
or semipermeable sheet 720 thereon is shown. The sheet 720 is
optionally held on the base 710 (e.g., by a tensioning ring or
clamp, not shown) to hold the sheet 720 (which may otherwise be
flexible) in a taut or rigid position, and electromagnetic
radiation 740 passes through the plate 700 to a build region 750.
Similarly, in FIG. 32, a build plate 800 includes a base 810 with a
rough surface topology 812 and a permeable sheet or semipermeable
sheet 820. Electromagnetic radiation 840 passes through the plate
to a build region 850. The configuration in FIG. 32 has a surface
topology 812 with a reduced roughness as compared to the surface
topology 712 of FIG. 31.
[0255] In contrast to FIG. 30, the surface topologies 712, 812 of
FIGS. 31 and 32, respectively, have an uneven or rough surface.
Although the surface roughness may cause scattering and/or blockage
of the radiation 740, 840, which is normally not desirable, the
surface roughness may be sufficient to maintain a gap between the
bottom surface of the sheet 720, 820, respectively, but still
maintain a suitable optical pathway of the radiation 740, 840. As
illustrated in FIG. 31, the surface roughness 712 scatters the
radiation 740 at an angle of .alpha..sub.1, while the surface
roughness 812 in FIG. 32, scatters the radiation 840 at an angle of
.alpha..sub.2, which is less than .alpha..sub.1. It should be
understood that the angles .alpha..sub.1, .alpha..sub.2 would vary
over the longitudinal area of the sheets 720, 820 based on the
particular geometry and scattering angles at a given location of
the surface topology 712, 812; however, in general, a rougher
surface would typically result in greater scattering angles than a
smoother surface. In some embodiments, the optical scattering angle
at all points along the longitudinal area of the sheet is less than
20%, 10%, 5.0% or 1.0%.
[0256] A smooth surface topology 612 as shown in FIG. 30 would
result in very little, if any, light scattering or light blockage.
However, in the configuration shown in FIG. 30, the gaspermeability
of the sheet 612 may be limited to flow in the lateral direction.
In FIGS. 31 and 32, the gap may permit additional polymerization
inhibitor, such as oxygen or other gases, to flow through the gap
to the respective build regions 750, 850. The surface roughness of
the topology 712 in FIG. 31 is greater (i.e., more uneven) than
that of the topology 812 in FIG. 32, which results in a greater
average scattering angle .alpha..sub.1 as compared with scattering
angle .alpha..sub.2.
[0257] Small areas of contact between the sheet 720, 820 and the
base 710, 810 may be permitted because the polymerization inhibitor
may travel through the sheet 720, 820 laterally as well as
vertically. In some embodiments, the gap may be maintained such
that any point on the bottom of the sheet is no more than a given
distance from a continuous path to the supply of air from the
perimeter of the build plate 700, 800. In particular embodiments,
the distance is no more than about two to five times the thickness
of the sheet 720, 820.
[0258] The surface roughness may include a random pattern of
surface features. It should be understood that the term "random"
includes patterns that are not perfectly random. The surface
roughness may be formed by various techniques, including spraying
the top surface of the base 710, 810 with an abrasive media to
create surface features that may reduce the adhesion between the
base 710, 810 and the sheet 720, 820. For example, if the base is
formed of glass, spraying the base with glass beads of
approximately 50-150 .mu.m diameter with a stream of air
pressurized to about 40, 60, 80, 90 to 100, 110, or 120 psi from a
distance of about 2-10 inches may create pits in the glass ranging
from about 0.1, 0.5, 1.0, 2.0 to 3.0, 4.0 or 5.0 .mu.m deep and
1.0, 2.0, 5.0 to 7.0, 8.0 or 10 .mu.m in diameter. If covering
about 0.1%, 1.0%, 3.0%, 5.0% to 10%, 15% or 20% or more of the area
of the base, these pits or indentations may effectively maintain a
gap for the polymerization inhibitor. The surface roughness may be
a random pattern.
[0259] Other abrasives may be used to create surface roughness,
including aluminum oxide, crushed glass grit, glass beads, silicon
carbide, pumice, steel shot and steel grit. Chemical etching may
also be used to create a pattern of surface features. Acid
solutions such as hydrofluorosilic acid, sodium fluoride and
hydrogen fluoride may dissolve a base material, such as glass,
slowly and can dissolve the material starting at microscopic
surface imperfections that are randomly distributed across the
surface. If the acid is left on the surface for a sufficiently
short time, the acid may only affect small areas of the surface and
may create indentations or pits similar to those formed by
blasting.
[0260] In some embodiments, the surface roughness on the base
and/or the sheet may include a non-random set of patterned features
having dimensions similar to those described herein, e.g., channels
or wells ranging from about 0.1, 0.5, 1.0 to 2.0, 3.0, 4.0 or 5.0
.mu.m deep and 1.0, 2.0, 3.0, 4.0 to 5.0, 6.0, 7.0, 8.0, 9.0 or 10
.mu.m in width and/or length. The channels or wells may cover at
least about 0.1%, 1.0%, 3.0%, 5.0% to 10%, 15% or 20% or more of
the area of the base to maintain a gap for the polymerization
inhibitor. For example, as illustrated in FIG. 36, a build plate
1100 has a rigid support base 1110 with a patterned surface
topology 1112 including channels 1114 and a permeable or
semipermeable sheet 1120 is on the base 1110.
[0261] In some embodiments, the surface topology that maintains the
gap may be formed on the flexible sheet instead of on the base. As
illustrated in FIG. 33, a build plate 900 having a rigid,
gas-impermeable base 910 and a flexible sheet 920 with a surface
topology 922 thereon. Radiation 940 passes through the base 910 and
sheet 920 to define a build surface 950. The surface topology 922
may be similar or the same in terms of dimensions as that shown on
the bases 710, 820 in FIGS. 31 and 32 and may be configured to form
a gap between the base 910 and the sheet 920.
[0262] Without wishing to be bound by any particular theory, it is
currently believed that trace amounts of fluid used for cleaning,
moisture from the air (humidity), chemical components from the
monomer resin that are able to migrate through the sheet are
possible sources of small amounts of fluid that may block a
continuous path for air or, other polymerization inhibitors to
areas of the build plate. If the top surface of the base and the
bottom of the sheet are both sufficiently smooth (e.g., as shown in
FIG. 30), then a very small amount of fluid may create an air free
zone over a large area of the window, for example, by collecting in
the area between the base and the sheet. Even a small amount of
surface roughness as described in FIGS. 31 and 32 may reduce or
eliminate the area over which fluid may spread and block the path
of gas flow.
[0263] The permeability of the build plates described herein, via
the sheet and the gap, to the polymerization inhibitor may depend
upon conditions such as the pressure of the atmosphere and/or
inhibitor, the choice of inhibitor, the rate or speed of
fabrication, etc. In general, when the inhibitor is oxygen, the
permeability of the semipermeable member to oxygen may be from 10
or 20 Barrers, up to 1000 or 2000 Barrers, or more. For example, a
semipermeable sheet with a permeability of 10 Barrers used with
pure oxygen or highly enriched oxygen, atmosphere under a pressure
of 150 PSI may perform substantially the same as a semipermeable
member with a permeability of 500 Barrers when the oxygen is
supplied from the ambient atmosphere under atmospheric
conditions.
[0264] For example, as illustrated in FIG. 34, the base 810 may be
positioned in a housing 1000 having an interior chamber 1010 and an
inlet/outlet 1020. The base 810 may have a curved or beleved edge
portion 814, which may increase gas flow to the build surface 850.
A tensioning ring or clamp may be used to hold the sheet 820 on the
chamber 1010 and adjacent the base 810. A tensioning ring or clamp
may be used to hold the sheet 820 on the chamber 1010 and adjacent
the base 810. The chamber 1010 may be a controlled pressure
environment and/or may have a gas, such as a polymerization
inhibitor (e.g., oxygen) supplied via the inlet/outlet 1020.
Similarly, as illustrated in FIG. 35, the base 910 may be
positioned in the housing 1000, and the base 910 may have a curved
or beleved edge portion 914. In some embodiments, the sheet 810 may
be held in position on the base 810 by creating a reduced pressure
environment in the chamber 1010 with or without the use of
additional holding mechanisms, such as a tensioning ring or clamp,
while still providing sufficient polymerization inhibitor to
maintain the dead zone. Reduced pressure of about 0.9 to 0.1 atm or
about 0.5 atm may be used.
In some embodiments, the build plate comprises: (i) a polymer film
layer such as the sheets (having any suitable thickness, e.g., from
0.001, 0.01, 0.1 or 1 millimeters to 5, 10 or 100 millimeters, or
more), having a top surface positioned for contacting said
polymerizable liquid and a bottom surface, and (ii) a rigid,
impermeable, optically transparent supporting base, such as the
base (having any suitable thickness, e.g., from 0.01, 0.1 or 1
millimeters to 10, 100, or 200 millimeters, or more), contacting
said film layer bottom surface. The base may be formed of glass,
silicone, quartz, sapphire, polymer materials or other optically
transparent materials in the desired optical range.
[0265] Because an advantage of some embodiments of the present
invention is that the size of the build surface on the build plate
may be reduced due to the absence of a requirement for extensive
lateral "throw" as in the Joyce or Chen devices noted above, in the
methods, systems and apparatus of the present invention lateral
movement (including movement in the X and/or Y direction or
combination thereof) of the carrier and object (if such lateral
movement is present) is preferably not more than, or less than, 80,
70, 60, 50, 40, 30, 20, or even 10 percent of the width (in the
direction of that lateral movement) of the build region.
[0266] While in some embodiments the carrier is mounted on an
elevator to advance up and away from a stationary build plate, on
other embodiments the converse arrangement may be used: That is,
the carrier may be fixed and the build plate lowered to thereby
advance the carrier away therefrom. Numerous different mechanical
configurations will be apparent to those skilled in the art to
achieve the same result, in all of which the build plate is
"stationary" in the sense that no lateral (X or Y) movement is
required to replenish the inhibitor thereon, or no elastic build
plate that must be stretched and then rebound (with associated
over-advance, and back-up of, the carrier) need be employed.
12. Build Plates with an Adhered Permeable Sheet and Gas Flow
Enhancing Features
[0267] In some embodiments, additional or alternative gas flow
enhancing features may be incorporated into the build plate. A gas
flow enhancing feature includes any structure that increases
permeability of the build plate and/or creates gaps or voids for
gas flow. For example, an adhesive layer may be used to secure the
permeable sheet to the base, for example, as illustrated in FIGS.
37-49, and a gas flow enhancing feature, such as a channel, other
surface topology, or gas permeable material (e.g., mesh) for
increasing gas flow to the build surface may be provided. The
adhesive layer may be gas permeable.
[0268] As illustrated in FIG. 37, the build plate 1200 may include
a rigid, optically transparent, gas-impermeable planar base 1210
having an upper surface with an uneven surface topology or channels
1212. An adhesive layer 1214 is on the upper surface of the base
1212. A permeable sheet 1220 has an upper surface that includes the
build surface for forming a three-dimensional object. The lower
surface of the permeable sheet is positioned on the adhesive layer
1214 opposite the base 1210. In this configuration, the build plate
1200 permits gas flow to the build surface because gas is permitted
to flow through the channels 1212 and the gas permeable adhesive
1214 and permeable sheet 1220.
[0269] In particular embodiments, the permeable sheets described
herein may have a thickness of about 5, 10, 50, 100, or 200 nm to
1.0, 5.0, 10, 50, 100 mm or greater (up to about 1-2 centimeters),
the adhesive layer may have a thickness of about 1, 5, 10, 20, or
50 micron-100, 500, 1000 microns or greater (up to about 1-2
centimeters) and the channel layer may have a thickness of about 5,
10, 50, or 100 microns to 1, 5, 10, 50, 100 millimeters or more (up
to 1-5 centimeters). The dimensions of the channels may be about
10, 20, 50 or 100 nm to 1, 5, 10, 100, 500 millimeters or more (up
to about 1-2 centimeters).
