Systems and methods for post-processing additively manufactured objects

Patent metadata

Field	Value
Publication number	US-12275191-B2
Application number	US-202218050797-A
Country	US
Kind code	B2
Filing date	Oct 28, 2022
Priority date	Oct 28, 2021
Publication date	Apr 15, 2025
Grant date	Apr 15, 2025

Abstract

Systems, methods, and devices for post-processing additively manufactured objects are disclosed herein. In some embodiments, a method includes receiving a plurality of additively manufactured objects having excess material thereon. The method can include removing the excess material from the plurality of additively manufactured objects by rotating the plurality of additively manufactured objects. The method can also include adjusting an environmental temperature while rotating the plurality of additively manufactured objects according to a dynamic temperature profile that facilitates removal of the excess material from the plurality of additively manufactured objects. The dynamic temperature profile can include (a) a first temperature configured to decrease a viscosity of the excess material, and (b) a second temperature configured to increase a stiffness of the plurality of additively manufactured objects.

First claim

We claim:

1. A method comprising:
receiving a plurality of additively manufactured objects fabricated from a curable material, wherein excess curable material remains on the plurality of additively manufactured objects after fabrication;
removing the excess curable material from the plurality of additively manufactured objects by rotating the plurality of additively manufactured objects; and
adjusting an environmental temperature while rotating the plurality of additively manufactured objects according to a dynamic temperature profile that facilitates removal of the excess curable material from the plurality of additively manufactured objects, wherein the dynamic temperature profile comprises:
setting the environmental temperature to a first temperature during a first time period in which the plurality of additively manufactured objects are rotated at a first rotation speed, the first temperature configured to decrease a viscosity of the excess curable material, and
setting the environmental temperature to a second temperature during a second time period in which the plurality of additively manufactured objects are rotated at a second rotation speed, the second temperature configured to increase a stiffness of the plurality of additively manufactured objects to resist deformation of the plurality of additively manufactured objects due to forces generated by the rotation at the second rotation speed,
wherein the first temperature is greater than the second temperature, and wherein the first rotation speed is less than the second rotation speed.

2. The method of claim 1 , wherein the plurality of additively manufactured objects comprise a partially cured polymeric resin, and the excess curable material comprises uncured polymeric resin.

3. The method of claim 2 , wherein the uncured polymeric resin comprises a viscosity of at least 15 Pa-s at 20° C.

4. The method of claim 1 , wherein the dynamic temperature profile comprises decreasing the environmental temperature from the first temperature to the second temperature over time.

5. The method of claim 1 , wherein the first time period occurs before the second time period.

6. The method of claim 1 , further comprising:
receiving sensor data indicative of a cleaning status of the plurality of additively manufactured objects; and
adjusting the environmental temperature based on the cleaning status.

7. The method of claim 1 , wherein the environmental temperature is adjusted toward the first temperature using one or more of the following: an infrared radiation source, a heat sink, a heating plate, a heated gas, or a heated fluid.

8. The method of claim 7 , wherein the environmental temperature is adjusted toward the first temperature by immersing the plurality of additively manufactured objects in the heated fluid while rotating the plurality of additively manufactured objects.

9. The method of claim 1 , wherein the environmental temperature is adjusted toward the second temperature using one or more of the following: a thermoelectric cooler, a cold plate, a cold gas, or a cold fluid.

10. The method of claim 1 , further comprising curing the plurality of additively manufactured objects by applying radiation to the plurality of additively manufactured objects while rotating the plurality of additively manufactured objects.

11. The method of claim 1 , further comprising applying a material to the plurality of additively manufactured objects while rotating the plurality of additively manufactured objects.

12. The method of claim 11 , wherein the material comprises a wash fluid.

13. The method of claim 11 , wherein the material comprises a coating.

14. The method of claim 1 , further comprising collecting at least some of the excess curable material removed from the plurality of additively manufactured objects.

15. The method of claim 14 , further comprising reusing the collected excess curable material in a subsequent additive manufacturing process.

16. The method of claim 1 , wherein the plurality of additively manufactured objects comprise a plurality of orthodontic appliances.

17. The method of claim 1 , wherein the plurality of additively manufactured objects are rotated on a rotor comprising a plurality of adjustable mounting structures, each adjustable mounting structure supporting a subset of the plurality of additively manufactured objects.

18. The method of claim 17 , further comprising repositioning the plurality of adjustable mounting structures while rotating the plurality of additively manufactured objects to apply variable forces to the plurality of additively manufactured objects.

19. The method of claim 17 , wherein the rotor comprises a central shaft and a plurality of arms, each arm comprising a first end and a second end opposite the first end, wherein the first end of each arm is coupled to the central shaft and a second end of each arm is coupled to a respective one of the plurality of adjustable mounting structures.

20. The method of claim 17 , wherein each subset of additively manufactured objects is fabricated on a build platform, and wherein the build platform is coupled to the respective adjustable mounting structure.

Assignees

• Align Technology Inc

Inventors

• Meenakshisundaram Viswanath
• Kaza Srinivas
• Li Chunhua
• Pickens Lance Robert
• Stromenger Shawn
• Sato Jun
• O'Leary Siobhan
• Webber Peter
• Kelly Brett E
• Chavez Jennifer

Classifications

• B29C71/04

  by wave energy or particle radiation {, e.g. for curing or vulcanising preformed articles (during moulding, e.g. in a mould B29C35/08)} · CPC title

• B29C35/0805

  using electromagnetic radiation · CPC title

• B29C64/30

  Auxiliary operations or equipment · CPC title

• B29C64/357

  Recycling · CPC title

• B29C64/124

  using layers of liquid which are selectively solidified · CPC title