Carbon, Inc.

University of North Carolina at Chapel Hill

Liquidia Technologies, Inc.

Samsung Electronics Co., Ltd.

Carbon3d, Inc.

California Institute of Technology

Jason P Rolland

Joseph M DeSimone

Kai Chen

Justin Poelma

Lloyd Mahlon Robeson

James Goodrich

Benjamin Maynor

Robert Pinschmidt

Edward T Samulski

Joseph Desimone

Ginger Denison Rothrock

Robert L Henn

R Jude Samulski

Ansley E Dennis

Alexander Ermoshkin

Xinyu Gu

Larken Elizabeth Euliss

Robert K Pinschmidt, Jr

Matthew S Menyo

Ariel Herrmann

Courtney F Converse

Julia D Cushen

Joseph M Desimone

Bob E Feller

John R Tumbleston

Mu San Zhang

Nordstrom Kirk Phelps

William R McCall

Jessica D Drazba

Larken E Euliss

Benjamin W Maynor

David F Moore

Matthew Panzer

Paul Raphael Resnick

Andrew Gordon Wright

Rick Hubertus Nicolas Curvers

Alex Ermoshkin

Ginger M Denison Rothrock

Oshin Nazarian

Robert Praino

Ansley E Exner

Stephen R Quake

David Shirvanyants

Michael Van Dam

David Moore

Philip M DeSimone

Kyle Henn

Larkin E Euliss

Derek A Schorzman

Jason Yarbrough

Jennifer Y Kelly

Zhillian Zhou

Ginger M Denison

Raymond Dominey

Joseph P DeSimone

Kyle Matthew Benjamin Henn

Ariel M Herrmann

Ginger Rothrock-Denison

Stephanie Gratton

Andrew James Murphy

Apparatus for, and associated method of, making a three-dimensional object from a light polymerizable resin by inkjet additive manufacturing are described. The methods and apparatus employ dual precursor resins, including but not limited to dual cure resins having a first component photopolymerizable and a second component polymerizable by a mechanism different from the first component.

Additive manufacturing with dual precursor resins

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

Provided herein is a method of recycling additively manufactured articles or recovered coating material that comprises a crosslinked polymer formed from a single-cure resin comprising a reactive blocked prepolymer, into a regenerated resin useful for additive manufacturing. Recyclable light-polymerizable resins, methods of making recyclable objects from such resins, and methods for sustainable manufacturing are also provided.

Reversible thermosets for additive manufacturing

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

Methods of producing three-dimensional objects with apparatus having feed channels

A method of forming a three-dimensional object is described. The method may use a polymerizable liquid, or resin, useful for the production by additive manufacturing of a three-dimensional object, comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from said first component.

Methods for producing three-dimensional objects

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

Provided herein are methods of recycling additively manufactured objects (e.g., stereolithographically produced objects), the additively manufactured objects comprising linear polyurethane, branched polyurethane, linear polyurea, branched polyurea, a copolymer thereof, or a combination thereof. Compositions comprising the same and methods of use thereof are also provided.

Sustainable additive manufacturing resins and methods of recycling

A polymerizable liquid useful for the production of a three-dimensional object comprised of silicone, or a copolymer thereof, which includes at least one constituent selected from the group consisting of (i) a blocked or reactive blocked siloxane-containing prepolymer, (ii) a blocked or reactive blocked siloxane-containing polyisocyanate, and (iii) a blocked or reactive blocked siloxane-containing polyisocyanate chain extender. Methods of using the same in additive manufacturing processes such as continuous liquid interface production are also described.

Blocked silicone dual cure resins for additive manufacturing

A method of forming a three-dimensional object comprised of a silicone polymer is carried out by: (a) providing a silicone dual cure resin; (b) forming a three-dimensional intermediate from that resin, where the intermediate has the shape of, or a shape to be imparted to, the three-dimensional object, and where the resin is solidified in that intermediate object by irradiating with light; and then (c) further reacting the three-dimensional intermediate to form the three-dimensional object. The silicone dual cure resin includes: (i) a light polymerizable first reactant; (ii) a photoinitiator; (iii) at least one additional reactant(s), and (iv) optionally a catalyst. At least one of the first reactant and the additional reactant(s) contains a siloxane linkage.

