Build plate assemblies for continuous liquid interphase printing having lighting panels and related methods, systems and devices

Patent metadata

Field	Value
Publication number	US-2022016838-A1
Application number	US-202117491966-A
Country	US
Kind code	A1
Filing date	Oct 1, 2021
Priority date	Dec 3, 2015
Publication date	Jan 20, 2022
Grant date	—

Abstract

A build plate assembly for a three-dimensional printer includes: a lighting panel having individually addressable pixels configured to selectively emit light and/or transmit light from illumination below the pixels to a top surface top surface of the lighting panel; a rigid, optically transparent, gas-impermeable planar screen or base having an upper surface having an uneven surface topology and a lower surface that is affixed to the top surface of the lighting panel; and a flexible, optically transparent, gas-permeable sheet having upper and lower surfaces, the upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface positioned opposite the base, wherein the build plate is configured to permit gas flow to the build surface.

First claim

That which is claimed is:

1 . A method of forming a three-dimensional object, comprising:
providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween; filling said build region with a polymerizable liquid, continuously or intermittently irradiating said build region with light through said optically transparent member to form a solid polymer from said polymerizable liquid, continuously or intermittently advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer, wherein said optically transparent member comprises a build plate comprising:
a lighting panel having individually addressable pixels configured to selectively emit light and/or transmit light from illumination below the pixels to a top surface top surface of the lighting panel;
a rigid, optically transparent, gas-impermeable planar screen or base having an upper surface and a lower surface that is affixed to the top surface of the lighting panel;
a flexible, optically transparent, gas-permeable sheet having upper and lower surfaces, the upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface positioned opposite the base, wherein the build plate is configured to permit gas flow to the build surface.

2 . The method of claim 1 , wherein said build plate further comprises an adhesive layer between the gas-permeable sheet and the gas-impermeable planar base, and a channel layer defining channels therein.

3 . The method of claim 1 , wherein said filling, irradiating, and/or advancing steps are carried out while also concurrently:
(i) continuously maintaining a dead zone of polymerizable liquid in contact with said build surface, and (ii) continuously maintaining a gradient of polymerization zone between said dead zone and said solid polymer and in contact with each thereof, said gradient of polymerization zone comprising said polymerizable liquid in partially cured form.

4 . The method of claim 1 , wherein the carrier with said polymerized region adhered thereto is unidirectionally advanced away from said build surface on said stationary build plate.

5 . The method of claim 1 , said filling step further comprising vertically reciprocating said carrier with respect to said build surface to enhance or speed the refilling of said build region with said polymerizable liquid.

6 . The method of claim 5 , wherein said vertically reciprocating step comprises an upstroke and a downstroke, with the distance of said upstroke greater than the distance of said downstroke, to thereby concurrently carry out said advancing step in part or in whole.

7 . The method of claim 1 , wherein said vertically reciprocating step comprises an upstroke, and wherein the speed of said upstroke accelerates over a period of time during said upstroke.

8 . The method of claim 7 , wherein said upstroke begins gradually.

9 . The method of claim 1 , wherein said vertically reciprocating step comprises a downstroke, and wherein the speed of said downstroke decelerates over a period of time during said downstroke.

10 . The method of claim 9 , wherein said downstroke ends gradually.

11 . The method of claim 1 , wherein said vertically reciprocating step is carried out over a total time of from 0.01 seconds up to 10 seconds, and/or over an upstroke distance of travel of from 0.02 millimeters to 10 millimeters.

12 . The method of claim 1 , wherein said advancing is carried out intermittently at a rate of one individual advance per minute up to 1000 individual advances per minute, each followed by a pause during which an irradiating step is carried out.

13 . The method of claim 12 , wherein each of said individual advances is carried out over an average distance of travel for each advance of from 10 microns to 200 microns.

14 . The method of claim 1 , wherein said build surface is fixed and stationary in the lateral dimensions.

15 . The method of claim 1 , wherein said build surface is fixed and stationary in the vertical dimension.

16 . The method of claim 1 , wherein said optically transparent member comprises a semipermeable member, and said continuously maintaining a dead zone is carried out by feeding an inhibitor of polymerization through said optically transparent member in an amount sufficient to maintain said dead zone and said gradient of polymerization

17 . The method of claim 16 , wherein said gradient of polymerization zone is maintained for a time of at least 5 seconds.

18 . An apparatus for forming a three-dimensional object from a polymerizable liquid, comprising:
(a) a support; (b) a carrier operatively associated with said support on which carrier said three-dimensional object is formed; (c) an optically transparent member having a build surface, with said build surface and said carrier defining a build region therebetween; (d) a liquid polymer supply operatively associated with said build surface and configured to supply liquid polymer into said build region for solidification or polymerization; (e) a radiation source configured to irradiate said build region through said optically transparent member to form a solid polymer from said polymerizable liquid; (f) optionally at least one drive operatively associated with either said transparent member or said carrier; (g) a controller operatively associated with said carrier, and/or optionally said at least one drive, and said radiation source for advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer, wherein said optically transparent member comprises a build plate having an optically transparent, gas-impermeable planar screen or base of comprising:
a lighting panel having individually addressable pixels configured to selectively emit light and/or transmit light from illumination below the pixels to a top surface top surface of the lighting panel;
a rigid, optically transparent, gas-impermeable planar screen or base having an upper surface and a lower surface that is affixed to the top surface of the lighting panel;
a flexible, optically transparent, gas-permeable sheet having upper and lower surfaces, the upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface positioned opposite the base, wherein the build plate is configured to permit gas flow to the build surface; and
the radiation source comprises the planar screen.

19 . The apparatus of claim 18 , wherein said build plate further comprises an adhesive layer between the gas-permeable sheet and the gas-impermeable planar base, and a channel layer defining channels therein.

20 . The apparatus of claim 18 , said controller further configured to oscillate or reciprocate said carrier with respect to said build surface to enhance or speed the refilling of said build region with said polymerizable liquid.

Assignees

• Carbon Inc

Inventors

• Feller Bob E
• Hermann Ariel M
• Tumbleston John R
• Moore David
• Dachs Ii Gregory W

Classifications

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/255 Primary

  Enclosures for the building material, e.g. powder containers · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29C64/124

  using layers of liquid which are selectively solidified · CPC title

• B33Y30/00

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