[0270] The adhesive layers described herein may be a gas-permeable
adhesive, such as a poly(dimethylsiloxane) (PDMS) film (e.g., as a
silicone transfer film adhesive that can be applied using a
polyester release liner, such as ARseal.TM. 8026 (Adhesives
Research, Glen Rock, Pa. (USA)). The adhesive layer is preferably
an adhesive that is both gas-permeable and has good adhesive
qualities with respect to the material of the base (e.g., glass,
silicone, quartz, sapphire, polymer materials) and the material of
the sheet (e.g., polymers described below). In this configuration,
air flow may be permitted through the uneven surface topology
(channels 1212) of the base 1210, and through the gas permeable
adhesive 1214 and sheet 1220.
[0271] In some embodiments, the build plate may include two or more
materials laminated or adhered to form the base/channels. As
illustrated in FIG. 38, a build plate 1300 has a bottom support
portion or base 1310 formed of a first material and a channel layer
1311 that includes the surface topology (channels) 1312. In some
embodiments, the base 1310 and channel layer 1311 are formed of two
different materials. For example, the channel layer 1311 may be a
patterned rigid polymer that provides the surface topology 1312 and
the base 1310 may be formed of glass, silicone, quartz, sapphire or
polymer materials that are adhered to the top portion by an
adhesive 1314 to a permeable sheet 1320. In this configuration, the
base 1310 may be formed of a material that provides additional
support, and the channel layer 1311 may be formed of a material
that is easily formed to provide the surface topology 1312.
[0272] As shown in FIG. 39, a build plate 1500 includes a base
1510, a channel layer 1511 with a surface topology 1512, an
adhesive layer 1514 and a permeable sheet 1520. The channel layer
surface topology (channels) 1512 faces the base 1510 and may be
formed of a gas-permeable material, such as a gas-permeable rigid
polymer or other materials that may be molded, for example, by
embossing or other suitable patterning techniques. The pattern may
be formed by screen printing, etching, photolithography, and the
like.
[0273] As shown in FIG. 40, a channel layer 1511 may be provided
between the base 1510 and the adhesive 1514. The channel layer 1511
and adhesive 1514 may be formed of a gas permeable material, such
that oxygen or other polymerization inhibitors may pass through the
channels of the surface topology 1512, the gas permeable material
of the channel layer 1511, the adhesive 1514 and the permeable
sheet 1520 so that the build plate of FIG. 40 permits gas flow to
the build plate surface. In some embodiments, the base 1510 may be
formed of glass, silicone, quartz, sapphire or polymer materials
and may be impermeable, although a permeable base layer may also be
used. The channel layer 1511 may be formed of a molded permeable
polymer, such as poly(dimethylsiloxane) (PDMS), including porous
and composite PDMS materials.
[0274] For example, as illustrated in FIGS. 41A-41C, a permeable
channel layer 1611, such as a PDMS layer, may be pressed against or
laminated on a channel mold 1650 (FIG. 41A) to form the channels
1612 on one side of the permeable channel layer 1611. An adhesive
layer 1614 and a permeable sheet 1620 may be laminated on the
permeable channel layer 1611 (FIG. 41B). As shown in FIG. 41B, the
permeable channel layer 1611 is attached to the mold 1650 during
lamination of the permeable sheet 1620 and adhesive layer 1614,
which may reduce or prevent deformation or folding/wrinkling of the
permeable channel layer 1611 when the permeable sheet 1620 and
adhesive layer 1614 are attached. The mold 1650 may then be removed
and the permeable channel layer 1611/adhesive 1614/permeable sheet
1620 may be attached to a base 1612 (FIG. 41C). In some
embodiments, the permeable channel layer 1611 may be bonded to the
base 1610 as shown in FIG. 41C by a chemical bonding method. For
example, the channel layer 1611 may be formed of PDMS and may have
an oxidative treatment to activate the PDMS surface and create a
chemical bond to a base 1610, such as a glass base. Example bonding
techniques include oxygen plasma treatments, UV ozone treatments
and/or wet chemical treatments of the channel layer surface to
create a bond with the base 1610. As illustrated, the channel layer
1611 includes channels on a bottom surface thereof; however, it
should be understood that the channels may be formed at the top
surface opposite the base.
[0275] As illustrated in FIG. 42, in some embodiments, a build
plate 1700 includes a base 1710, a permeable sheet 1720, a
permeable channel layer 1711 having a surface topography 1712 and
an adhesive 1714 that adheres the sheet 1720 to the channel layer
1711. An additional elastomer layer 1730 may be added between the
base 1710 and the permeable channel layer 1711 to increase an
elasticity of the build surface. The additional elastomer layer
1730 may be permeable or impermeable, and in some embodiments, the
elastomer layer may be formed of a material that is less rigid than
the base layer, such as silicone elastomer (Sylgard.RTM. 184 (Dow
Corning, Midland, Mich., USA)) or PDMS used with a glass or quartz
base. Without wishing to be bound by any particular theory, a
mechanically responsive, pliant material (elastomer layer) may
reduce pressure differentials caused by moving the build platform.
In some embodiments, the build surface of the build plate 1700 may
be pliant such that it oscillates up and down as the build platform
and/or carrier is moved. The resulting movement may reduce or
prevent the window surface from building up a large pressure
differential as the three-dimensional object and/or carrier
advances away from the build platform. In addition, the oscillation
may facilitate flow of the resin to the build surface. It should be
understood that the additional elastomer layer 1730 may be
integrated together with the permeable channel layer 1711 and/or
have channels at the top or bottom of the layer; however, a
separate channel layer 1711 may provide channels in closer
proximity to the build surface and consequently increase oxygen
flow. Moreover, the elastomer layer may be made out of any suitable
material, including impermeable layers and the channel layer 1711
may be formed of a gas permeable material as described herein. It
should also be understood that the dimensions (thickness) of the
additional elastomer layer 1711 may be selected to provide a
desired mechanical elasticity at the build surface. For example, a
thicker, harder material may respond similarly to thinner, softer
elastomer layers. In some embodiments, the additional elastomer
layer is 0.1, 0.5, 1, 3, 5, 6, 10 to 20, 50, or 100 mm thick and
has a Young's modulus of about 0.5, 1.0 to 2.0, 2.5, 3.0 to 5.0,
10, 50 or 100 MPa.
[0276] In some embodiments, transparent, composite materials (e.g.,
composite elastomer/PDMS layers) may be used in one or more layers
(the permeable sheet, the adhesive, the permeable channel layer,
the elastomer layer and/or the base) to provide additional
functionality. For example, luminescence-based oxygen sensing
particles may be interspersed in one of the gas permeable layers to
sense an oxygen concentration therein. The oxygen concentration at
one of the layers may be used to estimate or extrapolate a
concentration of oxygen in the resin. Examples of oxygen-sensitive
indicators include fluorophores that include ruthenium-based
molecules, metallo-porphyrin-type molecules, fluorescein compounds,
polycyclic aromatic hydrocarbons and other organic compounds. See,
e.g., S. M. Grist, L. Chrostowski, K. C. Cheung, Optical Oxygen
Sensors for Applications in Microfluidic Cell Culture, Sensors, 10,
9286-9316 (2010) and U.S. Pat. No. 8,398,922, the disclosure of
which is hereby incorporated by reference in its entirety.
Accordingly, fluorescent oxygen sensing materials may be
incorporated into the build plate and excited by either the
radiation source (e.g., the radiation source 11 of FIG. 2) or by a
separately provided radiation source. The amount of oxygen, for
example, in the resin, may be based on a lifetime of the
luminescence of the sensing material and/or an intensity of the
luminescence of the sensing material. Moreover, the sensing
material may be incorporated into the build plate or a portion of
the build plate at a concentration that is sufficiently low so as
to maintain sufficient transparency of the build plate.
[0277] As another example, conductive materials such as conductive
nanoparticles may be used in one or more layers (the permeable
sheet, the adhesive, the permeable channel layer, the elastomer
layer and/or the base) to provide active heating of the build
plate. Heating of the build plate may in turn heat the resin and
reduce the viscosity of the resin. A voltage may be applied to the
conductive, transparent material to drive a current, and the
conductive material may function as a resistive heater. See X.
Gong, W. Wen, Polydimethylsiloxane-based Conducting Composites and
their Applications in Microfluidic Chip Fabrication,
Biomicrofluidics, 3, 012007 (2009) and U.S. Pat. No. 8,243,358, the
disclosure of which is hereby incorporated by reference in its
entirety.
[0278] The rigid base and flexible sheet can be made of any
suitable material that is optically transparent at the relevant
wavelengths (or otherwise transparent to the radiation source,
whether or not it is visually transparent as perceived by the human
eye--i.e., an optically transparent window may in some embodiments
be visually opaque). In some embodiments, the rigid base is
impermeable with respect to the polymerization inhibitor.
[0279] In some embodiments, the flexible sheet may be formed from a
thin film or sheet of material which is flexible when separated
from the apparatus of the invention, but which is clamped and
tensioned when installed in the apparatus (e.g., with a tensioning
ring) so that it is rendered rigid in the apparatus. Polymer films
are preferably fluoropolymer films, such as an amorphous
thermoplastic fluoropolymer, in a thickness of 0.01 or 0.05
millimeters to 0.1 or 1 millimeters, or more. In some embodiments,
Biogeneral Teflon AF 2400 polymer film, which is 0.0035 inches
(0.09 millimeters) thick, and Random Technologies Teflon AF 2400
polymer film, which is 0.004 inches (0.1 millimeters) thick may be
used. Tension on the film is preferably adjusted with a tension
ring to about 10 to 100 pounds, depending on operating conditions
such as fabrication speed.
[0280] Particular materials include TEFLON AF.RTM. fluoropolymers,
commercially available from DuPont. Additional materials include
perfluoropolyether polymers such as described in U.S. Pat. Nos.
8,268,446; 8,263,129; 8,158,728; and 7,435,495. For example, the
sheet may include an amorphous thermoplastic fluoropolymer like
TEFLON AF 1600.TM. or TEFLON AF 2400.TM. fluoropolymer films, or
perfluoropolyether (PFPE), particularly a crosslinked PFPE film, or
a crosslinked silicone polymer film. Many other materials are also
possible to use, as long as the flux of the polymerization
inhibitor is adequate to attenuate the photo-polymerization to
create the dead zone. Other materials could include semicrystalline
fluoropolymers, such as thin films (10-50 microns thick) of
fluorinated ethylene propylene (FEP), paraformaldehyde (PFA),
polyvinylidene fluoride (PVDF) or other materials known in the art.
The permeability of these materials (FEP, PFA, PVDF) to the
polymerization inhibitor oxygen may be lower than TEFLON AF, but
with the attenuation of oxygen concentration, oxygen pressure,
temperature, and light characteristics (wavelength, intensity),
adequate creation of the dead zone may be achieved.
[0281] It will be appreciated that essentially all solid materials,
and most of those described above, have some inherent "flex" even
though they may be considered "rigid," depending on factors such as
the shape and thickness thereof and environmental factors such as
the pressure and temperature to which they are subjected. In
addition, the terms "stationary" or "fixed" with respect to the
build plate is intended to mean that no mechanical interruption of
the printingprocess occurs, or no mechanism or structure for
mechanical interruption of the process (as in a layer-by-layer
method or apparatus) is provided, even if a mechanism for
incremental adjustment of the build plate (for example, adjustment
that does not lead to or cause collapse of the gradient of
polymerization zone) is provided.