Silicone dual cure resins for additive manufacturing

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

Methods for producing three-dimensional objects with apparatus having feed channels

A method of forming a dual cure three-dimensional object by additive manufacturing may be carried out by mixing a first precursor liquid and a second precursor liquid to produce a polymerizable liquid comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component (e.g., a second reactive component) that is different from the first component (e.g., that does not contain a cationic photoinitiator, or is further solidified by a different physical mechanism, or further reacted, polymerized or chain extended by a different chemical reaction). In the foregoing: (i') at least one reactant of the second solidifiable component is contained in the first precursor liquid, and (ii&#x2032;) at least one reactant or catalyst of the second solidifiable component is contained in the second precursor liquid. Once mixed, the three-dimensional object may be formed from the resin by a dual cure additive manufacturing process.

Dual precursor resin systems for additive manufacturing with dual cure resins

Provided herein is a resin product useful for the production of three-dimensional objects by additive manufacturing, and methods using the same. The resin may include a reactive blocked prepolymer comprising a prepolymer blocked with reactive blocking groups; a polyol; a photoinitiator; and at least one organometallic catalyst. A packaged product useful for the production of three-dimensional objects by additive manufacturing, the product comprising a single container having a single chamber and a resin in the chamber with all components mixed together, is also provided.

Dual cure resins for additive manufacturing

Provided is a method of making a cured object having a surface coating bonded thereto, which may include: providing an intermediate object produced in an additive manufacturing process such as stereolithography by light polymerization of a dual cure resin, the resin comprising a mixture of (i) a light polymerizable first component, and (ii) a second component that is different from the first component; applying a first reactive coating composition to a surface portion of the object to form a first coating thereon; optionally, but in some embodiments preferably, applying a second reactive coating composition to the first coating to form a second coating thereon; and heating the object at (and for) a time and to a temperature sufficient to bond the first coating to the surface portion, and bond the second coating when present to the first coating, and form the cured object having a surface coating bonded thereto.

Bonded surface coating methods for additively manufactured products

An epoxy dual cure resin useful for additive manufacturing of three-dimensional objects includes: (i) a photoinitiator; (ii) monomers and/or prepolymers that are polymerizable by exposure to actinic radiation or light; (iii) optionally, a light absorbing pigment or dye; (iv) an epoxy resin; (v) optionally, but in some embodiments preferably, an organic hardener co-polymerizable with the epoxy resin; (vi) optionally but preferably a dual reactive compound having substituted thereon a first reactive group reactive with said monomers and/or prepolymers that are polymerizable by exposure to actinic radiation or light, and a second reactive group reactive with said epoxy resin (e.g., an epoxy acrylate); (vii) optionally a diluent; (viii) optionally a filler; and (ix) optionally, a co-monomer and/or a co-prepolymer. Methods of using the same in additive manufacturing are also described.

Epoxy dual cure resins for additive manufacturing

A method of making a three-dimensional object by additive manufacturing from a blended resin including (i) at least one light polymerizable first component and, (ii) at least one, or a plurality of, second solidifiable components that are different from said first component, the method including: providing a first resin and a second resin, where the resins produce three-dimensional objects having different mechanical properties from one another when all are produced under the same process conditions; mixing the first and second resins with one another to produce the blended resin, the blended resin producing a three-dimensional object having mechanical properties intermediate between that of objects produced by the first and second resins when all are produced under the same process conditions; and dispensing the blended resin to the build region of an additive manufacturing apparatus; and then optionally but preferably producing a three-dimensional object from the blended resin in the apparatus.

Resin dispenser for additive manufacturing

Growing community of inventors

San Carlos, CA, United States of America

Jason P Rolland