Apparatus and method for spin-out to a platform in additive manufacturing

Abstract

A method of separating excess resin from an object includes: additively manufacturing an object on a build platform, the object (115, 415) carrying excess resin therein and / or thereon; removing the object from the build platform; placing the object in a cradle (100, 400) and / or cradle support (155, 455), optionally wherein a surface (110, 140) of the cradle is aligned with a surface of the object (125, 145) and contacts the surface of the object when the cradle and / or cradle support is moved under centripetal force; placing the cradle and / or cradle support in a spin apparatus; centrifugally separating the excess resin from the object; and removing the cradle, cradle support, and / or object from the spin apparatus, at least a portion of the excess resin being separated from the object.

Description

[0001] Cross-references to related applications This application claims priority to U.S. Provisional Application No. 63 / 619,511, filed January 10, 2024, the disclosure of which is hereby incorporated by reference in its entirety. Technical Field

[0002] This invention relates to methods and apparatus for producing objects by additive manufacturing. In particular, this invention relates to methods and apparatus for removing excess resin from objects produced by additive manufacturing. Background Technology

[0003] A collection of additive manufacturing techniques, sometimes called "stereolithography," creates three-dimensional objects by sequentially polymerizing photopolymerizable resins. Such techniques can be "bottom-up," where light is projected through a light-transmitting window onto the resin at the bottom of the grown object, or "top-down," where light is projected onto the resin at the top of the grown object, which then dips downwards into a resin bath. The introduction of a faster stereolithography technique, sometimes called Continuous Liquid Interface Production (CLIP), combined with the introduction of “dual-curing” resins for additive manufacturing, has extended the utility of stereolithography from prototyping to manufacturing (see, for example, U.S. Patents Nos. 9,211,678, 9,205,601, and 9,216,546; J. Tumbleston, D. Shirvanyants, N. Ermoshkin, et al., Continuous liquid interface production of 3D Objects, Science 347, 1349-1352 (2015); and U.S. Patents Nos. 9,676,963, 9,453,142, and 9,598,606).

[0004] Stereolithography resins are generally viscous. As a result, excess unpolymerized resin can adhere to the surfaces of additively manufactured objects after they have been produced. This resin generally needs to be removed for further processing or use, but removing such residual resin can be difficult.

[0005] Residual resin can be removed by centrifugation, as described in PCT Publication No. WO2019 / 209732, U.S. Publication No. 2023 / 0330937, U.S. Publication No. 2021 / 0323234, and U.S. Patent No. 11,491,725, the disclosure of each of which is incorporated herein by reference in its entirety. However, high spin speeds can cause deformation of the object, and low spin speeds may result in insufficient removal of residual resin.

[0006] Accordingly, new methods are still needed to separate residual resin from additively manufactured objects. Summary of the Invention

[0007] According to some embodiments, a method for separating excess resin from an object includes: (a) additively manufacturing the object on a build platform, wherein the object carries excess resin therein and / or thereon; (b) removing the object from the build platform; (c) placing the object in a bracket and / or bracket support, optionally wherein the surface of the bracket is aligned with (e.g., opposite to) the surface of the object and contacts the surface of the object as the bracket and / or bracket support moves under centrifugal force; (d) placing the bracket and / or bracket support in a centrifugal spinning device; (e) centrifuging the excess resin from the object; and (f) removing the bracket, bracket support, and / or object from the centrifugal spinning device, wherein at least a portion of the excess resin has been separated from the object.

[0008] In some embodiments, the surface of the bracket includes a convex profile that aligns with (e.g., is the opposite of) a concave profile of the surface of the object when the object is in the bracket; and / or the bracket includes a concave profile that aligns with (e.g., is the opposite of) a convex profile of the surface of the object when the object is in the bracket.

[0009] In some embodiments, the bracket and / or bracket support includes at least one (e.g., multiple) discharge holes and / or channels for guiding the removal of excess resin.

[0010] In some embodiments, the surface of the bracket is substantially aligned with the surface of the object (e.g., the profile of the bracket surface is the opposite of the profile of the object surface). In some embodiments, when excess resin is centrifuged from the object, the centripetal forces on the surface of the object are distributed substantially evenly.

