Devices, systems, processes, and methods relating to 3D printers comprising pressurized resin production of three-dimensional target objects

Abstract

Pressure Delivered 3D Dynamic Printing (PD3DP) comprise 3D printing wherein the polymerizable material (typically a resin) is delivered under positive pressure as each layer of a target object is built / printed. Such positive pressure can be applied intermittently and even reversed to provide a cyclical application of the pressure to assist delivery of the resin, placement of the resin at locations suitable for the shape of the target object, curing of the resin, and releasing of the target object from the projection place between printing of successive layers.

Description

Pressure-delivered 3D dynamic printing (PD3DP) involves 3D printing in which polymerizable material (typically resin) is delivered under positive pressure as layers of a target object are built / printed. This positive pressure can be applied intermittently and even reversed to provide cyclical pressure application, thereby assisting in resin delivery, positioning the resin to fit the shape of the target object, curing the resin, and releasing the target object from its projected position between sequential layer printings. Abstract

Claims

Attorney Docket No.: 3132-002-03US Inventors: Scott Robert Leatham et al. CLAIMS What is claimed is:

1. A Pressure Delivered 3D Dynamic Printing (PD3DP) system having a pressure projection panel disposed between a curing energy source and an inlet port for a 3D-printing material in a build arena, and comprising computer-implemented programming to selectively, cyclically press the pressure projection panel and the 3D-printing material against each other and release from each other in the build arena in coordination with layer-by-layer printing of at least one target object in the build arena.

2. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 1 wherein the build arena comprises a build plate at an opposing side of the build arena opposed to the pressure projection panel, the projection panel and the build plate being controllably, selectively moveable relative to each other in a z-axis in a layer-by-layer fashion according to instructions provided to at least one of the projection panel and the build plate, and wherein the projection panel selectively applies at least one of positive pressure and negative pressure to the resin according to the instructions as the resin is applied to a layer of a target object being printed in the build arena.

3. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 2 wherein the system selectively applies both the positive pressure and the negative pressure.

4. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 3 wherein the computer-implemented programming selectively applies pressure to create an immersion field within at least one of the target object or encircling shell fully encircling the target object, wherein the immersion field contains liquid 3D printing material up to at least about a top of the target object or encircling shell.

5. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 4 wherein the computer-implemented programming selectively applies pressure to create a perimeter bead of liquid 3D printing material at a top of the immersion field, the perimeter bead of in place by surface tension. 37 | P a g eAttorney Docket No.: 3132-002-03US Inventors: Scott Robert Leatham et al.

6. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 5 wherein the computer-implemented programming selectively directs a 3D print pattern from the curing energy source to a top of the 3D printing material.

7. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 2D wherein the computer-implemented programming selectively directs a 3D print pattern from the curing energy source to a top of the 3D printing material in a step-wise fashion to successively build the target object in a layer-by-layer fashion.

8. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 7 wherein the inlet port traverses through the build plate.

9. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 8 wherein the pressure projection panel is transparent.

10. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 9 wherein the pressure projection panel is pliable.

11. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 10 wherein the pressure projection panel is low-friction.

12. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 11 wherein the pressure projection panel is all of transparent, pliable and low-friction.

13. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 12 wherein the 3D printing material is a liquid photosensitive resin that cures into a solid when struck with a suitable activation light from the curing energy source.

14. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 13 wherein the curing energy source is a light delivery source.

15. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 14 wherein the curing energy source is an ultraviolet light delivery source.

16. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 15 wherein the curing energy source is a heat delivery source.

17. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 16 wherein the curing energy source is an iris focused thermal radiation source.

18. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 17 wherein the PD3DP system comprises a thermal management system for rapid cooling and heating by the thermal radiation source. 38 | P a g eAttorney Docket No.: 3132-002-03US Inventors: Scott Robert Leatham et al.

19. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 18 wherein the curing energy source is an electron beam source.

20. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 19 wherein the curing energy source delivers non-visible directional energy.

21. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 20 wherein the computer-implemented programming contains instructions combining pressure applied to the 3D printing material, layer thickness, energy delivered to uncured 3D printing material, timing of build plate release from the pressure projection panel.

22. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 21 wherein the PD3DP system comprises a reversible pump to deliver the 3D-printing material to the build arena.

23. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 22 wherein the computer-implemented programming controls the reversible pump to deliver resin at a controlled micrometer level to the build arena 24. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 23 wherein the computer-implemented programming controls resin delivery by the reversible pump to control pressure within the 3D printing material.

25. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 24wherein the PD3DP system comprises a 3D printing material catchment system to catch and redeploy unused 3D printing material.

26. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 25 wherein computer-implemented programming instructs the pressure projection panel to press against the 3D-printing material after a layer of the 3D-printing material has been introduced into the build arena and before directing curing energy to the new layer of 3D- printing material.

27. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 9 wherein the build plate is moved toward and away from pressure projection panel as a part of delivery of 3D-printing material to the build arena and release of cured 3D-printing material from the pressure projection panel. 39 | P a g eAttorney Docket No.: 3132-002-03US Inventors: Scott Robert Leatham et al.

28. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 27 wherein the positive pressure and the negative pressure are implemented by applying or reversing the direction of flow of 3D-printing material into the build arena.

29. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 28 wherein the system lacks a preexisting printing vat in the build arena.

30. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 29 wherein the system lacks a permanent printing vat in the build arena.

31. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 30 wherein the system further holds in the build arena at least a partial dynamically printed target object printed by the PD3DP system.

32. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 31 wherein the computer-implemented programming comprises instructions to print a target object.

33. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 32 wherein the computer-implemented programming comprises instructions to print a target object and not to print any surrounding structure.

34. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 33 wherein an outer surface of the target object has no unintended bumps, flashing or ridges extending more than 0.1mm from the outer surface.

35. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 34 wherein an outer surface of the target object has no surface artifact extending more than 0.01mm from the outer surface.

36. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 35 wherein the surface artifact is at least one of an unintended bump, flashing or ridge.

37. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 32 wherein the computer-implemented programming comprises instructions to print a target object within an encircling shell fully encircling the target object.

38. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 37 wherein dynamically created, non-vertical guywires hold the target object to the encircling shell.

39. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 38 wherein the dynamically created, non-vertical guywires are about 200 µm or less in diameter. 40 | P a g eAttorney Docket No.: 3132-002-03US Inventors: Scott Robert Leatham et al.

40. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 37 to 39 wherein the encircling shell and the target object are made of a same 3D printing material.

41. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 37 to 39 wherein the encircling shell and the target object each contain different 3D printing materials.

42. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 41 wherein the encircling shell further holds at least one dynamically created auxiliary structure.

43. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 42 wherein the auxiliary structure comprises a plumbing that conducts printing material from a first location within the encircling shell to a second location within the encircling shell.

44. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 43 wherein the PD3DP system is in process of building the target object.

45. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 44 wherein the 3D printer system comprises a top down stereolithography (SLA) or digital light projection (DLP) system capable of 3D printing the target object from a photosensitive liquid resin.

46. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 45 wherein the 3D printer system comprises a bottom up stereolithography (SLA) or digital light projection (DLP) system capable of 3D printing the target object from a photosensitive liquid resin.

47. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 46 wherein the PD3DP system contains a plurality of inlet ports supplying 3D printing material to the encircling shell, each inlet port supplying a different 3D printing material.

48. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 47 wherein the PD3DP system contains a plurality of inlet ports supplying 3D printing material to the encircling shell, each inlet port supplying a same 3D printing material.

49. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 48 wherein the different 3D printing materials are different photosensitive resins. 41 | P a g eAttorney Docket No.: 3132-002-03US Inventors: Scott Robert Leatham et al.

50. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 49 wherein the pressure projection panel is made of glass or transparent polytetrafluoroethylene.

51. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 50 wherein the computer-implemented programming comprises instructions to pump resin between the build platform and the pressure projection panel at a positive pressure of about 70to 140000 Pascals.

52. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 51 wherein the PD3DP system does not have a wiper.

53. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 52 wherein the PD3DP system does have a wiper.

54. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 53 wherein the PD3DP system comprises a projection panel cartridge comprising a wiper.

55. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of claim 54 wherein the projection panel cartridge is removable.

56. The Pressure Delivered 3D Dynamic Printing (PD3DP) system any one of claims 1 to 55 wherein the PD3DP system comprises at least two projection panel cartridges, one having a wiper and without a wiper is removable.

57. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 1 to 56 wherein the computer implemented programming instructs the printing of multiple target objects and multiple encircling shells.

58. A method comprising manufacturing a system according to any of claims 1 to 57.

59. A method comprising using a system according to any one of claims 1 to 57.

60. A target object printed by a Pressure Delivered 3D Dynamic Printing (PD3DP).

61. The target object of claim 60 wherein the target object is located within the Pressure Delivered 3D Dynamic Printing (PD3DP).

62. The target object of claim 61 wherein the target object is not located within an encircling shell within the PD3DP system.

63. The target object of claim 61 wherein the target object is located within an encircling shell within the PD3DP system. 42 | P a g eAttorney Docket No.: 3132-002-03US Inventors: Scott Robert Leatham et al.

64. The target object of any one of claims 61 to 63 wherein the target object has no unintended bumps, flashing or ridges extending more than 0.1mm from an outer surface of the target object.

65. The target object of any one of claims 61 to 64 wherein the target object is an open shell.

66. The target object of claim 65 wherein the open shell is a drink glass.

67. The target object of any one of claims 61 to 66 wherein the target object is a closed shell.

68. The target object of any one of claims 61 to 67 wherein the target object is a filter.

69. A method of layer-by-layer printing a target object via Pressure Delivered 3D Dynamic Printing (PD3DP) comprising: a) providing a PD3DP system; and, b) PD3DP printing a target object within the PD3DP system, wherein the PD3DP printing comprises selectively, intermittently pressing and releasing a pressure projection panel against uncured 3D-printing material in a layer-by-layer fashion to assist in building the target object.

70. The method of claim 69 wherein computer-implemented programming instructs the pressure projection panel to press against the 3D-printing material after a layer of the 3D- printing material has been introduced into the build arena and before directing curing energy to the new layer of 3D-printing material.

71. The method of claim 70 wherein the computer-implemented programming instructs the pressure projection panel to be pulled away from the 3D-printing material after the directing of the curing energy to the new layer of 3D-printing material.

72. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 69 to 71 wherein build plate is moved toward and away from pressure projection panel to implement the pressing against and releasing of the pressure projection panel and the 3D- printing material.

73. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 69 to 72 wherein the PD3DP system does not have a preexisting printing vat within a build arena of the PD3DP system.

74. The Pressure Delivered 3D Dynamic Printing (PD3DP) system of any one of claims 69 to 73 wherein the method further comprises simultaneously PD3DP printing an encircling shell around the target object. 43 | P a g eAttorney Docket No.: 3132-002-03US Inventors: Scott Robert Leatham et al.

75. The method of claim 74 wherein the method further comprises: a) printing guywires connecting the encircling shell and the target object.

76. The method of any one of claims 74 to 75 wherein the method further comprises PD3DP printing at least one auxiliary structure within the interior space of the encircling shell.

77. The method of claim 76 wherein the auxiliary structure comprises a plumbing that conducts printing material from a first location within the encircling shell to a second location within the encircling shell, and the method further comprises transmitting printing material through the plumbing from the first location to the second location within the encircling shell during the printing of the encircling shell and target object.

78. The method of claim 76 wherein the auxiliary structure comprises a manifold.

79. The method of claim 76 wherein the auxiliary structure comprises at least one of baffles, partitions, angled supports and stacked objects.

80. The method of claim 79 wherein the baffles, partitions, angled supports or stacked objects are supported by vertical anchors.

81. The method of claim 77 wherein the plumbing comprises at least one of a pipe, an elbow, a splitter, a joint, a reservoir, an expansion chamber, a restrictor, a flow-through gap, a ballast chamber, a concentric geometry, a diffusion plate, or an on-demand valve.

82. The method of any one of claims 69 to 81 wherein the method further comprises removing the target object from the PD3DP system.

83. The method of any one of claims 74 to 82 wherein the method further comprises removing the target object from the encircling shell.

84. The method of any one of claims 69 to 83 wherein the PD3DP system comprises a reversible pump and the method further comprises reversing the reversible pump prior to directing curing energy to the new layer of 3D-printing material.

85. The method of claim 84 wherein the reversible pump prior is a micro-metering reversible pump. 44 | P a g e

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