[0282] The build plates, e.g., including the base and the sheet,
has, in some embodiments, a total thickness of from 0.01, 0.1 or 1
millimeters to 10 or 100 millimeters, or more (depending upon the
size of the item being fabricated, whether or not it is laminated
to or in contact with an additional supporting plate such as glass,
etc.).
[0283] The permeability of the build plates described herein, via
the sheet and the channels or other gas flow enhancing feature, to
the polymerization inhibitor will depend upon conditions such as
the pressure of the atmosphere and/or inhibitor, the choice of
inhibitor, the rate or speed of fabrication, etc. In general, when
the inhibitor is oxygen, the permeability of the semipermeable
member to oxygen may be from 10 or 20 Barrers, up to 1000 or 2000
Barrers, or more. For example, a semipermeable sheet with a
permeability of 10 Barrers used with a pure oxygen, or highly
enriched oxygen, atmosphere under a pressure of 150 PSI may perform
substantially the same as a semipermeable member with a
permeability of 500 Barrers when the oxygen is supplied from the
ambient atmosphere under atmospheric conditions.
[0284] In some embodiments, the build plate comprises: (i) a
polymer film layer such as the sheets (having any suitable
thickness, e.g., from 0.001, 0.01, 0.1 or 1 millimeters to 5, 10 or
100 millimeters, or more), having a top surface positioned for
contacting said polymerizable liquid and a bottom surface, and (ii)
a rigid, impermeable, optically transparent supporting base, such
as the base (having any suitable thickness, e.g., from 0.01, 0.1 or
1 millimeters to 10, 100, or 200 millimeters, or more), contacting
said film layer bottom surface. The base may be formed of glass,
silicone, quartz, sapphire, polymer materials or other optically
transparent materials in the desired optical range.
[0285] Because an advantage of some embodiments of the present
invention is that the size of the build surface on the build plate
may be reduced due to the absence of a requirement for extensive
lateral "throw" as in the Joyce or Chen devices noted above, in the
methods, systems and apparatus of the present invention lateral
movement (including movement in the X and/or Y direction or
combination thereof) of the carrier and object (if such lateral
movement is present) is preferably not more than, or less than, 80,
70, 60, 50, 40, 30, 20, or even 10 percent of the width (in the
direction of that lateral movement) of the build region.
[0286] While in some embodiments the carrier is mounted on an
elevator to advance up and away from a stationary build plate, on
other embodiments the converse arrangement may be used: That is,
the carrier may be fixed and the build plate lowered to thereby
advance the carrier away therefrom. Numerous different mechanical
configurations will be apparent to those skilled in the art to
achieve the same result, in all of which the build plate is
"stationary" in the sense that no lateral (X or Y) movement is
required to replenish the inhibitor thereon, or no elastic build
plate that must be stretched and then rebound (with associated
over-advance, and back-up of, the carrier) need be employed.
[0287] In some embodiments, an adhesive layer may be used to secure
a patterned permeable sheet to the base, for example, as
illustrated in FIG. 43. As illustrated in FIG. 43, the build plate
1800 may include a rigid, optically transparent, gas-impermeable
planar base 1810 having an upper surface and a lower surface with
an adhesive layer 1814 on the upper surface of the base 1810. A
permeable sheet 1820 has an upper surface that includes the build
surface for forming a three-dimensional object. The lower surface
of the permeable sheet 1820 includes an uneven surface topology or
channels 1822 and is positioned on the adhesive layer opposite the
base 1810. In this configuration, the build plate 1800 permits gas
flow to the build surface, e.g., via the surface topology channels
1822 of the permeable sheet 1820. In this configuration, air flow
may be permitted through the uneven surface topology of the sheet,
and through the gas permeable adhesive and sheet and/or fluid
blockage may be reduced.
[0288] It should be understood that, although the surface topology
shown in FIGS. 36-48 is illustrated as a regular pattern,
additional patterned surface may be used, including random etched
surfaces, such as those shown in FIGS. 31-35. Moreover, additional
layers may be added to the build plates. For example, embodiments
are illustrated as an adhesive layer and a permeable sheet on the
base; however, an additional adhesive layer may be applied to the
permeable sheet and an additional permeable sheet may be positioned
on the additional adhesive layer in a stacked configuration. Three
or more adhesive/sheet layers may be used. The additional permeable
sheets may or may not include a surface topology for increasing air
flow to the build surface.
[0289] In some embodiments, a patterned adhesive layer may be used
to secure the permeable sheet to the base, for example, as
illustrated in FIGS. 44-46. As illustrated in FIG. 44, the build
plate 1900 may include a rigid, optically transparent,
gas-impermeable planar base 1910 having an upper surface a lower
surface. The adhesive layer 1914 is on the upper surface of the
base 1910. The permeable sheet 1920 has an upper surface that
includes the build surface for forming a three-dimensional object.
The lower surface of the permeable sheet 1920 is positioned on the
adhesive layer 1914 opposite the base. In this configuration, the
build plate 1900 permits gas flow to the build surface, for example
through the channels or gaps between the adhesive portions the form
the patterned adhesive layer 1914. As shown in FIG. 45, the
patterned adhesive 2014 of the build plate 2000 may be drops or
beads of adhesive that may be deposited by a spray nozzle or
pipette droplet dispenser in a pattern between the base 2010 and
the sheet 2020.
[0290] The adhesive pattern layer may be any suitable pattern that
permits sufficient air/gas flow to the built surface of the build
plate. For example, as shown in FIG. 46A, the adhesive pattern may
be in strips 2110 that form gas channels therebetween and are
positioned on the base 2100. In FIG. 46B the adhesive pattern is in
the form of squares 2210 on the base, and in FIG. 46C, the adhesive
pattern is in the form of an alternative pattern of squares 2310 on
the base 2300. The longitudinal profile of the adhesive may also be
in any suitable shape (rectangles, rounded edges, etc.).
[0291] The adhesive layer may be a gas-permeable adhesive, such as
a poly(dimethylsiloxane) (PDMS) film (e.g., a silicon transfer film
adhesive that is applied using a polyester release liner, such as
ARseal.TM. 8026 (Adhesives Research, Glen Rock, Pa. (USA)). The
adhesive layer is preferably an adhesive that is both gas-permeable
and has good adhesive qualities with respect to the material of the
base (e.g., glass, silicon, quartz, sapphire, polymer materials)
and the material of the sheet (e.g., polymers described below).
However, in some embodiments, the adhesive in not necessarily
gas-permeable, and sufficient gas flow may be obtained through the
gaps or channels between the adhesive portions. Moreover, the
adhesive may be sprayed on the base in a random pattern, for
example that may be sprayed onto the top surface of the base. Any
suitable technique may be used to form the adhesive pattern,
including screen printing, etching, photolithography and the
like.
[0292] The patterned adhesive may be applied to a smooth base
and/or permeable sheet as illustrated in FIGS. 44-45 or the base
and/or permeable sheet may also have a pattern, such as those shown
in FIGS. 31-35. Moreover, additional layers may be added to the
build plates. For example, although FIGS. 44-45 illustrate an
adhesive layer and a permeable sheet on the base, an additional
adhesive layer may be applied to the permeable sheet and an
additional permeable sheet may be positioned on the additional
adhesive layer in a stacked configuration. Three or more
adhesive/sheet layers may be used. The additional adhesive layers
may be patterned adhesive layers or may be a substantially
continuous adhesive sheet (such as a gas-permeable adhesive sheet).
The dimensions of the adhesive pattern may be similar or the same
as those described above with respect to a patterned base or
permeable sheet.
[0293] In some embodiments, an adhesive layer may be used to secure
the permeable sheet to the base and the permeable sheet may include
channels, for example, as illustrated in FIGS. 47 and 48. As
illustrated in FIG. 47, the build plate 2400 may include a rigid,
optically transparent, gas-impermeable planar base 2410 having an
upper surface and a lower surface with an adhesive layer 2414 on
the upper surface of the base 2410. The permeable sheet 2420 has an
upper surface that includes the build surface for forming a
three-dimensional object. Channels 2422 may be formed in the sheet
2420 to increase the gas flow to the build surface. As shown in
FIG. 48, a build plate 2500 includes a patterned permeable sheet
2420 that is adhered (e.g., by lamination or by an adhesive) to
another permeable sheet 2522 to form channels 2521. The sheet 2420
is mounted on the base 2510 by an adhesive 2514.
[0294] The channels of FIGS. 47 and 48 may be formed by any
suitable technique. For example, two or more permeable sheet layers
may be laminated together. In some embodiments, a spacer, such as a
plurality of tubes, may be positioned between the layers during
lamination. When the spacers are removed, the resulting laminated
sheet includes apertures or channels where the spacers were
positioned. In some embodiments, such as shown in FIG. 48, the
permeable sheet may include a patterned sheet 2520 and an
unpatterned sheet 2522 that are laminated to one another, such as
through thermal lamination. The surface topology of pattern on the
patterned sheet layer 2520 thus provides the channels 2521 in the
resulting laminated sheet. The surface topology may include a rough
surface having irregular and/or random features; however, in some
embodiments, the surface topology may be molded or otherwise formed
in a regular or somewhat regular pattern. The surface topology
and/or the channels may dimensions of between about 10-25 .mu.m
wide and about 50-100 .mu.m deep. The surface topology of the
patterned sheet 2520 may be formed by a mechanical abrasive,
chemical, etching and/or laser cutting.
[0295] In some embodiments, the channel layer may be provided by a
mesh layer that may be used to increase gas flow to the build plate
surface. As illustrated in FIG. 49, a build plate 2600 includes a
rigid, optically transparent planar base 2610 having an upper
surface and an opposing lower surface, a first adhesive layer 2614
on the base upper surface, and a mesh layer 2616 on the adhesive
layer 2614 opposite the base 2610. A second gas permeable adhesive
layer 2618 is on the mesh layer 2616 opposite the base 2610. A
flexible, optically transparent, gas-permeable sheet 2620 is on the
second adhesive layer 2618 opposite the base. The sheet 2620 has
upper and lower surfaces and includes a build surface for forming a
three-dimensional object on the upper surface. The build plate 2600
is configured to permit gas flow to the build surface via the mesh
layer 2616, the permeable adhesive 2618 and the permeable sheet
2620.
[0296] The mesh layer 2616 may include a polyester screen mesh, or
a fiberglass fabric. The mesh layer 2616 may be optically
transparent. In some embodiments, the mesh layer has cross-linked
fibers or other materials having a thickness of about 10-50 microns
or, more preferably, 25 microns. The spacing or pitch between the
fibers may be between about 50-500 microns.
[0297] The first adhesive layer 2614 may be gas permeable or gas
impermeable. The first and/or second adhesive layers 2614, 2618 may
be formed of a poly(dimethylsiloxane) (PDMS) film (e.g., a silicon
transfer film adhesive).
[0298] In this configuration, the mesh layer 2616 provides a
plurality of channels that increase gas flow to the build surface.
The mesh layer 2616 may have any suitable thickness or dimensions
for increasing gas flow to the build surface of the sheet; however,
in some embodiments, the mesh layer 2616 has a thickness in a
vertical direction of about 10-50 microns.
[0299] It should be understood that additional mesh layers may be
provided. For example, two or more mesh layers may be adhered to
one another by an adhesive layer.
[0300] It should be understood that additional layers may be added
to the build plates. For example, an additional adhesive layer may
be applied to the permeable sheet and an additional permeable sheet
may be positioned on the additional adhesive layer in a stacked
configuration. Three or more adhesive/sheet layers may be used. Two
or more mesh layers may also be used. An elastomer layer analogous
to the elastomer layer 1730 may also be included between the base
and the mesh layer 2616.
12. Alternate Methods and Apparatus.
[0301] While the present invention is preferably carried out by
continuous liquid interphase polymerization, as described in detail
above and in further detail below, in some embodiments alternate
methods and apparatus for bottom-up three-dimension fabrication may
be used, including layer-by-layer fabrication. Examples of such
methods and apparatus include, but are not limited to, those
described in U.S. Pat. No. 5,236,637 to Hull, U.S. Pat. No.