[0011] In some embodiments, the bracket includes a first bracket portion configured to contact a first surface of an object, and optionally, the bracket includes a second bracket portion configured to contact a second surface of the object. In some embodiments, the surface of the first bracket portion is aligned with (e.g., is opposite to) the first surface of the object, and optionally, the surface of the second bracket portion is aligned with (e.g., is opposite to) the second surface of the object.

[0012] In some embodiments, the bracket and / or bracket support is attached to or forms part of the transfer frame, which is attached to part of the spinning device, and placing the bracket and / or bracket support in the spinning device also includes placing the transfer frame in the spinning device.

[0013] In some embodiments, the transfer frame includes a plurality of brackets and / or bracket supports; and a plurality of objects are additively manufactured, removed from the build platform, and placed in the plurality of brackets and / or bracket supports. In some embodiments, (e) and (f) are performed on the plurality of objects.

[0014] In some embodiments, the method includes heating an excess of resin to a level sufficient to reduce its viscosity during the centrifugation step.

[0015] In some embodiments, the method includes adding a gas or liquid to an excess resin in an amount sufficient to reduce its viscosity during the centrifugal separation step.

[0016] In some embodiments, the centrifugation step is performed in a gas at or below ambient pressure.

[0017] In some embodiments, centrifugation is performed at a speed of about 600, about 800, about 1000, or about 1200 rpm from about 100, about 200, or about 400 revolutions per minute (rpm).

[0018] In some embodiments, the method further includes: (g) collecting the centrifuged excess resin; (h) optionally combining the centrifuged excess resin with additional resin; and then (i) additively manufacturing at least one additional object from the centrifuged excess resin (optionally combined with additional resin).

[0019] In some embodiments, the object is an intermediate object produced from a dual-curing resin, and the method further includes curing the object after step (e) to produce a finished object.

[0020] In some embodiments, the object includes a lattice and / or includes one or more internal channels or cavities, and has at least one surface opening in fluid communication with the channels or cavities, and excess resin in the channels or cavities flows out of the channels or cavities through the at least one surface opening during a centrifugal separation step.

[0021] In some embodiments, the object is a footwear insole, and when the insole is in a bracket, the surface of the bracket is aligned with the surface of the insole (e.g., their opposites).

[0022] In some embodiments, the object is a saddle, and when the saddle is in the bracket, the surface of the bracket is aligned with the surface of the saddle (e.g., their opposites).

[0023] According to some embodiments, an apparatus for separating excess resin from an additively manufactured object includes: (a) a rotor; and (b) a bracket and / or bracket support, optionally attached to or part of a transfer frame, wherein the bracket and / or bracket support and the optional transfer frame are configured to be reversibly attached to the rotor and centrifugally swung by the rotor. In some embodiments, the surface of the bracket is aligned with (e.g., opposite to) the surface of the object and contacts the surface of the object as the bracket moves under centripetal force.

[0024] In some embodiments, the object is a shoe insole or a saddle (e.g., a bicycle saddle).

[0025] In some embodiments, the bracket and / or bracket support is attached to or is a portion of the transfer frame, and the transfer frame is reversibly attached to the rotor.

[0026] In some embodiments, the surface of the bracket includes a convex profile that aligns with (e.g., is the opposite of) a concave profile of the surface of the object when the object is in the bracket; and / or the bracket includes a concave profile that aligns with (e.g., is the opposite of) a convex profile of the surface of the object when the object is in the bracket.

[0027] In some embodiments, the surface of the bracket is substantially aligned with the surface of the object (e.g., the profile of the bracket surface is the opposite of the profile of the object surface). In some embodiments, when excess resin is centrifuged from the object, the centripetal forces on the surface of the object are distributed substantially evenly.

[0028] According to some embodiments, a combination of additive manufacturing equipment and product is provided, comprising the equipment described above and an additively manufactured object within a bracket and / or bracket support.

[0029] According to some embodiments, a transfer frame includes: a base portion configured to be attached to a spinning device; a bracket (e.g., a bracket embodiment of the present invention) and / or a bracket support (e.g., a bracket support embodiment of the present invention) connected to the base portion. In some embodiments, the bracket support includes a basket portion attached to the base portion and optionally includes a bracket. Attached Figure Description

[0030] Figures 1A-1C Some bracket embodiments of the present invention are illustrated schematically.

[0031] Figure 2A and Figure 2B These are different views of computer-aided drawings of the bracket embodiment of the present invention.

