Carbon, Inc.

Carbon3d, Inc.

Liquidia Technologies, Inc.

Alexander Ermoshkin

Edward T Samulski

Joseph M DeSimone

Nikita Ermoshkin

David Shirvanyants

Nordstrom Kirk Phelps

Jason P Rolland

John R Tumbleston

Soren Rademacher

Lloyd Mahlon Robeson

Ariel Herrmann

Joseph Desimone

David F Moore

Bob E Feller

Derek A Schorzman

Robert K Pinschmidt, Jr

Jacob J Sprague

Derek Alan Faust

David Moore

Philip M DeSimone

Zachary Polizzi

Stephen Paul Land

Henry Quarles Bibb, Iii

Ariel M Herrmann

Joseph M Desimone

Described herein are methods, systems and apparatus (including associated control methods, systems and apparatus), for the production of a three-dimensional object by 'bottom up' additive manufacturing, in which a carrier is vertically reciprocated with respect to a build surface, to enhance or speed the refilling of the build region with a solidifiable liquid. In preferred (but not necessarily limiting) embodiments, the three-dimensional object is produced from a liquid interface by continuous liquid interface production (i.e., “CLIP”).

Three-dimensional printing with reciprocal feeding of polymerizable liquid

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

Method and apparatus for three-dimensional fabrication

A build plate for a three-dimensional printer includes a rigid, optically transparent, gas-permeable planar base having an upper surface and an opposing lower surface; a gas permeable adhesive layer on the base upper surface; and a flexible, optically transparent, gas-permeable sheet having upper and lower surfaces, the upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface positioned on the adhesive layer opposite the base.

Build plates for continuous liquid interface printing having permeable base and adhesive for increasing permeability and related methods, systems and devices

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

Continuous liquid interphase printing

A method of forming a three-dimensional object includes: providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; filling the build region with a polymerizable liquid, irradiating the build region with light through the optically transparent member to form a solid polymer from the polymerizable liquid, and advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer. The irradiating step includes projecting focused light at the build region, and the advancing step is carried out at a rate that is dependent on an average light intensity of the focused light.

Three-dimensional printing with supported build plates

Described herein are methods, systems and apparatus (including associated control methods, systems and apparatus), for the production of a three-dimensional object by 'bottom up' additive manufacturing, in which a carrier is vertically reciprocated with respect to a build surface, to enhance or speed the refilling of the build region with a solidifiable liquid. In preferred (but not necessarily limiting) embodiments, the three-dimensional object is produced from a liquid interface by continuous liquid interface production (i.e., 'CLIP').

The present disclosure describes an apparatus for additively manufacturing a three-dimensional object. The apparatus includes a radiation source, a carrier on which the three-dimensional object is made, an applicator assembly configured to apply a polymerizable liquid, and a frame, with the applicator assembly and the radiation source connected to the frame. A first drive assembly interconnects the applicator assembly and the frame and a second drive assembly interconnects the carrier and the frame. The frame defines a build region between the applicator assembly and the carrier. The applicator assembly includes a polymerizable liquid supply chamber, an application roller, and a metering roller. The applicator assembly may optionally include a post-metering roller. An apparatus comprising a first and a second applicator assembly and a smaller scale version of the apparatus are also described.

Apparatuses for additively manufacturing three-dimensional objects

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.

Three-dimensional printing with build plates having surface topologies for increasing permeability and related methods

A method of forming a three-dimensional object is carried out by: providing a carrier and a pool of immiscible liquid, the pool having a liquid build surface, the carrier and the liquid build surface defining a build region therebetween; filling the build region with a polymerizable liquid, wherein the immiscible liquid is immiscible with the polymerizable liquid (in some embodiments wherein the immiscible liquid has a density greater than the polymerizable liquid); irradiating the build region through at least a portion of the pool of immiscible liquid to form a solid polymer from the polymerizable liquid and advancing the carrier away from the liquid build surface to form the three-dimensional object comprised of the solid polymer from the polymerizable liquid. Optionally, but in some embodiments preferably, the method is carried out while also continuously maintaining a gradient of polymerization zone between the liquid build surface and the solid polymer and in contact with each thereof, the gradient of polymerization zone comprising the polymerizable liquid in partially cured form.

Continuous three dimensional fabrication from immiscible liquids

The present disclosure describes an additive manufacturing apparatus. The apparatus includes a chamber () having a planar circumferential top edge portion () defining a chamber orifice (); a stage () movably positioned in the chamber (), the two together configured to receive a viscous resin; a dispenser () facing the stage () and operatively associated therewith, the dispenser () configured to apply a planar coating of viscous resin; a primary drive () operatively associated with the dispenser () and chamber (), the primary drive () configured to move the dispenser () across the chamber orifice (); a light engine () facing the stage () and operatively associated therewith, the light engine () configured to expose a coating of resin on the stage () planar top surface () to patterned light; and a stage drive () operatively associated with the stage () and configured to retract the stage () into the chamber (), following exposure of a coating of resin. Methods of making a three-dimensional object by additive manufacturing are also described.

Additive manufacturing method and apparatus for the production of dental crowns and other objects

The present disclosure describes an apparatus () for additively manufacturing a three-dimensional object. The apparatus () includes a radiation source (), a carrier () on which the three-dimensional object is made, an applicator assembly () configured to apply a polymerizable liquid, and a frame (), with the applicator assembly and the radiation source connected to the frame. A first drive assembly () interconnects the applicator assembly and the frame and a second drive assembly () interconnects the carrier and the frame. The frame defines a build region () between the applicator assembly and the carrier. The applicator assembly includes a polymerizable liquid supply chamber, an application roller (), and a metering roller (). The applicator assembly may optionally include a post-metering roller (). An apparatus comprising a first and a second applicator assembly and a smaller scale version of the apparatus are also described.

Growing community of inventors

Pittsboro, NC, United States of America

Alexander Ermoshkin