Multi-film containers for additive fabrication and related systems and methods

Patent metadata

Field	Value
Publication number	US-11167491-B2
Application number	US-201916427912-A
Country	US
Kind code	B2
Filing date	May 31, 2019
Priority date	Jun 1, 2018
Publication date	Nov 9, 2021
Grant date	Nov 9, 2021

Abstract

Multi-film containers for use in additive fabrication devices are provided. According to some aspects, a container may include multiple films that are at least partially detached from one another. In some embodiments, the multiple films may include films formed from different materials. As one example, an upper film may be formed so as to be relatively impermeable to substances within a source material of an additive fabrication device, whereas a lower film may be formed so as to provide desirable mechanical properties. In some cases, the multiple films may be commonly tensioned while being unattached to one another.

First claim

What is claimed is:

1. An additive fabrication device configured to form layers of solid material on a build platform by curing liquid photopolymer, each layer of material being formed so as to contact a container in addition to the surface of the build platform and/or a previously formed layer of material, the additive fabrication device comprising:
a container having an interior bottom surface, the container comprising:
a first film suspended between sides of the container, the first film forming at least part of the interior bottom surface of the container; and
a second film suspended between the sides of the container and arranged beneath the first film such that the second film forms no part of the interior bottom surface of the container,
wherein the second film is at least partially detached from the first film,
wherein the second film comprises polyethylene terephthalate (PET), and
wherein the first film and the second film have different physical properties; and

an energy source configured to direct actinic radiation through the first film and the second film.

2. The additive fabrication device of claim 1 , wherein the first film and the second film have different elasticities.

3. The additive fabrication device of claim 1 , wherein the first film and the second film have different oxygen permeabilities.

4. The additive fabrication device of claim 1 , wherein the first film comprises poly(4-methyl-1-pentene) (PMP).

5. The additive fabrication device of claim 1 , further comprising a moveable distribution arm housed within the container, and wherein the first film and the second film are attached to the distribution arm.

6. The additive fabrication device of claim 1 , further comprising a moveable distribution arm housed within the container, and wherein the first film and the second film are bonded to each other around the distribution arm and are not attached to the distribution arm such that motion of the distribution arm will provide a uniform tension to the first and second film.

7. The additive fabrication device of claim 5 , further comprising a variable tensioning device configured to move the distribution arm to thereby increase or decrease tension forces within the first film and the second film.

8. The additive fabrication device of claim 7 , wherein the variable tensioning device comprises an actuator configured to move a pin within a non-linear slot, thereby moving the distribution arm.

9. The additive fabrication device of claim 1 , wherein the sides of the container are rigid.

10. A container for use in an additive fabrication device configured to fabricate parts by curing a liquid photopolymer to form layers of cured photopolymer, the container having an interior bottom surface, the container comprising:
a first film suspended between sides of the container, the first film forming at least part of the interior bottom surface of the container; and
a second film suspended between the sides of the container and arranged beneath the first film such that the second film forms no part of the interior bottom surface of the container,
wherein the first film and the second film each include at least one region that is transparent to a first wavelength of actinic radiation,
wherein the second film is at least partially detached from the first film, and
wherein the second film comprises polyethylene terephthalate (PET), and
wherein the first film and the second film have different physical properties.

11. The container of claim 10 , wherein the first film and the second film have different elasticities.

12. The container of claim 10 , wherein the first film and the second film have different oxygen permeabilities.

13. The container of claim 10 , wherein the first film comprises poly(4-methyl-1-pentene) (PMP).

14. The container of claim 10 , further comprising a moveable distribution arm housed within the container, and wherein the first film and the second film are attached to the distribution arm.

15. The container of claim 10 , further comprising a moveable distribution arm housed within the container, and wherein the first film and the second film are bonded to each other around the distribution arm and are not attached to the distribution arm such that motion of the distribution arm will provide a uniform tension to the first and second film.

16. The container of claim 10 , wherein an end of the first film is attached to a first side of the sides of the container and has a fixed position relative to the first side.

Assignees

• Formlabs Inc

Inventors

• Frantzdale Benjamin
• Oikonomopoulos Konstantinos
• Wighton Shane
• Megretski Dmitri
• Damiano Adam
• Loomis James
• Reed Christian

Classifications

• B33Y40/00

  Auxiliary operations or equipment, e.g. for material handling · CPC title

• B29C64/264

  Arrangements for irradiation · CPC title

• B29C64/236

  for motion in a direction within the plane of a layer · CPC title

• B29C64/153

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title

• G01L5/0076

  Force sensors associated with manufacturing machines (G01L5/0066, G01L5/0071 and B23Q17/09 take precedence; for the specific machine or operation involved see relevant class, e.g. B21 - B42) · CPC title