7,438,846 to John and U.S. Pat. No. 8,110,135 to El-Siblani, and in
U.S. Patent Application Publication Nos. 2013/0292862 to Joyce and
2013/0295212 to Chen et al. The disclosures of these patents and
applications are incorporated by reference herein in their
entirety.
[0302] The present invention is explained in greater detail in the
following non-limiting Examples, and features which may be
incorporated in carrying out the present invention are further
explained in PCT Applications Nos. PCT/US2014/015486 (also
published as US 2015/0102532); PCT/US2014/015506 (also published as
US 2015/0097315), PCT/US2014/015497 (also published as US
2015/0097316), and in J. Tumbleston, D. Shirvanyants, N. Ermoshkin
et al., Continuous liquid interface production of 3D Objects,
Sciencexpress (16 Mar. 2015).
Example 1
High Aspect Ratio Adjustable Tension Build Plate Assembly
[0303] FIG. 6 is a top view and FIG. 7 is an exploded view of a 3
inch by 16 inch "high aspect" rectangular build plate (or "window")
assembly of the present invention, where the film dimensions are
3.5 inches by 17 inches. The greater size of the film itself as
compared to the internal diameter of vat ring and film base
provides a peripheral or circumferential flange portion in the film
that is clamped between the vat ring and the film base, as shown in
side-sectional view in FIG. 8. One or more registration holes (not
shown) may be provided in the polymer film in the peripheral or
circumferential flange portion to aid in aligning the polymer film
between the vat ring and film base, which are fastened to one
another with a plurality of screws (not shown) extending from one
to the other (some or all passing through holes in the peripheral
edge of the polymer film) in a manner that rigidly and securely
clamps the polymer film therebetween, while optionally allowing
some flexibility to contribute to embodiments employing vertical
reciprocation, as noted above.
[0304] As shown in FIGS. 7-8 a tension ring is provided that abuts
the polymer film and stretches the film to fix or rigidify the
film. The tension ring may be provided as a pre-set member, or may
be an adjustable member. Adjustment may be achieved by providing a
spring plate facing the tension ring, with one or more compressible
elements such as polymer cushions or springs (e.g., flat springs,
coil springs, wave springs etc.) therebetween, and with adjustable
fasteners such as screw fasteners or the like passing from the
spring plate through (or around) the tension ring to the film
base.
[0305] Polymer films are preferably fluoropolymer films, such as an
amorphous thermoplastic fluoropolymer, in a thickness of 0.01 or
0.05 millimeters to 0.1 or 1 millimeters, or more. In some
embodiments we use Biogeneral Teflon AF 2400 polymer film, which is
0.0035 inches (0.09 millimeters) thick, and Random Technologies
Teflon AF 2400 polymer film, which is 0.004 inches (0.1
millimeters) thick.
[0306] Tension on the film is preferably adjusted with the tension
ring to about 10 to 100 pounds, depending on operating conditions
such as fabrication speed.
[0307] The vat ring, film base, tension ring, and tension ring
spring plate may be fabricated of any suitable, preferably rigid,
material, including metals (e.g., stainless steel, aluminum and
aluminum alloys), carbon fiber, polymers, and composites
thereof.
[0308] Registration posts and corresponding sockets may be provided
in any of the vat ring, film base, tension ring and/or spring
plate, as desired.
Example 2
Round Adjustable Tension Round Build Plate Assembly
[0309] FIG. 9 is a top view and FIG. 10 is an exploded view of a
2.88 inch diameter round build plate of the invention, where the
film dimension may be 4 inches in diameter. Construction is in like
manner to that given in Example 1 above, with a circumferential
wave spring assembly shown in place. Tension on the film preferably
adjusted to a like tension as given in Example 1 above (again
depending on other operating conditions such as fabrication
speed).
[0310] FIG. 10 is an exploded view of the build plate of FIG.
8.
Example 3
Additional Embodiments of Adjustable Build Plates
[0311] FIG. 11 shows various alternate embodiments of the build
plates of FIGS. 7-10. Materials and tensions may be in like manner
as described above.
Example 4
Example Embodiment of an Apparatus
[0312] FIG. 12 is a front perspective view, FIG. 13 is a side view
and FIG. 14 is a rear perspective view of an apparatus 100
according to an exemplary embodiment of the invention. The
apparatus 100 includes a frame 102 and an enclosure 104. Much of
the enclosure 104 is removed or shown transparent in FIGS.
12-14.
[0313] The apparatus 100 includes several of the same or similar
components and features as the apparatus described above in
reference to FIG. 2. Referring to FIG. 12, a build chamber 106 is
provided on a base plate 108 that is connected to the frame 102.
The build chamber 106 is defined by a wall or vat ring 110 and a
build plate or "window" such as one of the windows described above
in reference to FIGS. 2 and 6-11.
[0314] Turning to FIG. 13, a carrier 112 is driven in a vertical
direction along a rail 114 by a motor 116. The motor may be any
suitable type of motor, such as a servo motor. An exemplary
suitable motor is the NXM45A motor available from Oriental Motor of
Tokyo, Japan.
[0315] A liquid reservoir 118 is in fluid communication with the
build chamber 106 to replenish the build chamber 106 with liquid
resin. For example, tubing may run from the liquid reservoir 118 to
the build chamber 106. A valve 120 controls the flow of liquid
resin from the liquid reservoir 118 to the build chamber 106. An
exemplary suitable valve is a pinch-style aluminum solenoid valve
for tubing available from McMaster-Carr of Atlanta, Ga.
[0316] The frame 102 includes rails 122 or other some other
mounting feature on which a light engine assembly 130 (FIG. 15) is
held or mounted. A light source 124 is coupled to the light engine
assembly 130 using a light guide entrance cable 126. The light
source 124 may be any suitable light source such as a BlueWave.RTM.
200 system available from Dymax Corporation of Torrington,
Conn.
[0317] Turning to FIG. 15, the light engine or light engine
assembly 130 includes condenser lens assembly 132 and a digital
light processing (DLP) system including a digital micromirror
device (DMD) 134 and an optical or projection lens assembly 136
(which may include an objective lens). A suitable DLP system is the
DLP Discovery.TM. 4100 system available from Texas Instruments,
Inc. of Dallas, Tex. Light from the DLP system is reflected off a
mirror 138 and illuminates the build chamber 106. Specifically, an
"image" 140 is projected at the build surface or window.
[0318] Referring to FIG. 14, an electronic component plate or
breadboard 150 is connected to the frame 102. A plurality of
electrical or electronic components are mounted on the breadboard
150. A controller or processor 152 is operatively associated with
various components such as the motor 116, the valve 120, the light
source 124 and the light engine assembly 130 described above. A
suitable controller is the Propeller Proto Board available from
Parallax, Inc. of Rocklin, Calif.
[0319] Other electrical or electronic components operatively
associated with the controller 152 include a power supply 154 and a
motor driver 158 for controlling the motor 116. In some
embodiments, an LED light source controlled by pulse width
modulation (PWM) driver 156 is used instead of a mercury lamp
(e.g., the Dymax light source described above).
[0320] A suitable power supply is a 24 Volt, 2.5 A, 60 W, switching
power supply (e.g., part number PS1-60 W-24 (HF60 W-SL-24)
available from Marlin P. Jones & Assoc, Inc. of Lake Park,
Fla.). If an LED light source is used, a suitable LED driver is a
24 Volt, 1.4 A LED driver (e.g., part number 788-1041-ND available
from Digi-Key of Thief River Falls, Minn.). A suitable motor driver
is the NXD20-A motor driver available from Oriental Motor of Tokyo,
Japan.
[0321] The apparatus of FIGS. 12-15 has been used to produce an
"image size" of about 75 mm by 100 mm with light intensity of about
5 mW/cm.sup.2. The apparatus of FIGS. 12-15 has been used to build
objects at speeds of about 100 to 500 mm/hr. The build speed is
dependent on light intensity and the geometry of the object.
Example 5
Another Example Embodiment of an Apparatus
[0322] FIG. 16 is a front perspective view of an apparatus 200
according to another exemplary embodiment of the invention. The
apparatus 200 includes the same components and features of the
apparatus 100 with the following differences.
[0323] The apparatus 200 includes a frame 202 including rails 222
or other mounting feature at which two of the light engine
assemblies 130 shown in FIG. 15 may be mounted in a side-by-side
relationship. The light engine assemblies 130 are configured to
provide a pair of "tiled" images at the build station 206. The use
of multiple light engines to provide tiled images is described in
more detail above.
[0324] The apparatus of FIG. 16 has been used to provide a tiled
"image size" of about 150 mm by 200 mm with light intensity of
about 1 mW/cm.sup.2. The apparatus of FIG. 16 has been used to
build objects at speeds of about 50 to 100 mm/hr. The build speed
is dependent on light intensity and the geometry of the object.
Example 6
Another Example Embodiment of an Apparatus
[0325] FIG. 18 is a front perspective view and FIG. 19 is a side
view of an apparatus 300 according to another exemplary embodiment
of the invention. The apparatus 300 includes the same components
and features of the apparatus 100 with the following
differences.
[0326] The apparatus 300 includes a frame 302 including rails 322
or other mounting feature at which a light engine assembly 330
shown in FIG. 20 may be mounted in a different orientation than the
light assembly 130 of the apparatus 100. Referring to FIGS. 19 and
20, the light engine assembly 330 includes a condenser lens
assembly 332 and a digital light processing (DLP) system including
a digital micromirror device (DMD) 334 and an optical or projection
lens assembly 336 (which may include an objective lens). A suitable
DLP system is the DLP Discovery.TM. 4100 system available from
Texas Instruments, Inc. of Dallas, Tex. Light from the DLP system
illuminates the build chamber 306. Specifically, an "image" 340 is
projected at the build surface or window. In contrast to the
apparatus 100, a reflective mirror is not used with the apparatus
300.
[0327] The apparatus of FIGS. 18-20 has been used to provide "image
sizes" of about 10.5 mm by 14 mm and about 24 mm by 32 mm with
light intensity of about 200 mW/cm.sup.2 and 40 mW/cm.sup.2 The
apparatus of FIGS. 18-20 has been used to build objects at speeds
of about 10,000 and 4,000 mm/hr. The build speed is dependent on
light intensity and the geometry of the object.
Example 7
Control Program with Lua Scripting
[0328] Current printer technology requires low level control in
order to ensure quality part fabrication. Physical parameters such
as light intensity, exposure time and the motion of the carrier
should all be optimized to ensure the quality of a part. Utilizing
a scripting interface to a controller such as the Parallax
PROPELLER.TM. microcontroller using the programming language "Lua"
provides the user with control over all aspects of the printer on a
low level. See generally R. Ierusalimschy, Programming in Lua
(2013) (ISBN-10: 859037985X; ISBN-13: 978-8590379850).
[0329] This Example illustrates the control of a method and
apparatus of the invention with an example program written
utilizing Lua scripting. Program code corresponding to such
instructions, or variations thereof that will be apparent to those
skilled in the art, is written in accordance with known techniques
based upon the particular microcontroller used.
[0330] Concepts.
[0331] A part consists of slices of polymer which are printed
continuously. The shape of each slice is defined by the frame that
is being displayed by the light engine.
[0332] Frame. The frame represents the final output for a slice.
The frame is what manifests as the physical geometry of the part.
The data in the frame is what is projected by the printer to cure
the polymer.
[0333] Slice.
[0334] All the 2D geometry that will be outputted to a frame should
be combined in a Slice. Slices can consist of procedural geometry,
Slices of a 3D model or any combination of the two. The slice
generating process allows the user to have direct control over the
composition of any frame.
[0335] Slice of a 3D Model.