[0032] Figure 3This is another view of a computer-aided drawing of an embodiment of the bracket of the present invention.

[0033] Figure 4 The diagram schematically illustrates one possible bracket and transfer frame construction related to the present invention.

[0034] Figure 5A and Figure 5B These are pictures of specific embodiments of the transfer frame and bracket of the present invention. Detailed Implementation

[0035] The invention will now be described more fully below with reference to the accompanying drawings, in which embodiments of the invention are illustrated. However, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be exhaustive and complete and will fully convey the scope of the invention to those skilled in the art.

[0036] Similarity numbers refer to similar elements in various locations. In the drawings, the thickness of certain lines, layers, components, elements, or features may be enlarged for clarity. Dashed lines indicate optional features or operations when used, unless otherwise specified.

[0037] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the terms “comprising” or “including” as used in this specification designate the presence of the stated features, integers, steps, operations, elements, components, and / or sets or combinations thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or sets or combinations thereof.

[0038] As used herein, the term “and / or” includes any and all possible combinations of the associated listed items or one or more of the associated listed items, as well as cases where there are no combinations when interpreted as alternatives (“or”).

[0039] Unless otherwise specified, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. It will also be understood that terms (such as those defined in commonly used dictionaries) shall be interpreted as having the same meaning as they have in the context of the specification and claims, and shall not be interpreted in an idealized or overly formal sense, unless expressly so defined herein. For the sake of brevity and / or clarity, well-known functions or constructions may not be described in detail.

[0040] It will be understood that when an element is referred to as being “on”, “attached” to, “connected” to, “joined” with, or “in contact” with another element, it may be directly on, attached to, connected to, joined to, or in contact with the other element, or there may be intervening elements. Conversely, when an element is referred to, for example, as being “directly on”, “directly attached” to, “directly connected” to, “directly joined” to, or “directly in contact” with another element, no intervening elements are present. It will also be appreciated by those skilled in the art that a reference to a structure or feature configured to be “adjacent” to another feature may have a portion that overlaps or is placed under the adjacent feature.

[0041] For ease of description, spatial relative terms such as “below,” “below,” “down,” “above,” and “up” are used herein to describe the relationship of an element or feature to another element or feature as shown in the figures. It will be understood that spatial relative terms are intended to encompass different orientations of the device in use or operation, other than those depicted in the figures. For example, if the device in the figure is inverted, it is described as an element “below” or “below” other elements or features and then oriented “above” other elements or features. Thus, the exemplary term “below” can encompass both above and below orientations. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptive terms used herein will be interpreted accordingly. Similarly, terms such as “up,” “down,” “vertical,” and “horizontal” are used herein for illustrative purposes only, unless otherwise specifically indicated.

[0042] It will be understood that while the terms "first," "second," etc., may be used herein to describe various elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. Rather, these terms are used only to distinguish one element, component, region, layer, and / or segment from another. Therefore, a first element, component, region, layer, or segment discussed herein may be referred to as a second element, component, region, layer, or segment without departing from the teachings of the invention. The order of operations (or steps) is not limited to the order presented in the claims or figures unless otherwise specifically indicated.

[0043] As used herein, “a plurality of” any element means two or more of such elements and may include 3, 5, 10, 20, 30, 40, 50, 100, 1000, 10000 or more, and includes any range defined therebetween.

[0044] All patents or published patent applications cited are incorporated herein by reference in their entirety. In the event of any conflict of terminology, this application shall prevail.

[0045] According to embodiments of the present invention, a method is provided for separating excess resin from an additively manufactured object. Such a method includes: (a) additively manufacturing an object on a build platform, wherein the object carries excess resin therein and / or thereon; (b) removing the object from the build platform; (c) placing the object in a carrier, optionally wherein the surface of the carrier is aligned with (e.g., opposite to) the surface of the object and contacts the surface of the object as the carrier moves under centrifugal force; (d) placing the carrier in a centrifugal spinneret; (e) centrifuging the excess resin from the object; and (f) removing the carrier and / or the object from the centrifugal spinneret, wherein at least a portion of the excess resin is separated from the object.

