Method of additive manufacturing by fabrication through multiple zones

Patent metadata

Field	Value
Publication number	US-2019061230-A1
Application number	US-201816173565-A
Country	US
Kind code	A1
Filing date	Oct 29, 2018
Priority date	Feb 5, 2015
Publication date	Feb 28, 2019
Grant date	—

Abstract

A method of forming a three-dimensional object is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween, with the carrier positioned adjacent and spaced apart from the build surface at a start position; then (b) forming an adhesion segment of the three-dimensional object (c) optionally but preferably forming a transition segment of the three dimensional object; and then (d) forming a body segment of the three dimensional object. In each case, the segment can be formed by: (i) filling the build region with a polymerizable liquid, (ii) continuously or intermittently irradiating the build region with light through the optically transparent, and (iii) continuously or intermittently advancing the carrier away from the build surface, to thereby form that segment from the polymerizable liquid.

First claim

That which is claimed is:

1 . A method of forming a three-dimensional object, comprising:
(a) providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween, with said carrier positioned adjacent and spaced apart from said build surface at a start position; then (b) forming an adhesion segment of said three-dimensional object by:
(i) filling said build region with a polymerizable liquid,
(ii) irradiating said build region with light through said optically transparent member (e.g., by a single exposure), while
(iii) maintaining said carrier stationary or advancing said carrier away from said build surface at a first cumulative rate of advance, to thereby form from said polymerizable liquid a solid polymer adhesion segment of said object adhered to said carrier; then
(c) optionally but preferably forming a transition segment of said three dimensional object by
(i) filling said build region with a polymerizable liquid,
(ii) continuously or intermittently irradiating said build region with light through said optically transparent member, and
(iii) continuously or intermittently advancing said carrier away from said build surface at a second cumulative rate of advance to thereby form from said polymerizable liquid a transition segment of said object between said adhesion segment and said build surface;
wherein said second cumulative rate of advance is greater than said first cumulative rate of advance; and then
(d) forming a body segment of said three dimensional object by:
(i) filling said build region with a polymerizable liquid,
(ii) continuously or intermittently irradiating said build region with light through said optically transparent, and
(iii) continuously or intermittently advancing said carrier away from said build surface at a third cumulative rate of advance, to thereby form from said polymerizable liquid a body segment of said object between said transition segment and said build surface;
wherein said third cumulative rate of advance is greater than said first and/or said second cumulative rate of advance.

Assignees

• Carbon Inc

Inventors

• Ermoshkin Alexander
• Shirvanyants David
• Tumbleston John R

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/245

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

• B29C64/129 Primary

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

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title