[0336] A slice is a special type of 2D geometry derived from a 3D
model of a part. It represents the geometry that intersects a plane
that is parallel to the window. Parts are usually constructed by
taking 3D models and slicing them at very small intervals. Each
slice is then interpreted in succession by the printer and used to
cure the polymer at the proper height.
[0337] Procedural Geometry.
[0338] Procedurally generated geometry can also be added to a
slice. This is accomplished by invoking shape generation functions,
such as "addcircle", "addrectangle", and others. Each function
allows projection of the corresponding shape onto the printing
window. A produced part appears as a vertically extruded shape or
combination of shapes.
[0339] Coordinate Spaces: Stage.
[0340] The coordinate system that the stage uses is usually
calibrated such that the origin is 1-20 microns above the
window.
[0341] Coordinate Spaces: Slice.
[0342] Coordinate system of the projected slice is such that origin
is located at the center of the print window.
Quick Start.
[0343] The following is the most basic method of printing a part
from a sliced 3D model. Printing a sliced model consists of 4 main
parts: Loading the data, preparing the printer, printing, and
shutdown.
[0344] Loading Data.
[0345] In this section of the code the sliced model data is loaded
into memory. The file path to the model is defined in the Constants
section of the code. See the full code below for details.
--Loading Model
[0346] modelFilePath="Chess King.svg"
numSlices=loadslices(modelFilePath)
[0347] Preparing the printer it is important to do two things
before printing. You must first turn on the light engine with the
relay function, and if applicable, the desired fluid height should
be set.
--Prepare Printer
[0348] relay(true)--turn light on showframe(-1)--ensure nothing is
exposed during setup setlevels(0.55, 0.6)--if available, printer
set fluid pump to maintain about 55% fill
[0349] Printing.
[0350] The first step of the printing process is to calibrate the
system and set the stage to its starting position by calling
gotostart. Next we begin a for loop in which we print each slice.
The first line of the for loop uses the infoline command to display
the current slice index in the sidebar. Next we determine the
height at which the next slice should be cured. That value is
stored to nextHeight. Following this we move the stage to the
height at which the next slice needs to be cured. To ensure a clean
print it can sometimes be necessary to wait for oxygen to diffuse
into the resin. Therefore we call sleep for a half second (the
exact time for preExposureTime is defined in the constants section
as well). After this it's time to actually cure the resin so we
call showframe and pass it the index of the slice we want to print,
which is stored in sliceIndex by the for loop. We sleep again after
this for exposureTime seconds in order to let the resin cure.
Before moving on to the next frame, we call showframe(-1) in order
to prevent the light engine from curing any resin while the stage
is moving to the next height.
TABLE-US-00001 --Execute Print gotostart( )--move stage to starting
position for sliceIndex =0,numSlices-1 do infoline(5,
string.format("Current Slice: %d", sliceIndex)) nextHeight =
sliceheight(sliceIndex)--calculate the height that the stage should
be at to expose this frame moveto(nextHeight, stageSpeed)--move to
nextHeight sleep(preExposureTime)--wait a given amount of time for
oxygen to diffuse into resin , prepExposureTime is predefined in
the Constants section showframe(sliceIndex)--show frame to expose
sleep(exposureTime)--wait while frame exposes, exposureTime is
predefined in the Constants section showframe(-1)-- show nothing to
ensure no exposure while stage is moving to next position end
Shutdown.
[0351] The final step in the printing process is to shut down the
printer. Call relay(false) to turn the light engine off. If you are
using fluid control, call setlevels(0,0) to ensure the valve is
shut off. Finally it is a good idea to move the stage up a bit
after printing to allow for easy removal of the part.
--Shutdown
[0352] relay(false) setlevels(0,0) --Lift stage to remove part
moveby(25, 16000) Fully completed code implementing instructions
based on the above is set forth below.
TABLE-US-00002 --Constants exposureTime = 1.5-- in seconds
preExposureTime = 0.5 -- in seconds stageSpeed = 300 --in mm/hour
--Loading Model modelFilePath = "Chess King.svg" numSlices =
loadslices(modelFilePath) --calculating parameters maxPrintHeight =
sliceheight(numSlices-1)--find the highest point in the print, this
is the same as the height of the last slice. Slices are 0 indexed,
hence the -1. infoline(1, "Current Print Info:") infoline(2,
string.format("Calculated Max Print Height: %dmm", maxPrintHeight))
infoline(3, string.format("Calculated Est. Time: %dmin",
(maxPrintHeight/stageSpeed)*60 +
(preExposureTime+exposureTime)*numSlices/60)) infoline(4,
string.format("Number of Slices: %d", numSlices)) --Prepare Printer
relay(true)--turn light on showframe(-1) --ensure nothing is
exposed durring setup setlevels(.55, .6)--if available, printer set
fluid pump to maintain about 55% fill --Execute Print gotostart(
)--move stage to starting position for sliceIndex =0,numSlices-1 do
infoline(5, string.format("Current Slice: %d", sliceIndex))
nextHeight = sliceheight(sliceIndex)--calculate the height that the
stage should be at to expose this frame moveto(nextHeight,
stageSpeed)--move to nextHeight sleep(preExposureTime)--wait a
given amount of time for oxygen to diffuse into resin ,
prepExposureTime is predefined in the Constants section
showframe(sliceIndex)--show frame to expose
sleep(exposureTime)--wait while frame exposes, exposureTime is
predefined in the Constants section showframe(-1)-- show nothing to
ensure no exposure while stage is moving to next position end
--Shutdown relay(false) setlevels(0,0) --Lift stage to remove part
moveby(25, 16000)
[0353] Gotostart.
[0354] The main purpose of gotostart is to calibrate the stage.
This function resets the coordinate system to have the origin at
the lowest point, where the limit switch is activated. Calling this
command will move the stage down until the limit switch in the
printer is activated; this should occur when the stage is at the
absolute minimum height.
gotostart( ) moves stage to start at the maximum speed which varies
from printer to printer. gotostart( )--moving to origin at default
speed gotostart(number speed) moves stage to start at speed given
in millimeters/hour. gotostart(15000)--moving stage to origin at
15000 mm/hr -speed: speed, in mm/hour, at which the stage will move
to the start position.
MOVETO
[0355] moveto allows the user to direct the stage to a desired
height at a given speed. Safe upper and lower limits to speed and
acceleration are ensured internally. moveto(number targetHeight,
number speed)
moveto(25, 15000)--moving to 25 mm at 15,000 mm/hr moveto(number
targetHeight, number speed, number acceleration) This version of
the function allows an acceleration to be defined as well as speed.
The stage starts moving at initial speed and then increases by
acceleration. moveto(25, 20000, 1e7)--moving the stage to 25 mm at
20,000 mm/hr while accelerating at 1 million mm/hr 2 moveto(number
targetHeight, number speed, table controlPoints, function callback)
This function behaves similar to the basic version of the function.
It starts at its initial speed and position and moves to the
highest point on the control point table. callback is called when
the stage passes each control point.
TABLE-US-00003 function myCallbackFunction(index)--defining the
callback function print("hello") end moveto(25, 20000,
slicecontrolpoints( ), myCallbackFunction)-- moving the stage to
25mm at 20,000mm/hr while calling myCallbackFunction at the control
points generated by slicecontrolpoints( )
[0356] moveto(number targetHeight, number speed, number
acceleration, table controlPoints, function callback) This function
is the same as above except the user can pass an acceleration. The
stage accelerates from its initial position continuously until it
reaches the last control point.
TABLE-US-00004 [0356] function myCallbackFunction(index)--defining
the callback function print("hello") end moveto(25, 20000, 0.5e7,
slicecontrolpoints( ), myCallbackFunction)-- moving the stage to
25mm at 20,000mm/hr while accelerating at 0.5 million
mm/hr{circumflex over ( )}2 and also calling myCallbackFunction at
the control points generated by slicecontrolpoints( )
[0357] -targetHeight: height, in mm from the origin, that the stage
will move to. [0358] -initialSpeed: initial speed, in mm/hour, that
the stage will start moving at. [0359] -acceleration: rate, in
mm/hour.sup.2, that the speed of the stage will increase from
initial speed. [0360] -controlPoints: a table of target heights in
millimeters. After the stage reaches a target height, it calls the
function callback. [0361] -callback: pointer to a function that
will be called when the stage reaches a control point. The callback
function should take one argument which is the index of the control
point the stage has reached. moveby
[0362] moveby allows the user to change the height of the stage by
a desired amount at a given speed. Safe upper and lower limits to
speed and acceleration are ensured internally. moveby(number
dHeight, number initalSpeed)
[0363] 1 moveby(-2, 15000)--moving down 2 mm at 15,000 mm/hr [0364]
moveby(number dHeight, number initialSpeed, number acceleration)
[0365] This version of the function allows an acceleration to be
defined as well as speed. The stage starts moving at initial speed
and then increases by acceleration until it reaches its
destination. [0366] 1 moveby(25, 15000, 1e7)--moving up 25 mm at
15,000 mm/hr while accelerating 1e7 mm/hr 2 [0367] moveby(number
dHeight, number initialSpeed, table controlPoints, function
callback) [0368] This function usage allows the user to pass the
function a table of absolute height coordinates. After the stage
reaches one of these target heights, it calls the function
`callback.` Callback should take one argument which is the index of
the control point it has reached.
TABLE-US-00005 [0368] function myCallbackFunction(index)--defining
the callback function print("hello") end moveby(25, 20000,
slicecontrolpoints( ), myCallbackFunction)--moving the stage up
25mm at 20,000mm/hr while calling myCallbackFunction at the control
points generated by slicecontrolpoints( )
[0369] moveby(number dHeight, number initialSpeed, number
acceleration, table controlPoints, function callback) This function
is the same as above except the user can pass an acceleration. The
stage accelerates from its initial position continuously until it
reaches the last control point.
TABLE-US-00006 [0369] function myCallbackFunction(index)--defining
the callback function print("hello") end moveby(25, 20000,
1e7,slicecontrolpoints( ), myCallbackFunction)--moving the stage up
25mm at 20,000mm/hr while calling myCallbackFunction at the control
points generated by slicecontrolpoints( ) and accelerating at
1e7mm/hr{circumflex over ( )}2
[0370] -dHeight: desired change in height, in millimeters, of the
stage. [0371] -initialSpeed: initial speed, in mm/hour, at which
the stage moves. [0372] -acceleration: rate, in mm/hour.sup.2, that
the speed of the stage will increase from initial speed. [0373]
-controlPoints: a table of target heights in millimeters. After the
stage reaches a target height, it calls the function callback.
[0374] -callback: pointer to a function that will be called when
the stage reaches a control point. The callback function should
take one argument which is the index of the control point the stage
has reached.
Light Engine Control
[0375] light [0376] relay is used to turn the light engine on or
off in the printer. The light engine must be on in order to print.
Make sure the relay is set to off at the end of the script.
relay(boolean lightOn)
[0377] relay(true)--turning light on [0378] -lightOn: false turns
the light engine off, true turns the light engine on.
Adding Procedural Geometry
[0378] [0379] Functions in this section exist to project shapes
without using a sliced part file. Every function in this section
has an optional number value called figureIndex. Each figure in a
slice has its own index. The figures reside one on top of another.
Figures are drawn so that the figure with the highest index is `on
top` and will therefore not be occluded by anything below it. By
default indexes are assigned in the order that they are created so
the last figure created will be rendered on top. One can, however,
change the index by passing the desired index into figureIndex.
[0380] Every function in this section requires a sliceIndex
argument. This value is the index of the slice that the figure will
be added to. [0381] Note that generating this procedural geometry
does not guarantee that it will be visible or printable. One must
use one of the functions such as fillmask or linemask outlined
below. addcircle
[0382] addcircle(number x, number y, number radius, number
sliceIndex) addcircle draws a circle in the specified slice
slice.
addCircle(0,0, 5, 0)--creating a circle at the origin of the first
slice with a radius of 5 mm
[0383] -x: is the horizontal distance, in millimeters, from the
center of the circle to the origin.