[0046] (a) Additive manufacturing of objects on a construction platform Techniques for producing objects (including “green” intermediate objects) from such resins via additive manufacturing are known. Suitable techniques include bottom-up and top-down additive manufacturing, generally referred to as stereolithography. Such methods are known and described, for example, in U.S. Patent Nos. 5,236,637 by Hull, 5,391,072 and 5,529,473 by Lawton, 7,438,846 by John, 7,892,474 by Shkolnik, 8,110,135 by El-Siblani, 2013 / 0292862 by Joyce, and 2013 / 0295212 by Chen et al. The disclosures of these patents and applications are incorporated herein by reference in their entirety.

[0047] In some embodiments, the additive manufacturing step is performed by one of a series of methods sometimes referred to as continuous liquid interface production (CLIP). CLIP is known and described, for example, in: U.S. Patents numbered 9,211,678, 9,205,601, and 9,216,546; J. Tumbleston et al., Continuous liquid interface production of 3D Objects, Science 347, 1349-1352 (2015); and R. Janusziewcz et al., Layerless fabrication with continuous liquid interface production, Proc. Natl. Acad. Sci. USA 113, 11703-11708 (October 18, 2016). Other examples of methods and apparatus for performing specific embodiments of CLIP include, but are not limited to: U.S. Patent Application Publication No. US 2017 / 0129169 (May 11, 2017); U.S. Patent Application Publication No. US 2016 / 0288376 (October 6, 2016); U.S. Patent Application Publication No. US 2015 / 0360419 (December 17, 2015); U.S. Patent Application Publication No. 2015 / 0331402 (November 19, 2015); U.S. Patent Application Publication No. US 2017 / 0129167 (May 11, 2017); and others. U.S. Patent Application Publication No. 2018 / 0243976 (published August 30, 2018); U.S. Patent Application Publication No. 2018 / 0126630 (published May 10, 2018); U.S. Patent Application Publication No. 2018 / 0290374 (published October 11, 2018); PCT Patent Publication No. WO 2015 / 164234 (see also U.S. Patents Nos. 10,259,171 and 10,434,706); and PCT Patent Publication No. WO 2017 / 210298 (see also U.S. Patent Application No. 2019 / 0160733).

[0048] Generally, any additive manufacturing process that results in an excess and / or undesirable amount of resin on and / or within the additively manufactured object can be used.

[0049] In additive manufacturing, an object is typically attached to a build platform (also called a carrier) directly and / or indirectly via a support structure (including polymer supports and / or intervening material layers). Such build platforms are known in the art and are described in the references cited herein. In a typical additive manufacturing process, the build platform is placed directly into a spinning device, and excess resin is removed from the additively manufactured object while the object is attached to the build platform. However, in some cases, additional support may be required during spinning. Accordingly, in this invention, the additively manufactured object is removed from the build platform and placed in, on, and / or adjacent to, a carrier device such that the object contacts at least a portion of the carrier when the carrier is spun in the spinning device.

[0050] While any suitable resin may be used in the methods described herein, dual-curing resins are used in some embodiments. Such resins are known and described, for example, in U.S. Patents numbered 9,676,963, 9,453,142, and 9,598,606. Specific examples of suitable dual-curing resins include, but are not limited to, medical polyurethanes, elastic polyurethanes, rigid polyurethanes, flexible polyurethanes, cyanate esters, epoxy resins, and silicone dual-curing resins from Carbon Inc., all of which are available from Carbon, Inc., 1089 Mills Way, Redwood City, California 94063 USA. Generally, any resin with a viscosity low enough to allow it to be removed from an object under centripetal force can be used.

[0051] A variety of suitable objects can be used in the methods of this invention, including but not limited to saddles (e.g., bicycle saddles), footwear (e.g., insoles), etc. In some embodiments, the additively manufactured object is a footwear insole, and when the insole is in a bracket, the surface of the bracket is aligned with the surface of the insole. In some embodiments, the additively manufactured object is a saddle, and when the saddle is in a bracket, the surface of the bracket is aligned with the surface of the saddle.

[0052] In some embodiments, the object includes one or more features (e.g., surface features) that deform if excess resin on and / or in the object is removed when the object is swirled on the construction surface and / or not supported by a bracket. In some embodiments, the object includes a lattice and / or includes one or more internal channels and / or cavities, and has at least one opening on its surface in fluid communication with the channels and / or cavities. Such openings are configured such that excess resin within the channels and / or cavities can flow through them and out of the channels / cavities during a centrifugal separation step.

