Window thermal profile calibration in additive manufacturing

Patent metadata

Field	Value
Publication number	US-11498274-B2
Application number	US-201917298149-A
Country	US
Kind code	B2
Filing date	Nov 22, 2019
Priority date	Dec 3, 2018
Publication date	Nov 15, 2022
Grant date	Nov 15, 2022

Abstract

Methods, systems, and/or apparatuses for making an object on a bottom-up stereolithography apparatus that includes a light source ( 11 ), a drive assembly ( 14 ), optionally a heater ( 34 ) and/or cooler ( 34 ), and a controller ( 15 ). The light source, optional heater and/or cooler, and/or the drive assembly have at least one adjustable parameter that is adjustable by said controller. An example method comprises (a) installing a removable window cassette ( 12 ) on said apparatus in a configuration through which said light source projects, said window cassette comprising an optically transparent member ( 12 a ) having a build surface on which an object can be produced, and with said optically transparent member having at least one thermal profile associated therewith; and then (b) modifying said at least one adjustable parameter by said controller based on said at least one thermal profile of said optically transparent member; and then (c) producing the object on said build surface from a light-polymerizable liquid by bottom-up stereolithography.

First claim

We claim:

1. A method of making an object on a bottom-up stereolithography apparatus, the apparatus including a light source, a drive assembly, optionally a heater and/or cooler, and a controller operatively associated with said light source, said optional heater and/or cooler, and said drive assembly, with the light source, optional heater and/or cooler, and/or the drive assembly having at least one adjustable parameter that is adjustable by said controller, the method comprising:
(a) installing a removable window cassette on said apparatus in a configuration through which said light source projects, said window cassette comprising an optically transparent member having a build surface on which an object can be produced, and with said optically transparent member having at least one thermal profile associated therewith; and then
(b) modifying said at least one adjustable parameter by said controller based on said at least one thermal profile of said optically transparent member; and then
(c) producing the object on said build surface from a light-polymerizable liquid by bottom-up stereolithography.

2. The method of claim 1 , wherein:
said window cassette includes a unique identifier operatively associated therewith, and
said modifying step is carried out by:
(i) detecting said unique identifier, and then
(ii) transferring correction instructions for said at least one thermal profile and corresponding to said unique identifier from a data storage media to said controller.

3. The method of claim 1 , wherein said window cassette includes a data storage media thereon, said data storage media containing said thermal profile; and
said modifying step is carried out by:
(i) operatively associating said data storage media with said controller and then p 2 (ii) transferring correction instructions for said at least one thermal profile from said data storage media to said controller.

4. The method of claim 1 , wherein said optically transparent member comprises a plurality of distinct layers.

5. The method of claim 1 , wherein said optically transparent member comprises:
(i) a rigid or flexible, semi-permeable or impermeable, support member;
(ii) either a semipermeable member on said support member or an immiscible layer on said support member;
(iii) an inhibitor of polymerization in said semipermeable member when present;
(iv) optionally but preferably, a cushioning member between said impermeable support member and said semipermeable member; and
(v) optionally but preferably, feed space between said impermeable support member and said semipermeable member, said feed space configured for supplying additional inhibitor of polymerization into said semipermeable member.

6. The method of claim 1 , wherein said modifying step enhances at least one performance characteristic of said apparatus.

7. The method of claim 1 , wherein said modifying said at least one adjustable parameter by said controller based on said at least one thermal profile of said optically transparent member comprises modifying a drive speed of said drive assembly and/or adjusting an intensity and/or exposure time of the light source.

8. The method of claim 1 , wherein said heater and/or cooler is present, and said modifying said at least one adjustable parameter by said controller based on said at least one thermal profile of said optically transparent member comprises modifying an activation of said heater and/or cooler.

9. The method of claim 1 , wherein said thermal profile includes at least one thermal profile characteristic.

10. The method of claim 9 , wherein said thermal profile includes an independent thermal profile characteristic.

11. The method of claim 9 , wherein said thermal profile includes a thermal profile characteristic that is based on at least one other thermal profile characteristic.

12. The method of claim 9 , wherein said thermal profile characteristic is at least one of thermal diffusivity of said optically transparent member, thermal capacitance of said optically transparent member, geometry and/or shape of said optically transparent member, and/or a temperature at a location where polymerization occurs on said of said optically transparent member.

13. The method of claim 5 , wherein said optically transparent member comprises said cushioning member between said impermeable support member and said semipermeable member.

14. The method of claim 13 , wherein said optically transparent member comprises said feed space between said impermeable support member and said semipermeable member.

15. A method of making an object on a bottom-up stereolithography apparatus, the apparatus including a light source, a drive assembly, optionally a heater and/or cooler, and a controller operatively associated with said light source, said optional heater and/or cooler, and said drive assembly, with the light source, optional heater and/or cooler, and/or the drive assembly having at least one adjustable parameter that is adjustable by said controller, the method comprising:
(a) installing a removable window cassette on said apparatus in a configuration through which said light source projects, said window cassette comprising an optically transparent member having a build surface on which an object can be produced, and with said optically transparent member having at least one thermal profile associated therewith; and then
(b) receiving, by said controller, correction instructions for said at least one thermal profile from a data source;
(c) modifying said at least one adjustable parameter by said controller based on said correction instructions; and then
(d) producing the object on said build surface from a light-polymerizable liquid by bottom-up stereolithography.

16. The method of claim 15 , wherein said correction instructions are received over a network.

17. The method of claim 16 , wherein said data source is a database, said window cassette includes a unique identifier operatively associated therewith, and said receiving step is carried out by:
(i) detecting said unique identifier, and then
(ii) transferring said identifier via said network to said database; and
(iii) receiving said correction instructions from said database.

18. The method of claim 15 , wherein said data source is a data storage media attached to said window cassette; and
said receiving step is carried out by:
(i) operatively associating said data storage media with said controller; and
(ii) receiving said correction instructions from said data storage media.

Assignees

• Carbon Inc

Inventors

• Mohsenizadeh Daniel N
• Laaker Kyle
• Truong Ronald A

Classifications

• B29C64/124 Primary

  using layers of liquid which are selectively solidified · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y30/00

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

• B33Y50/00

  Data acquisition or data processing for additive manufacturing · CPC title

• B29C64/245 Primary

  Platforms or substrates (support structures intended to be sacrificed after manufacture B29C64/40) · CPC title