[0384] -y: is the vertical distance, in millimeters, from the
center of the circle to the origin.
[0385] -radius: is the radius of the circle measured in
millimeters.
[0386] -sliceIndex: index of the slice to which the figure will be
added.
[0387] Returns: figure index of the figure.
addrectangle [0388] addrectangle(number x, number y, number width,
number height number sliceIndex) addrectangle draws a rectangle in
the specified slice. addrectangle(0,0, 5,5, 0)--creating a 5
mm.times.5 mm square with its top left corner at the origin.
[0389] -x: horizontal coordinate, in millimeters, of the top left
corner of the rectangle.
[0390] -y: vertical coordinate, in millimeters, of the top left
corner of the rectangle.
[0391] -width: width of the rectangle in millimeters.
[0392] -height: height of the rectangle in millimeters.
[0393] -sliceIndex: index of the slice to which the figure will be
added.
[0394] Returns: figure index of the figure.
addline [0395] addline(number x0, number y0, number x1, number y1,
number sliceIndex) addline draws a line segment. addLine(0,0,
20,20, 0)--creating a line from the origin to 20 mm along the x and
y axis on the first slice.
[0396] -x0: horizontal coordinate of the first point in the
segment, measured in millimeters.
[0397] -y0: vertical coordinate of the first point in the segment,
measured in millimeters.
[0398] -x1: horizontal coordinate of the second point in the
segment, measured in millimeters.
[0399] -y2: vertical coordinate of the second point in the segment,
measured in millimeters.
[0400] -sliceIndex: index of the slice to which the figure will be
added. Returns: figure index of the figure.
addtext
[0401] text(number x, number y, number scale, string text, number
sliceIndex) addtext draws text on the specified slice starting at
position `x, y` with letters of size `scale`.
addtext(0,0, 20, "Hello world", 0)--writing Hello World at the
origin of the first slice [0402] -x: horizontal coordinate,
measured in millimeters, of the top left corner of the bounding box
around the text. [0403] -y: vertical coordinate, measured in
millimeters, of the top left corner of the bounding box around the
text. [0404] -scale: letter size in millimeters, interpretation may
vary depending on the underlying operating system (Windows, OSX,
Linux, etc). [0405] -text: the actual text that will be drawn on
the slice. [0406] -sliceIndex: index of the slice to which the
[0407] figure will be added. Returns: figure index [0408] of the
figure.
[0409] 2.4 Fill & Line Control
[0410] 2.4.1 fillmask [0411] fillmask(number color, number
sliceIndex, number figureIndex) fillmask is used to control how the
procedural geometry is drawn. fillmask tells the figure in question
to fill the entirety of its interior with color. [0412] -color: can
be any number on the range 0 to 255. Where 0 is black and 255 is
white, any value in between is a shade of grey interpolated
linearly between black and white based on the color value. Any
value less than 0 will produce a transparent color. [0413]
myCircle=addCircle(0,0,5,0)--creating the circle to fill [0414]
fillmask(255, 0, myCircle)--Creating a white filled circle [0415]
-sliceIndex:the index of the slice that should be modified. [0416]
-figureIndex:the is used to determine which figure on the slice
should be filled. Each figure has its own unique index. If no
figureIndex is passed, the fill applies to all figures in the
slice.
[0417] 2.4.2 linemask [0418] linemask(number color, number
sliceIndex, number figureIndex) linemask is used to control how the
procedural geometry is drawn. linemask tells a figure to draw its
outline in a specific color. The width of the outline is defined by
the function linewidth. [0419]
myCircle=addCircle(0,0,20,0)--creating the circle to fill [0420]
linemask(255, 0, myCircle)--setting the outline of the circle to be
white [0421] fillmask(150,0, myCircle)--setting the fill of the
circle to be grey [0422] -color: can be any number on the range 0
to 255. Where 0 is black and 255 is white, any value in between is
a shade of grey interpolated linearly between black and white based
on the color value. Any value less than 0 will produce a
transparent color. [0423] -sliceIndex: the index of the slice that
should be modified. [0424] -figureIndex: is used to determine which
figure on the slice should be filled. Each figure has its own
unique index. If no figureIndex is passed, the fill applies to all
figures in the slice.
[0425] 2.4.3 linewidth [0426] linewidth(number width, number
sliceIndex, number [0427] figureIndex) linewidth is used to set the
width of the line that linemask will use to outline the figure.
[0428] linewidth(2,0)--setting the line width for every figure on
the first slice to 2 mm [0429] -sliceIndex: the index of the slice
that should be modified. [0430] -figureIndex: is used to determine
which figure on the slice should have its outline changed. Each
figure has its own unique index, see section 2.3 (Pg. 10) for more
details. If no figureIndex is passed, the fill applies to all
figures in the slice. loadmask [0431] loadmask(string filepath)
loadmask allows for advanced fill control. It enables the user to
load a texture from a bitmap file and use it to fill the entirety
of a figure with the texture. [0432]
texture=loadmask("voronoi_noise.png")--loading texture.
voronoi_noise.png is in the same directory as the script. [0433]
myCircie=addCircle(0,0,20,0)--creating the circle to fill [0434]
fillmask(texture, 0, myCircle)--filling the circle with voronoi
noise [0435] -filepath: file path to image file [0436] Returns: a
special data type which can be passed into a fillmask or linemask
function as the color argument.
Frames
[0437] showframe [0438] showframe(number sliceIndex) showframe is
essential to the printing process. This function sends the data
from a slice to the printer. Call showframes on a frame that
doesn't exist to render a black frame e.g. showframe(-1). [0439]
showframe(2)--showing the 3rd slice [0440] -sliceIndex: the index
of the slice to send to the printer. framegradient [0441]
framegradient(number slope) framegradient is designed to compensate
for differences in light intensity. calcframe [0442] calcframe( )
[0443] calcframe is designed to analyze the construction of a slice
calculates the last frame shown. [0444] showframe(0) [0445]
calcframe( ) [0446] Returns: the maximum possible distance between
any point in the figure and the edge.
[0447] 2.5.4 loadframe [0448] loadframe(string filepath) [0449]
loadframe is used to load a single slice [0450] from a supported
bitmap file. [0451] loadframe("slice.png")--slice.png is in the
same directory as the script [0452] -filepath: file path to slice
image.
Slices
[0452] [0453] addslice [0454] addslice(number sliceHeight) addslice
creates a new slice at a given height at the end of the slice
stack. [0455] addslice(0.05)--adding a slice at 0.05 mm [0456]
addslice(number sliceHeight, number sliceIndex) [0457]
addslice(0.05, 2)--adding a slice at 0.05 mm and at index 2. this
pushes all layers 2 and higher up an index. [0458] addslice creates
a new slice at a given height and slice index. [0459] -sliceHeight:
height, in millimeters, of the slice. [0460] -sliceIndex: index at
which the slice [0461] should be added. Returns: slice [0462]
index. loadslices [0463] loadslices(string filepath) loadslices
[0464] is used to load all the slices [0465] from a 2D slice file.
[0466] loadslices("Chess King.svg")--loading all the slices from
the Chess King.svg file [0467] -filepath: file path to the sliced
model. Acceptable [0468] formats are .cli and .svg. Returns: number
of slices. sliceheight [0469] sliceheight(number sliceIndex)
sliceheight [0470] is used to find the height of a slice in [0471]
mm off the base. [0472] addslice(0.05,0)--setting the first slice
to 0.05 mm [0473] sliceheight(0)--checking the height of slice 0,
in this example it should return 0.05 [0474] -sliceIndex: index of
the slice to check. Returns: slice height in mm.2.6.4
slicecontrolpoints [0475] slicecontrolpoints( ) slicecontrolpoints
is a helper function which creates a control point for each slice
of a model. These control points can be passed to the moveto or
moveby function to set it to callback when the stage reaches the
height of each slice. Make sure loadslices has been called prior to
calling this function. loadslices("Chess King.svg") control
Points=slicecontrolpoints( )
[0476] Returns: Lua table of control points.
Timing
Sleep
[0477] sleep(number seconds) sleep allows the user to pause the
execution of the program for a set number of seconds.
sleep(0.5)--sleeping for a half second [0478] -seconds: number of
seconds to pause script execution.
Clock
[0478] [0479] clock( ) clock returns the current time in seconds.
It is accurate at least up to the millisecond and should therefore
be used instead of Lua's built in clock functionality. clock should
be used as a means to measure differences in time as the start time
for the second count varies from system to system. [0480] t1=clock(
) [0481] loadslices("Chess King.svg") [0482] deltaTime=clock( )-t1
[0483] Returns: system time in seconds.
Fluid Control
[0484] This set of functions can be used with printer models that
support fluid control. Before the script finishes executing,
setlevels(0,0) should be called to ensure that the pump stops
pumping fluid into the vat.
getcurrentlevel [0485] getcurrentlevel( ) getcurrentlevel [0486]
returns the percentage of the vat [0487] that is full. [0488]
print(string.format("Vat is % d percent full.", getcurrentlevel(
)*100)) [0489] Returns: a floating point number on the range 0 to 1
that represents the percentage of the vat that is full. setlevels
[0490] setlevels(number min, number max) setlevels allows the user
to define how much fluid should be in the vat. The fluid height
will be automatically regulated by a pump. The difference between
min and max should be greater than 0.05 to ensure that the valve is
not constantly opening and closing. [0491]
setlevels(0.7,0.75)--keeping vat about 75 percent full -min: the
minim percentage of the vat that should be full. Entered as a
floating point number from 0 to 1. [0492] -max: the max percentage
of the vat that should be full. Entered as a floating point number
from 0 to 1.
User Feedback
[0493] 2.9.1 infoline [0494] infoline(int lineIndex, string text)
infoline allows the user to display up to 5 lines of text in a
constant position on the sidebar of the Programmable Printer
Platform. This function is often used to allow the user to monitor
several changing variables at once, [0495] infoline(1,
string.format("Vat is % d percent full.", getcurrentlevel( )*100))
[0496] -lineIndex: the index of the line. Indexes should be in the
range 1 to 5, 1 being the upper most line. -text: text to be
displayed at line index.
Global Configuration Table.
[0497] Before a print script is executed, all global variables are
loaded into a configuration table called cfg. Most of the data in
this table has already been read by the Programmable Printer
Platform by the time the users script executes, therefore, changing
them will have no effect. However, writing to the xscale, yscale,
zscale, xorig and yorig fields of the cfg, will effect all the
loadslices and addlayer calls that are made afterwards. If the
users script is designed to be run at a specific scale and/or
position, it is good practice to override the cfg with the correct
settings to ensure the scale and position can't be accidentally
changed by the Programmable Printer Platform.
cfg.xscale=3--overriding global settings to set scale on the x axis
to 3 cfg.yscale=2--overriding global settings to set scale on the y
axis to 2 cfg.zscale=1--overriding global settings to set scale on
the z axis to 1 cfg.xorig=-2.0--overriding global settings to set
the origin on the x axis 2 mm left cfg.yorig=0.25--overriding
global settings to set the origin on the y axis 0.25 mm in the
positive direction
Fields in cfg:
[0498] -serial port: name of serial port (changing this variable
wont effect code) -xscale: x scale -yscale: y scale -zscale: z
scale -xorig: x origin -yorig: y origin -hw xscale: pixel
resolution in x direction (changing this variable won't effect
code) -hw yscale: pixel resolution in y direction (changing this
variable won't effect code)
Useful Lua Standard Libraries.
[0499] The math standard library contains several different
functions that are useful in calculating geometry. The string
object is most useful in printing for manipulating info strings.