[0053] (b) Remove objects from the build platform Additively manufactured objects can be removed from the build platform by any suitable method, including by human, automated (e.g., via scraper) or robotic processes.

[0054] (c) Place the object in the tray Additively manufactured objects removed from the build platform can be placed in carriages (or carriages) by any suitable method, including by human, automated, or robotic processes. As used herein, a "carriage" is a support element that contacts at least one surface of the additively manufactured object when it is spun in a spinning apparatus. In some embodiments of the invention, the surface of the carriage is aligned with (e.g., opposite to) the surface of the object and contacts the surface of the object as the carriage moves under centripetal force. Supporting the object by the carriage during spinning reduces or eliminates deformation of features under centripetal force.

[0055] Figures 1A-1C Examples of certain bracket embodiments are shown. The bracket 100 includes a first bracket portion 105 that contacts a first surface 110 of the object when the additively manufactured object 115 is placed in the bracket 100 and the bracket 100 is spun under centripetal force. When not under centripetal force, the additively manufactured object 115 may or may not contact (or may not fully contact) the first bracket portion 105, but once the bracket 100 is placed in a spinning device (not shown) and spun, the additively manufactured object 115 will contact the first surface 110 of the first bracket portion 105.

[0056] In some embodiments, the first bracket portion 105 may include a recessed portion 120 aligned with (e.g., opposite to) a protrusion 125 on the first surface 110 of the additively manufactured object 115. Alternatively or additionally, the first bracket portion 105 may include a protrusion 130 aligned with (e.g., opposite to) a recessed portion 135 on the first surface 110 of the additively manufactured object 115. For example, under centripetal force, the recessed portion 120 of the first bracket portion 105 will contact the protrusion 125 of the additively manufactured object 115, and / or the protrusion 130 of the first bracket portion 105 will contact the recessed portion 135 of the additively manufactured object 115. Although the surface of the first bracket portion 105 does not need to be perfectly aligned with or form its perfect opposite to the first surface 110 of the additively manufactured object 115, the profile of the first bracket portion 105 may be aligned with the first surface 110 to a degree sufficient to prevent significant deformation of the first surface 110 when the object 115 is spun in a spinning device (not shown).

[0057] In some embodiments, the surface of the first bracket portion 105 is substantially aligned (e.g., substantially opposite) with the surface of the additively manufactured object 115 (here, the first surface 110). Therefore, during spinning, the surface of the first bracket portion 105 can be flush with the surface of the additively manufactured object 115. This allows for a substantially uniform distribution of centripetal forces on the surface (first surface 110) of the additively manufactured object 115 as it is spun in the spinning apparatus. In this configuration, deformation of the object 115 during spinning can be reduced or prevented.

[0058] Reference Figure 1C In some embodiments, the bracket 100 includes a second bracket portion 140 configured to contact a second surface 145 of the additively manufactured object 115. In a particular embodiment, the surface of the first bracket portion 105 is aligned with the first surface 110 of the additively manufactured object 115, and optionally, the surface 150 of the second bracket portion 140 is aligned with the second surface 145 of the additively manufactured object 115. However, in some embodiments, the second bracket portion 140 is absent or not aligned with the second surface 145 (or forms its opposite) (e.g., forms a flat surface) because centripetal forces press the additively manufactured object 115 against the first bracket portion 105. Additional bracket portions (not shown) that contact additional portions of the additively manufactured object 115 may also be present if desired. In some embodiments, the bracket 100 includes only the first bracket portion 105.

[0059] In some embodiments, the bracket 100 may include a bracket support 155 comprising a first support portion 160, a second support portion 165, and / or a third support portion 170 (and any additional support portions not shown), which supports the first bracket portion 105 and / or the additively manufactured object 115. However, in some embodiments, one or more of these support portions may be omitted. For example, the first bracket portion 105 may be directly attached to a transfer frame or a spinning device (not shown).

