Controlling layer separation in stereolithographic fabrication

Patent metadata

Field	Value
Publication number	US-2018134029-A1
Application number	US-201715812825-A
Country	US
Kind code	A1
Filing date	Nov 14, 2017
Priority date	Nov 14, 2016
Publication date	May 17, 2018
Grant date	—

Abstract

Systems, methods, and components are disclosed for controlling layer separation in stereolithographic fabrication of three-dimensional objects. Each layer of the three-dimensional object can be cured and separated in discrete portions to facilitate controlling forces in the layers of a three-dimensional object. For example, controlling curing and separation of layers of a three-dimensional object according to the systems, methods, and components disclosed can facilitate accurately forming the three-dimensional object from cured particle-loaded resins. More specifically, particle loading can decrease the shear strength of the cured resin and, thus, controlling the forces exerted on a given layer of a cured particle-loaded resin can be particularly useful for reducing the likelihood of deformation in a three-dimensional object including the particles. In turn, the accurately formed three-dimensional object including the particles can be densified to form a dimensionally accurate finished part.

First claim

What is claimed is:

1 . A method of additive manufacturing, the method comprising:
providing a layer of a resin on a media source disposed within a working volume defined by a build chamber; curing discrete portions of the layer of the resin on a substrate carried on a surface of a build plate in the working volume; separating the cured discrete portions of the layer from the media source, wherein the separation of at least one of the cured discrete portions is independent of the separation of at least another one of the cured discrete portions; and for a plurality of layers, repeating the steps of providing each respective layer of the resin, curing discrete portions of each respective layer of the resin, and separating the cured discrete portions of each respective layer of the resin to form a three-dimensional object.

2 . The method of claim 1 , wherein the resin includes particles suspended in at least one binder, and curing discrete portions of each respective layer of the resin includes crosslinking or polymerizing the at least one binder.

3 . The method of claim 1 , wherein curing the discrete portions of each respective layer includes, along each discrete portion of the respective layer of the resin, directing light energy into the working volume through a transparent portion of the media source, the light energy sufficient to cure at least one component of the resin.

4 . The method of claim 3 , wherein separating the cured discrete portions of each respective layer of the resin from the media source includes moving one or both of the build plate and the transparent portion of the media source relative to one another.

5 . The method of claim 4 , wherein separating the cured discrete portions of each respective layer of the resin from the media source includes substantially continuously moving of one or both of the build plate and the transparent portion of the media source relative to one another.

6 . The method of claim 5 , wherein curing the discrete portions of each respective layer of the resin includes substantially continuously curing adjacent discrete portions of the respective layer of the resin.

7 . The method of claim 4 , wherein separating the cured discrete portions of each respective layer of the resin from the media source includes moving one or both of the build plate and the transparent portion of the media source in a direction having a component parallel to the layer of the resin.

8 . The method of claim 7 , wherein each discrete segment of each respective layer of the resin spans a dimension of the surface of the build plate.

9 . The method of claim 8 , wherein separating the cured discrete portions of each respective layer of the resin from the media source includes moving the transparent portion of the media source in a direction transverse to the spanned dimension of the surface build plate.

10 . The method of claim 1 , wherein at least one cured discrete portion of each respective layer of the resin is separated from the media source before curing at least another discrete portion of the respective layer.

11 . The method of claim 10 , wherein at least one cured discrete portion of each respective layer of the resin is separated from the media before curing an adjacent discrete portion of the respective layer of the resin.

12 . A stereolithography system comprising:
a build chamber defining a working volume; a build plate disposed within the working volume, the build plate having a surface; an activation light source; and a media source disposed within the working volume, the media source including a transparent portion, the activation light source positioned to direct activation light, through the transparent portion of the media source, to the surface of the build plate, and one or both of the build plate and the transparent portion of the media source movable relative to one another to change a position of the transparent portion of the media source by an increment substantially equal to a width of the transparent portion of the media source in a direction parallel to the surface of the build plate.

13 . The system of claim 12 , wherein the width of the transparent portion of the media source is less than a dimension of the surface of the build plate in a direction of the changed position of the transparent portion of the media source.

14 . The system of claim 12 , wherein the transparent portion of the media source is movable relative to the build plate along the direction parallel to the surface of the build plate.

15 . The system of claim 12 , wherein the build plate is movable relative to the transparent portion of the media source along the direction parallel to the surface of the build plate.

16 . The system of claim 12 , wherein the media source further includes a dispersion section, a collection section, and a reservoir in fluid communication with the dispersion section and the collection section, the dispersion section along a first side of the transparent portion of the media source, the collection section along a second side, different from the first side, of the transparent portion of the media source, and the dispersion section and the collection section.

17 . The system of claim 16 , wherein the media source further includes a blade movable to spread resin from the dispersion section across the transparent portion of the media source.

18 . The system of claim 12 , wherein the transparent portion of the media source spans a dimension of the surface of the build plate.

19 . The system of claim 18 , wherein at least one of the build plate and the transparent portion of the media source is movable in a direction transverse to the spanned dimension of the surface of the build plate.

20 . The system of claim 12 , wherein the activation light source is a light source having a wavelength of about 300 nm to about 350 nm.

Assignees

• Desktop Metal Inc

Inventors

• Myerberg Jonah Samuel
• Gibson Michael Andrew
• Fulop Ricardo
• Tarkanian Michael J
• Chiang Yet-Ming
• Tobia Jay Collin
• Lam Olivia Molnar

Classifications

• B29C64/124 Primary

  using layers of liquid which are selectively solidified · CPC title

• B29C64/165

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B29C64/129

  characterised by the energy source therefor, e.g. by global irradiation combined with a mask · CPC title

• A61K6/818

  comprising zirconium oxide · CPC title

• A61K6/807

  comprising magnesium oxide · CPC title