For details contact LabLua at Departamento de Informatica, PUC-Rio,
Rua Marques de Sao Vicente, 225; 22451-900 Rio de Janeiro, RJ,
Brazil
Example 8
Lua Script Program for Continuous Print
[0500] This example shows a Lua script program corresponding to
Example 7 above for continuous three dimension printing.
TABLE-US-00007 --Constants sliceDepth = .05--in millimeters
exposureTime = .225-- in seconds --Loading Model modelFilePath =
"Chess King.svg" numSlices = loadslices(modelFilePath)
controlPoints = slicecontrolpoints( )--Generate Control Points
--calculating parameters exposureTime =
exposureTime/(60*60)--converted to hours stageSpeed =
sliceDepth/exposureTime--required distance/required time
maxPrintHeight = sliceheight(numSlices-1)--find the highest point
in the print, this is the same as the height of the last slice.
Slices are 0 indexed, hence the -1. infoline(1, "Current Print
Info:") infoline(2, string.format("Calulated Stage Speed:
%dmm/hr\n", stageSpeed)) infoline(3, string.format("Calculated Max
Print Height: %dmm", maxPrintHeight)) infoline(4,
string.format("Calculated Est. Time: %dmin",
(maxPrintHeight/stageSpeed)*60)) --Create Callback Function for use
with moveto function movetoCallback(controlPointIndex)
showframe(controlPointIndex) end --Prepare Printer
relay(true)--turn light on setlevels(.55, .6)--if available,
printer set fluid pump to maintain about 50% fill --Execute Print
gotostart( )--move stage to starting position
moveto(maxPrintHeight, stageSpeed, controlPoints, movetoCallback)
--Shutdown relay(false) setlevels(0,0) --Lift stage to remove part
moveby(25, 160000)
Example 9
Lua Script Program for Cylinder and Buckle
[0501] This example shows a Lua script program for two fitted parts
that use procedural geometry.
[0502] Cylinder:
TABLE-US-00008 --Constants exposureTime = 1.5-- in seconds
preExposureTime = 1 -- in seconds stageSpeed = 300 --in mm/hour
sliceDepth = .05 numSlices = 700 --Generating Model radius = 11
thickness = 4 smallCircleRad = 1.4 for sliceIndex = 0,numSlices-1
do addlayer(sliceDepth*(sliceIndex+1), sliceIndex)--the depth of a
slice*its index = height of slice largeCircle =
addcircle(0,0,radius, sliceIndex) linewidth(thickness, sliceIndex,
largeCircle) linemask(255, sliceIndex, largeCircle) for
i=0,2*math.pi, 2*math.pi/8 do addcircle(math.cos(i)*radius,
math.sin(i)*radius, smallCircleRad, sliceIndex) end
fillmask(0,sliceIndex) end --calculating parameters maxPrintHeight
= sliceheight(numSlices-1)--find the highest point in the print,
this is the same as the height of the last slice. Slices are 0
indexed, hence the -1. infoline(1, "Current Print Info:")
infoline(2, string.format("Calculated Max Print Height: %dmm",
maxPrintHeight)) infoline(3, string.format("Calculated Est. Time:
%dmin", (maxPrintHeight/stageSpeed)*60 +
(preExposureTime+exposureTime)*numSlices/60)) infoline(4,
string.format("Number of Slices: %d", numSlices)) --Prepare Printer
relay(true)--turn light on showframe(-1) --ensure nothing is
exposed durring setup setlevels(.55, .6)--if available, printer set
fluid pump to maintain about 55% fill --Execute Print gotostart(
)--move stage to starting position for sliceIndex =0,numSlices-1 do
infoline(5, string.format("Current Slice: %d", sliceIndex))
nextHeight = sliceheight(sliceIndex)--calculate the height that the
stage should be at to expose this frame moveto(nextHeight,
stageSpeed)--move to nextHeight sleep(preExposureTime)--wait a
given amount of time for oxygen to diffuse into resin ,
prepExposureTime is predefined in the Constants section
showframe(sliceIndex)--show frame to expose sleep(1.5)--wait while
frame exposes, exposureTime is predefined in the Constants section
showframe(-1)-- show nothing to ensure no exposure while stage is
moving to next position end --Shutdown relay(false) setlevels(0,0)
--Lift stage to remove part moveby(25, 160000)
Buckle:
TABLE-US-00009 [0503] --Constants exposureTime = 1.5-- in seconds
preExposureTime = 0.5 -- in seconds stageSpeed = 300 --in mm/hour
sliceDepth = .05 numSlices = 900 --Generating Model baseRadius = 11
thickness = 3 innerCircleRad = 7.5 for sliceIndex = 0,numSlices-1
do addlayer(sliceDepth*(sliceIndex+1))--the depth of a slice*its
index = height of slice if(sliceIndex < 100) then --base
addcircle(0,0, baseRadius, sliceIndex) fillmask(255, sliceIndex)
else -- inner circle innerCircle = addcircle(0,0, innerCircleRad,
sliceIndex) linewidth(thickness, sliceIndex, innerCircle)
linemask(255, sliceIndex, innerCircle) for i = 0,4*2*math.pi/8,
2*math.pi/8 do x = math.cos(i)*(innerCircleRad+thickness) y =
math.sin(i)*(innerCircleRad+thickness) cutLine = addline(x,y,
-x,-y, sliceIndex) linewidth(3, sliceIndex, cutLine) linemask(0,
sliceIndex, cutLine) end if (sliceIndex > 800) then --tips r0 =
innerCircleRad +2 if(sliceIndex < 850) then r0 = innerCircleRad
+ (sliceIndex-800)*(2/50) end for i = 0,4*2*math.pi/8, 2*math.pi/8
do ang = i + (2*math.pi/8)/2 x = math.cos(ang)*(r0) y =
math.sin(ang)*(r0) nubLine = addline(x,y, -x,-y, sliceIndex)
linewidth(2, sliceIndex, nubLine) linemask(255, sliceIndex,
nubLine) end fillmask(0,sliceIndex, addcircle(0,0,
innerCircleRad-(thickness/2), sliceIndex)) end end
showframe(sliceIndex) sleep(.02) end --calculating parameters
maxPrintHeight = sliceheight(numSlices-1)--find the highest point
in the print, this is the same as the height of the last slice.
Slices are 0 indexed, hence the -1. infoline(1, "Current Print
Info:") infoline(2, string.format("Calculated Max Print Height:
%dmm", maxPrintHeight)) infoline(3, string.format("Calculated Est.
Time: %dmin", (maxPrintHeight/stageSpeed)*60 +
(preExposureTime+exposureTime)*numSlices/60)) infoline(4,
string.format("Number of Slices: %d", numSlices)) --Prepare Printer
relay(true)--turn light on showframe(-1) --ensure nothing is
exposed durring setup setlevels(.55, .6)--if available, printer set
fluid pump to maintain about 55% fill --Execute Print gotostart(
)--move stage to starting position for sliceIndex =0,numSlices-1 do
infoline(5, string.format("Current Slice: %d", sliceIndex))
nextHeight = sliceheight(sliceIndex)--calculate the height that the
stage should be at to expose this frame moveto(nextHeight,
stageSpeed)--move to nextHeight sleep(preExposureTime)--wait a
given amount of time for oxygen to diffuse into resin,
prepExposureTime is predefined in the Constants section
showframe(sliceIndex)--show frame to expose sleep(1.5)--wait while
frame exposes, exposureTime is predefined in the Constants section
showframe(-1)-- show nothing to ensure no exposure while stage is
moving to next position end --Shutdown relay(false) setlevels(0,0)
--Lift stage to remove part moveby(25, 160000)
Example 10
Continuous Fabrication with Intermittent Irradiation and
Advancing
[0504] A process of the present invention is illustrated in FIG.
21, where the vertical axis illustrates the movement of the carrier
away from the build surface. In this embodiment, the vertical
movement or advancing step (which can be achieved by driving either
the carrier or the build surface, preferably the carrier), is
continuous and unidirectional, and the irradiating step is carried
out continuously. Polymerization of the article being fabricated
occurs from a gradient of polymerization or active surface, and
hence creation of "layer by layer" fault lines within the article
is minimized.
[0505] An alternate embodiment of the present invention is
illustrated in FIG. 22. In this embodiment, the advancing step is
carried out in a step-by-step manner, with pauses introduced
between active advancing of the carrier and build surface away from
one another. In addition, the irradiating step is carried out
intermittently, in this case during the pauses in the advancing
step. We find that, as long as the inhibitor of polymerization is
supplied to the dead zone in an amount sufficient to maintain the
dead zone and the adjacent gradient of polymerization or active
surface during the pauses in irradiation and/or advancing, the
gradient of polymerization is maintained, and the formation of
layers within the article of manufacture is minimized or avoided.
Stated differently, the polymerization is continuous, even though
the irradiating and advancing steps are not. Sufficient inhibitor
can be supplied by any of a variety of techniques, including but
not limited to: utilizing a transparent member that is sufficiently
permeable to the inhibitor, enriching the inhibitor (e.g., feeding
the inhibitor from an inhibitor-enriched and/or pressurized
atmosphere), etc. In general, the more rapid the fabrication of the
three-dimensional object (that is, the more rapid the cumulative
rate of advancing), the more inhibitor will be required to maintain
the dead zone and the adjacent gradient of polymerization.
Example 11
Continuous Fabrication with Reciprocation During Advancing to
Enhance Filling of Build Region with Polymerizable Liquid
[0506] A still further embodiment of the present invention is
illustrated in FIG. 23. As in Example 10 above, this embodiment,
the advancing step is carried out in a step-by-step manner, with
pauses introduced between active advancing of the carrier and build
surface away from one another. Also as in Example 10 above, the
irradiating step is carried out intermittently, again during the
pauses in the advancing step. In this example, however, the ability
to maintain the dead zone and gradient of polymerization during the
pauses in advancing and irradiating is taken advantage of by
introducing a vertical reciprocation during the pauses in
irradiation.
[0507] We find that vertical reciprocation (driving the carrier and
build surface away from and then back towards one another),
particularly during pauses in irradiation, serves to enhance the
filling of the build region with the polymerizable liquid,
apparently by pulling polymerizable liquid into the build region.
This is advantageous when larger areas are irradiated or larger
parts are fabricated, and filling the central portion of the build
region may be rate-limiting to an otherwise rapid fabrication.
[0508] Reciprocation in the vertical or Z axis can be carried out
at any suitable speed in both directions (and the speed need not be
the same in both directions), although it is preferred that the
speed when reciprocating away is insufficient to cause the
formation of gas bubbles in the build region.
[0509] While a single cycle of reciprocation is shown during each
pause in irradiation in FIG. 23, it will be appreciated that
multiple cycles (which may be the same as or different from one
another) may be introduced during each pause.
[0510] As in Example 10 above, as long as the inhibitor of
polymerization is supplied to the dead zone in an amount sufficient
to maintain the dead zone and the adjacent gradient of
polymerization during the reciprocation, the gradient of
polymerization is maintained, the formation of layers within the
article of manufacture is minimized or avoided, and the
polymerization/fabrication remains continuous, even though the
irradiating and advancing steps are not.
Example 12
Acceleration During Reciprocation Upstroke and
Deceleration During Reciprocation Downstroke to Enhance Part
Quality
[0511] We observe that there is a limiting speed of upstroke, and
corresponding downstroke, which if exceeded causes a deterioration
of quality of the part or object being fabricated (possibly due to
degradation of soft regions within the gradient of polymerization
caused by lateral shear forces a resin flow). To reduce these shear
forces and/or enhance the quality of the part being fabricated, we
introduce variable rates within the upstroke and downstroke, with
gradual acceleration occurring during the upstroke and gradual
deceleration occurring during the downstroke, as schematically
illustrated in FIG. 24.