[0060] Reference Figure 1B In some embodiments of the present invention, the first bracket portion 105 may include one or more (or a plurality of) discharge holes 175. Figure 1C The second bracket portion 140 or any other bracket portion may also include, as per the description of... Figure 1BThe discharge orifice 175 describes one or more discharge orifices. Such discharge orifices / orifices 175 may be configured to allow excess resin spun out of the additively manufactured object 115 to flow through at least a portion of the carrier 100, thus facilitating resin removal and recycling. For example, the discharge orifice 175 may be sized or positioned to receive resin flowing from the object 115 during the spun process. In some embodiments, the discharge orifice 175 may be aligned or partially aligned with an opening or space in the object 115 such that the discharge orifice 175 is in fluid communication with the opening or space in the object 115 (e.g., providing a fluid path) to facilitate resin removal from the object 115 via the discharge orifice 175. Alternatively or additionally, part or all of the carrier support 155 (e.g., the first support portion 160) may include one or more discharge orifices 175. The discharge orifice 175 may be of any shape or configuration, including spherical, polygonal, or irregular segments, and the bracket and / or bracket support may include mesh or lattice-shaped portions. Alternatively or additionally for the discharge orifice, the bracket 100 (including the first bracket portion 105 and / or the second bracket portion 140) may include channels or other surface features (not shown) for guiding excess resin away from the object 115 (and optionally in a direction that facilitates resin recycling). In some embodiments, the channels or other surface features for guiding resin away from the additively manufactured object are designed based on the structure of the additively manufactured object.

[0061] Figure 2A , Figure 2B and Figure 3 An example of a first bracket portion 105 is shown. This bracket 100 is configured to support a bicycle seat portion (not shown), and therefore, the surface of the first bracket portion 105 is the opposite of the bicycle seat portion. The bracket 100 also includes a plurality of drainage holes 175 therein.

[0062] In some embodiments of the invention, the additively manufactured object is placed in a bracket support without a bracket. In some embodiments, only the bracket support is needed to prevent deformation of the object.

[0063] The bracket 100 and / or bracket support 155 may be formed of any suitable material (including but not limited to polymers and / or metals).

[0064] (d) Place the bracket in the spinning device In some embodiments, the bracket and / or bracket support may be placed directly within the spinning device. In some embodiments, the bracket and / or bracket support is attached to a transfer frame or forms a portion of the transfer frame, which is attached to a portion of the spinning device, and placing the bracket and / or bracket support within the spinning device further includes placing the transfer frame within the spinning device. In some embodiments, the transfer frame includes a base portion configured to be attached to or connected to the spinning device; and the bracket and / or bracket support is attached to the base portion. Figure 4 This is a schematic diagram of a possible configuration of a transfer frame 480, which has a bracket 400 (including a first bracket portion 405), a bracket support 455, and an additively manufactured object 415 within the bracket 400. The base portion 485 may be configured to fit within or be attached to a swirl device (not shown) and may include forks, notches, or other features (not shown) that facilitate attachment to the swirl device. While the bracket 400 or bracket support 455 may be directly attached to the base portion 485, in some embodiments, a basket portion 490 may be connected to the base portion 485 and may include the bracket 400 or bracket support 455 and be attached to the base portion 485. The basket portion 490 may be solid (with or without multiple discharge holes) or may be as... Figure 4 The mesh or lattice structure shown is as described. The base portion 485 and the optional basket portion 490 may be formed of any suitable material (including, but not limited to, polymers and / or metals).

[0065] In some embodiments, the transfer frame 480 includes a plurality of brackets 400 (and / or bracket supports) such that a plurality of objects 115 can be swung around in a single transfer frame 480.

[0066] Figure 5A and Figure 5B The image shows a transfer frame 480 having a bracket support 455 and a bracket 400 (which includes a first bracket portion 405). The transfer frame 480 includes a base portion 485 and a basket portion 490.

[0067] (e) Centrifuge to separate excess resin from the object. The spun process is performed once the bracket and / or bracket support are placed in or attached to the spun apparatus, either individually or together with the transfer frame. Generally, the spun apparatus is a centrifugal separator located in a partially or fully enclosed chamber. In some embodiments, excess resin removed from the additively manufactured object is discharged from the enclosed chamber and may be collected either continuously or in batches. In some embodiments, the interior of the centrifugal separator is coated with a non-stick material, such as, for example, the non-stick material described in U.S. Publication No. 2015 / 0209198 A1, the disclosure of which is incorporated herein by reference.

[0068] In some embodiments, excess resin may be heated to a level sufficient to reduce its viscosity during the centrifugal separation step. Additionally, gas and / or liquid may be applied to the excess resin in an amount sufficient to reduce its viscosity during the centrifugal separation step. Such heating and / or application of gas / liquid may be performed before and / or during the centrifugal separation step.

