Optically enhanced patternable photosensitivity via oxygen excitation

Patent metadata

Field	Value
Publication number	US-10668708-B2
Application number	US-201615277645-A
Country	US
Kind code	B2
Filing date	Sep 27, 2016
Priority date	Sep 27, 2016
Publication date	Jun 2, 2020
Grant date	Jun 2, 2020

Abstract

A method is disclosed for performing a three dimensional (3D) printing process. The method involves generating a primary light beam having a wavelength sufficient to initiate polymerization of a photoresin, and patterning the primary light beam into a patterned primary beam. The patterned primary beam may be directed toward an ultraviolet (UV) or visible light sensitive photoresin to initiate polymerization of select areas of the photoresin. The photoresin may be illuminated with a secondary light beam having a wavelength of about 765 nm to stimulate triplet oxygen into singlet oxygen, to thus control oxygen inhibition in additional areas bordering the select areas, to control polymerization inhibition in the additional areas bordering the select areas.

First claim

What is claimed is:

1. A system for performing a three dimensional (3D) printing process to form a 3D part, the system including:
a beam delivery system for generating a primary light beam having a wavelength sufficient to initiate polymerization of a photoresin;
a digital mask for patterning the primary light beam into a patterned primary beam adapted to initiate polymerization of selected areas of a quantity of light responsive photoresin;
a controller configured to control the digital mask to pattern the primary light beam into the patterned primary beam;
a photoresin bath for holding the quantity of the photoresin, a portion of the quantity of the photoresin in the photoresin bath receiving the patterned primary beam to enable polymerization of select areas of the portion of the quantity of the photoresin; and
a secondary light source for generating a secondary light beam directed at the quantity of the photoresin, the secondary light beam forming a patterned beam having a wavelength of about 765 nm to stimulate triplet oxygen into singlet oxygen only in select additional areas of the photoresin that are not to be polymerized, and which border areas to be polymerized, to thus control oxygen inhibition in the select additional areas bordering the areas to be polymerized, to enhance control of the polymerization in the additional areas bordering the select areas, to assist in forming the 3D part.

2. The system of claim 1 , further comprising a 3D computer aided design system for interfacing with the controller and providing the controller information used to help form the patterned primary beam.

3. The system of claim 1 , further comprising an elevator configured to lower a layer of the photoresin which has been acted on by the patterned primary beam and the secondary light beam and turned to a solid, further into the photoresin bath, to thus expose an additional quantity of the photoresin to be used to form a subsequent layer of the 3D part.

4. The system of claim 3 , wherein the elevator is controlled by the controller to successively lower the elevator, step by step, further into the photoresin bath as each layer of the 3D part is formed.

5. The system of claim 1 , further including a spatial light modulator for controlling the beam delivery system.

6. The system of claim 1 , further including a spatial light modulator for controlling the secondary light source.

7. A system for performing a three dimensional (3D) printing process to form a 3D part, the system including:
a beam delivery system including a spatial light modulator for generating a primary light beam having a wavelength sufficient to initiate polymerization of a photoresin;
a mask for patterning the primary light beam into a patterned primary beam adapted to initiate polymerization of selected areas of a quantity of light responsive photoresin;
a controller configured to control the mask to pattern the primary light beam into the patterned primary beam;
a photoresin bath for holding the quantity of the photoresin, a portion of the quantity of the photoresin in the photoresin bath receiving the patterned primary beam to enable polymerization of select areas of the quantity of the photoresin;
an elevator configured to lower a newly formed layer of a 3D part deeper into the photoresin bath to enable formation of a subsequent layer; and
a secondary light source for generating a secondary light beam directed at the quantity of the photoresin, the secondary light beam forming a patterned secondary light beam having a wavelength including at least one of 765 nm, 1064 nm or 1273 nm, selected to stimulate triplet oxygen into singlet oxygen only in select additional areas of the photoresin that are not to be polymerized, and also which border areas to be polymerized, to thus control oxygen inhibition in the select additional areas bordering the select areas, to enhance control of the polymerization in the additional areas bordering the select areas, to assist in forming the 3D part.

8. The system of claim 7 , wherein the mask comprises a digitally controlled mask.

9. The system of claim 7 , further comprising a 3D computer aided design configured to provide information to the controller for use in generating the patterned primary beam.

10. The system of claim 7 , wherein the wavelength of the secondary beam is selected to be 765 nm.

11. The system of claim 7 , wherein the patterned primary beam comprises a wavelength between 270 nm and 400 nm.

12. The system of claim 7 , wherein the primary light beam comprises a wavelength of at least one of: 380 nm; 365 nm; or 280 nm.

13. The system of claim 7 , wherein the elevator is controlled so as to be successively lowered, step by step, further into the photoresin bath as each layer of the 3D part is formed.

14. The system of claim 13 , wherein the elevator is controlled by the controller.

15. A system for performing a three dimensional (3D) printing process to form a 3D part, the system including:
a beam delivery system including a spatial light modulator for generating a primary light beam having a wavelength sufficient to initiate polymerization of a photoresin;
a mask for patterning the primary light beam into a patterned primary beam adapted to initiate polymerization of selected areas of a quantity of light responsive photoresin;
a controller configured to control the mask to pattern the primary light beam into the patterned primary beam having a wavelength of between 270 nm and 400 nm;
a photoresin bath for holding the quantity of the photoresin, a portion of the quantity of the photoresin in the photoresin bath receiving the patterned primary beam to enable polymerization of select areas of the quantity of the photoresin; and
a secondary light source for generating a secondary light beam directed at the quantity of the photoresin, the secondary light beam forming a patterned secondary light beam having a wavelength of one of 765 nm, 1064 nm or 1263 nm, to stimulate triplet oxygen into singlet oxygen only in select additional areas of the photoresin that are not to be polymerized, and which border areas to be polymerized, to thus control oxygen inhibition in additional areas bordering the select areas, to enhance control of the polymerization in the additional areas bordering the select areas, to assist in forming the 3D part.

16. The system of claim 15 , further comprising an elevator configured to lower a newly formed layer of a 3D part deeper into the photoresin bath to enable formation of a subsequent layer.

17. The system of claim 16 , wherein the elevator is controlled by the controller.

18. The system of claim 15 , wherein the mask comprises a digital mask.

19. The system of claim 15 , wherein the primary light beam comprises a wavelength of at least one of: 380 nm; 365 nm; or 280 nm.

Assignees

• L Livermore Nat Security Llc

Inventors

• HENSLEIGH Ryan
• Duoss Eric

Classifications

• B29C64/20

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B29C64/264 Primary

  Arrangements for irradiation · CPC title

• B33Y50/02 Primary

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title