Example 13
Fabrication in Multiple Zones
[0512] FIG. 25 schematically illustrates the movement of the
carrier (z) over time (t) in the course of fabricating a
three-dimensional object by methods as described above, through a
first base (or "adhesion") zone, an optional second transition
zone, and a third body zone. The overall process of forming the
three-dimensional object is thus divided into three (or two)
immediately sequential segments or zones. The zones are preferably
carried out in a continuous sequence without pause substantial
delay (e.g., greater than 5 or 10 seconds) between the three zones,
preferably so that the gradient of polymerization is not disrupted
between the zones.
[0513] The first base (or "adhesion") zone includes an initial
light or irradiation exposure at a higher dose (longer duration
and/or greater intensity) than used in the subsequent transition
and/or body zones. This is to obviate the problem of the carrier
not being perfectly aligned with the build surface, and/or the
problem of variation in the positioning of the carrier from the
build surface, at the start of the process, by insuring that the
resin is securely polymerized to the carrier. Note an optional
reciprocation step (for initial distributing or pumping of the
polymerizable liquid in or into the build region) is shown before
the carrier is positioned in its initial, start, position. Note
that a release layer (not shown) such as a soluble release layer
may still be included between the carrier and the initial
polymerized material, if desired. In general, a small or minor
portion of the three-dimensional object is produced during this
base zone (e.g., less than 1, 2 or 5 percent by volume). Similarly,
the duration of this base zone is, in general, a small or minor
portion of the sum of the durations of the base zone, the optional
transition zone, and the body zone (e.g., less than 1, 2 or 5
percent).
[0514] Immediately following the first base zone of the process,
there is optionally (but preferably) a transition zone. In this
embodiment, the duration and/or intensity of the illumination is
less, and the displacement of the oscillatory step less, compared
to that employed in the base zone as described above. The
transition zone may (in the illustrated embodiment) proceed through
from 2 or 5, up to 50 or more oscillatory steps and their
corresponding illuminations. In general, an intermediate portion
(greater than that formed during the base zone, but less than that
formed of during the body zone), of the three dimensional object is
produced during the transition zone (e.g., from 1, 2 or 5 percent
to 10, 20 or 40 percent by volume). Similarly, the duration of this
transition zone is, in general, greater than that of the base zone,
but less than that of the body zone (e.g., a duration of from 1, 2
or 5 percent to 10, 20 or 40 percent that of the sum of the
durations of the base zone, the transition zone, and the body zone
(e.g., less than 1, 2 or 5 percent).
[0515] Immediately following the transition zone of the process
(or, if no transition zone is included, immediately following the
base zone of the process), there is a body zone, during which the
remainder of the three-dimensional object is formed. In the
illustrated embodiment, the body zone is carried out with
illumination at a lower dose than the base zone (and, if present,
preferably at a lower dose than that in the transition zone), and
the reciprocation steps are (optionally but in some embodiments
preferably) carried out at a smaller displacement than that in the
base zone (and, if present, optionally but preferably at a lower
displacement than in the transition zone). In general, a major
portion, typically greater than 60, 80, or 90 percent by volume, of
the three-dimensional object is produced during the transition
zone. Similarly, the duration of this body zone is, in general,
greater than that of the base zone and/or transition zone (e.g., a
duration of at least 60, 80, or 90 percent that of the sum of the
durations of the base zone, the transition zone, and the body
zone).
[0516] Note that, in this example, the multiple zones are
illustrated in connection with an oscillating mode of fabrication,
but the multiple zone fabrication technique described herein may
also be implemented with other modes of fabrication as illustrated
further in the examples below (with the transition zone illustrated
as included, but again being optional).
Example 14
Fabrication with Intermittent (or "Strobe") Illumination
[0517] The purpose of a "strobe" mode of operation is to reduce the
amount of time that the light or radiation source is on or active
(e.g., to not more than 80, 70, 60, 50, 40, or 30 percent of the
total time required to complete the fabrication of the
three-dimensional object), and increase the intensity thereof (as
compared to the intensity required when advancing is carried out at
the same cumulative rate of speed without such reduced time of
active illumination or radiation), so that the overall dosage of
light or radiation otherwise remains substantially the same. This
allows more time for resin to flow into the build region without
trying to cure it at the same time. The strobe mode technique can
be applied to any of the existing general modes of operation
described herein above, including continuous, stepped, and
oscillatory modes, as discussed further below.
[0518] FIG. 26A schematically illustrates one embodiment of
continuous mode. In the conventional continuous mode, an image is
projected and the carrier starts to move upwards. The image is
changed at intervals to represent the cross section of the
three-dimensional object being produced corresponding to the height
of the build platform. The speed of the motion of the build
platform can vary for a number of reasons. As illustrated, often
there is a base zone where the primary goal is to adhere the object
to the build platform, a body zone which has a speed which is
suitable for the whole object being produced, and a transition zone
which is a gradual transition from the speed and/or dosages of the
base zone to the speeds and/or dosages of the body zone. Note that
cure is still carried out so that a gradient of polymerization,
which prevents the formation of layer-by-layer fault lines, in the
polymerizable liquid in the build region, is preferably retained,
and with the carrier (or growing object) remaining in liquid
contact with the polymerizable liquid, as discussed above.
[0519] FIG. 26B schematically illustrates one embodiment of strobe
continuous mode. In strobe continuous the light intensity is
increased but the image is projected in short flashes or
intermittent segments. The increased intensity allows the resin to
cure more quickly so that the amount of flow during cure is
minimal. The time between flashes lets resin flow without being
cured at the same time. This can reduce problems caused by trying
to cure moving resin, such as pitting.
[0520] In addition, the reduced duty cycle on the light source
which is achieved in strobe mode can allow for use of increased
intermittent power. For example: If the intensity for the
conventional continuous mode was 5 mW/cm.sup.2 the intensity could
be doubled to 10 mW/cm.sup.2 and the time that the image is
projected could be reduced to half of the time, or the intensity
could be increased 5-fold to 25 mW/cm.sup.2 and the time could be
reduced to 1/5.sup.th of the previous light on time.
[0521] FIG. 27A schematically illustrates one embodiment of stepped
mode: In the conventional stepped mode an image is projected while
the build platform is stationary (or moving slowly as compared to
more rapid movement in between illumination). When one height
increment is sufficiently exposed the image is turned off and the
build platform is moved upwards by some increment. This motion can
be at one speed or the speed can vary such as by accelerating from
a slow speed when the thickness of uncured resin is thin to faster
as the thickness of the uncured resin is thicker. Once the build
platform is in the new position the image of the next cross section
is projected to sufficiently expose the next height increment.
[0522] FIG. 27B schematically illustrates one embodiment of strobe
stepped mode: In the strobe stepped mode the light intensity is
increased and the amount of time that the image is projected is
reduced. This allows more time for resin flow so the overall speed
of the print can be reduced or the speed of movement can be
reduced. For example: If the intensity for the conventional stepped
mode was 5 mW/cm.sup.2 and the build platform moves in increments
of 100 um in 1 second and the image is projected for 1 second the
intensity could be doubled to 10 mW/cm.sup.2, the time that the
image is projected could be reduced to 0.5 seconds, and the speed
of movement could be reduced to 50 um/second, or the time that the
stage is moving could be reduced to 0.5 seconds. The increased
intensity could be as much as 5 fold or more allowing the time
allotted for image projection to be reduced to 1/5.sup.th or
less.
[0523] FIG. 28A schematically illustrates one embodiment of
oscillatory mode: In the oscillatory mode an image is again
projected while the build platform is stationary (or moving slowly
as compared to more rapid movement in-between illuminations). When
one height increment is cured the image is turned off and the build
platform is moved upwards to pull additional resin into the build
zone and then moved back down to the next height increment above
the last cured height. This motion can be at one speed or the speed
can vary such as by accelerating from a slow speed when the
thickness of uncured resin is thin to faster as the thickness of
the uncured resin is thicker. Once the build platform is in the new
position the image of the next cross section is projected to cure
the next height increment.
[0524] FIG. 28B illustrates one embodiment of strobe oscillatory
mode. In the strobe oscillatory mode the light intensity is
increased and the amount of time that the image is projected is
reduced. This allows more time for resin flow so the overall speed
of the print can be reduced or the speed of movement can be
reduced. For example: If the intensity for the conventional
oscillatory mode was 5 mW/cm.sup.2 and the build platform moves up
by 1 mm and back down to an increment of 100 um above the previous
height in 1 second and the image is projected for 1 second the
intensity could be doubled to 10 mW/cm.sup.2, the time that the
image is projected could be reduced to 0.5 seconds, and the speed
of movement could be reduced to by half or the time that the stage
is moving could be reduced to 0.5 seconds. The increased intensity
could be as much as 5 fold or more allowing the time allotted for
image projection to be reduced to 1/5.sup.th or less. Segment "A"
of FIG. 29 is discussed further below.
[0525] FIG. 29A illustrates a segment of a fabrication method
operated in another embodiment of strobe oscillatory mode. In this
embodiment, the duration of the segment during which the carrier is
static is shortened to close that of the duration of the strobe
illumination, so that the duration of the oscillatory segment
may--if desired--be lengthened without changing the cumulative rate
of advance and the speed of fabrication.
[0526] FIG. 29B illustrates a segment of another embodiment of
strobe oscillatory mode, similar to that of FIG. 29, except that
the carrier is now advancing during the illumination segment
(relatively slowly, as compared to the upstroke of the oscillatory
segment).
Example 15
Varying of Process Parameters During Fabrication
[0527] In the methods of Example 13-14, the operating conditions
during the body zone are shown as constant throughout that zone.
However, various parameters can be altered or modified in the
course of the body zone, as discussed further below.
[0528] A primary reason for altering a parameter during production
would be variations in the cross section geometry of the
three-dimensional object; that is, smaller (easier to fill), and
larger (harder to fill) segments or portions of the same
three-dimensional object. For easier to fill segments (e.g., 1-5 mm
diameter equivalents), the speed of upwards movement could be quick
(up to 50-1000 m/hr) and/or the pump height could be minimal (e.g.,
as little at 100 to 300 um). For larger cross sectional segments
(e.g., 5-500 mm diameter equivalents) the speed of upward movement
can be slower (e.g., 1-50 mm/hr) and/or the pump height can be
larger (e.g., 500 to 5000 um). Particular parameters will, of
course, vary depending on factors such as illumination intensity,
the particular polymerizable liquid (including constituents thereof
such as dye and filler concentrations), the particular build
surface employed, etc.
[0529] In some embodiments, the overall light dosage (determined by
time and intensity) may be reduced as the "bulk" of the cross
section being illuminated increases. Said another way, small points
of light may need higher per unit dosage than larger areas of
light. Without wishing to be bound to any specific theory, this may
relate to the chemical kinematics of the polymerizable liquid. This
effect could cause us to increase the overall light dosage for
smaller cross sectional diameter equivalents.
[0530] In some embodiments, vary the thickness of each height
increment between steps or pumps can be varied. This could be to
increase speed with decreased resolution requirements (that is,
fabricating a portion that requires less precision or permits more
variability, versus a portion of the object that requires greater
precision or requires more precise or narrow tolerances). For
example, one could change from 100 um increments to 200 um or 400
um increments and group all the curing for the increased thickness
into one time period. This time period may be shorter, the same or
longer than the combined time for the equivalent smaller
increments.
[0531] In some embodiments, the light dosage (time and/or
intensity) delivered could be varied in particular cross sections
(vertical regions of the object) or even in different areas within
the same cross section or vertical region. This could be to vary
the stiffness or density of particular geometries. This can, for
example, be achieved by changing the dosage at different height
increments, or changing the grayscale percentage of different zones
of each height increment illumination.
[0532] The foregoing is illustrative of the present invention, and
is not to be construed as limiting thereof. The invention is
defined by the following claims, with equivalents of the claims to
be included therein.
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