[0069] In some embodiments, the centrifugation step is performed in a gas at or below ambient pressure.

[0070] While a variety of rotational speeds may be used depending on the resin, the additively manufactured object, and other conditions such as temperature and pressure, in some embodiments, centrifugal spinning is performed at speeds ranging from about 100, about 200, or about 400 revolutions per minute (rpm) to about 600, about 800, about 1000, or about 1200 rpm.

[0071] In some embodiments, the method of the present invention further includes: collecting excess resin separated by centrifugation; optionally combining the excess resin separated by centrifugation with additional resin; and then additively manufacturing at least one additional object from the excess resin separated by centrifugation (optionally combined with additional resin).

[0072] In some embodiments, the spinning device is the device described in U.S. Patents Nos. 11,084,216, 11,478,988, and 11,491,725, the disclosures of which are incorporated herein by reference in their entirety.

[0073] In some embodiments of the invention, apparatus is provided for separating excess resin from an additively manufactured object. Such apparatus may include: (a) a rotor; and (b) the bracket, bracket support, and / or transfer frame of the invention, wherein the bracket, bracket support, and / or transfer frame are configured to be reversibly or irreversibly attached to the rotor and centrifugally swung by the rotor. In some embodiments, the bracket is attached to or is part of the transfer frame, and the transfer frame is reversibly attached to the rotor.

[0074] (f) Remove the bracket and / or object from the spinning device. Once at least a portion (and in some cases, all of the excess and / or unwanted resin) of the additively manufactured object has been removed, the object can be removed from the spinning device, bracket, bracket support, and / or transfer frame. In some embodiments, no further processing is required. In other embodiments, one or more additional post-processing steps may be performed, including cleaning and / or further curing.

[0075] In some embodiments of the invention, the additively manufactured object is an intermediate object produced from a dual-curing resin, and the method further includes further curing the object after centrifugation / spinning. For example, in some embodiments, the object is then heated after excess resin is separated from the intermediate object. The heating can be active heating (e.g., baking in an oven (such as an electric furnace, gas furnace, solar furnace, or microwave oven, or a combination thereof)) or passive heating (e.g., at ambient temperature (room temperature)).

[0076] While some embodiments of the invention may include a cleaning step (before and / or after the resin removal method of the invention), in some embodiments, the cleaning step is avoided (particularly before the separation step), and therefore, excess resin removed from the object is not cleaned with cleaning fluid.

[0077] The foregoing is a description of the invention and should not be construed as limiting it. The invention is defined by the following claims, wherein equivalents of the claims are included.

Claims

1. A method for separating excess resin from an object, comprising: (a) Additively manufacturing an object on a building platform, wherein the object carries an excess of resin therein and / or thereon; (b) Remove the object from the building platform; (c) Placing the object in a bracket and / or bracket support, optionally wherein the surface of the bracket is aligned with the surface of the object (e.g., is its opposite) and contacts the surface of the object when the bracket and / or the bracket support moves under centripetal force; (d) Place the bracket and / or the bracket support in the spinning device; (e) Centrifuge the excess resin from the object; and (f) Remove the bracket, the bracket support and / or the object from the spinning device, wherein at least a portion of the excess resin is separated from the object.

2. The method according to claim 1, wherein, The surface of the bracket includes a convex profile that aligns with (e.g., is the opposite of) a concave profile of the surface of the object when the object is in the bracket; and / or the bracket includes a concave profile that aligns with (e.g., is the opposite of) a convex profile of the surface of the object when the object is in the bracket.

3. The method according to claim 1 or 2, wherein, The bracket and / or the bracket support includes at least one (e.g., multiple) discharge holes and / or channels for guiding the removal of excess resin.

4. The method according to any one of claims 1-3, wherein, The surface of the bracket is substantially aligned with the surface of the object (e.g., the profile of the bracket surface is the opposite of the profile of the object surface), optionally wherein the centripetal force on the surface of the object is substantially evenly distributed when the excess resin is centrifuged away from the object.

5. The method according to any one of claims 1-4, wherein, The bracket includes a first bracket portion configured to contact a first surface of the object, and optionally, the bracket includes a second bracket portion configured to contact a second surface of the object; Furthermore, the surface of the first bracket portion is aligned with the first surface of the object (e.g., its opposite), and optionally, the surface of the second bracket portion is aligned with the second surface of the object (e.g., its opposite).

