Carbon, Inc.

David Shirvanyants

Alexander Ermoshkin

Joseph M DeSimone

Edward T Samulski

Nikita Ermoshkin

Nordstrom Kirk Phelps

John R Tumbleston

Soren Rademacher

David F Moore

Clarissa Gutierrez

Derek Alan Faust

Prescott Sutter

Jason P Rolland

Robert K Pinschmidt, Jr

Stephen Paul Land

Henry Quarles Bibb, Iii

Zachary Polizzi

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

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

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.

A method of forming the body portion of a three-dimensional object from a polymerizable liquid by the process of continuous liquid interface printing is described. The body portion has a plurality of contiguous segments, and the process includes advancing a carrier for the object away from a build surface while irradiating a build region between the carrier and build surface in a pattern of advancing and irradiating defined by an operating mode. In the present invention, the operating mode is changed at least once during the formation of the body portion for different contiguous segments of the body portion.

Fabrication of three dimensional objects with multiple operating modes

A method of making a three-dimensional object is carried out by: (a) providing an apparatus comprising a radiation source, a carrier on which the three dimensional object is made, and a movable belt positioned therebetween, the belt having a first surface and an opposite second surface, with the belt comprised of an optically transparent material, and with the belt permeable to a polymerization inhibitor; (b) applying a polymerizable liquid to the first surface of the belt, and contacting the second surface of the belt to the polymerization inhibitor, (c) contacting a portion of the belt first surface having the polymerizable liquid thereon to the carrier or the three dimensional object so that the belt adheres thereto with the polymerizable liquid positioned therebetween; (d) irradiating the polymerizable liquid with actinic radiation through the belt from the radiation source to polymerize the polymerizable liquid positioned therebetween; then (e) optionally separating the belt from the carrier or the three dimensional object; and then (f) repeating steps (b) through (e) until the three dimensional object is completed. Apparatus for carrying out the method is also described.

Method and apparatus for three-dimensional fabrication

A method of forming a three-dimensional object is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween, with the carrier positioned adjacent and spaced apart from the build surface at a start position; then (b) forming an adhesion segment of the three-dimensional object (c) optionally but preferably forming a transition segment of the three dimensional object; and then (d) forming a body segment of the three dimensional object. In each case, the segment can be formed by: (i) filling the build region with a polymerizable liquid, (ii) continuously or intermittently irradiating the build region with light through the optically transparent, and (iii) continuously or intermittently advancing the carrier away from the build surface, to thereby form that segment from the polymerizable liquid.

Method of additive manufacturing by fabrication through multiple zones

A method of forming a three-dimensional object () includes: providing a carrier () and an optically transparent member () having a build surface, the carrier () and the build surface defining a build region therebetween; filling the build region with a polymerizable liquid (); irradiating the build region with light () through the optically transparent member () to form a solid polymer from the polymerizable liquid; and advancing the carrier () away from the build surface to form the three-dimensional object () from the solid polymer. The carrier () includes at least one retain and release () feature that is configured to: i) retain the three-dimensional object () formed from the solid polymer on the carrier () in a first state; and ii) facilitate release of the three-dimensional object () formed from the solid polymer from the carrier () in a second state.

Three-dimensional printing using carriers with release mechanisms

Described herein are methods 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 embodiments, the three-dimensional object is produced from a liquid interface by continuous liquid interface production (i.e., 'CLIP').

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Chapel Hill, NC, United States of America

David Shirvanyants