6. The method according to any one of claims 1-5, wherein, The bracket and / or the bracket support is attached to or forms part of the transfer frame, the transfer frame is attached to part of the spinning device, and placing the bracket and / or the bracket support in the spinning device also includes placing the transfer frame in the spinning device.

7. The method according to claim 6, in, The transfer frame includes multiple brackets and / or bracket supports; and In this process, multiple objects are additively manufactured, removed from the building platform, and placed in the multiple brackets and / or the bracket supports; and steps (e) and (f) are performed on the multiple objects.

8. The method according to any one of claims 1-7, further comprising heating the excess resin to a level sufficient to reduce its viscosity during the centrifugal separation step.

9. The method according to any one of claims 1-8, further comprising applying a gas or liquid to the excess resin in an amount sufficient to reduce its viscosity during the centrifugal separation step.

10. The method according to any one of claims 1-9, wherein, The centrifugation step is performed in a gas at or below ambient pressure.

11. The method according to any one of claims 1-10, wherein, The centrifugation is performed at a speed of approximately 600, approximately 800, approximately 1000, or approximately 1200 rpm, from approximately 100, approximately 200, or approximately 400 revolutions per minute (rpm).

12. The method according to any one of claims 1-11, further comprising: (g) Collect excess resin separated by centrifugation; (h) Optionally, the excess resin separated by centrifugation may be combined with additional resin; And then (i) Additively manufacture at least one additional object from the centrifugally separated excess resin, optionally combined with the additional resin.

13. The method according to any one of claims 1-12, wherein, The object is an intermediate object produced from a dual-curing resin, and the method further includes curing the object after step (e) to produce a finished object.

14. The method according to any one of claims 1-13, wherein, The object includes a lattice and / or includes one or more internal channels or cavities, and has at least one surface opening in fluid communication with the channels or cavities, wherein excess resin within the channels or cavities flows out of the channels or cavities through the at least one surface opening during the centrifugation step.

15. The method according to any one of claims 1-14, wherein, The object is a shoe insole, and when the insole is in the bracket, the surface of the bracket is aligned with the surface of the insole (e.g., their opposites).

16. The method according to any one of claims 1-14, wherein, The object is a saddle, and when the saddle is in the bracket, the surface of the bracket is aligned with the surface of the saddle (e.g., their opposites).

17. An apparatus for separating excess resin from an additively manufactured object, comprising: (a) Rotor; as well as (b) A bracket and / or a bracket support, optionally attached to or part of a transfer frame, wherein the bracket and / or the bracket support and optionally the transfer frame are configured to be reversibly attached to the rotor and centrifugally swung by the rotor. Optionally, the surface of the bracket is aligned with the surface of the object (e.g., its opposite) and contacts the surface of the object when the bracket moves under centripetal force.

18. The device according to claim 17, wherein, The object is a shoe insole or a saddle (e.g., a bicycle saddle).

19. The device according to claim 17 or claim 18, wherein, The bracket and / or the bracket support are attached to or are part of the transfer frame, and the transfer frame is reversibly attached to the rotor.

20. The device according to any one of claims 17-19, wherein, The surface of the bracket includes a convex profile that aligns with (e.g., is the opposite of) a concave profile of the surface of the object when the object is in the bracket; and / or the bracket includes a concave profile that aligns with (e.g., is the opposite of) a convex profile of the surface of the object when the object is in the bracket.

21. The device according to any one of claims 17-20, wherein, The surface of the bracket is substantially aligned with the surface of the object (e.g., the profile of the bracket surface is the opposite of the profile of the object surface), optionally wherein the centripetal force on the surface of the object is substantially evenly distributed when the excess resin is centrifuged away from the object.

22. A combination of additive manufacturing equipment and product, comprising the equipment according to any one of claims 17-21 and the additively manufactured object within the bracket and / or the bracket support.

23. A transfer framework, the transfer framework comprising The base portion is configured to be attached to the spinning device; A bracket (e.g., a bracket embodiment of the present invention) and / or a bracket support (e.g., a bracket support embodiment of the present invention) is connected to the base portion; Optionally, the bracket support includes a basket portion attached to the base portion and optionally includes the bracket.

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