Printing platform for a 3D printer, 3D printer, and method

Abstract

1. An apparatus (100) for printing a 3D model, the apparatus (100) comprising: a vat (106) configured to store photocurable ink, the vat (106) including an oxygen permeable membrane (105) at a bottom of the vat; and a printing platform (116) including a base (118) and a mesh on a first side of the base, the mesh having an adhesive strength of the photocurable ink to the mesh greater than an adhesive strength of the photocurable ink to the oxygen permeable membrane, the platform being configured to be displaced from the oxygen permeable membrane to form a 3D model from the photocurable ink.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 309,824, filed February 14, 2022, which is incorporated by reference in its entirety.

[0002] This application relates generally to the field of devices and methods for 3D models, and specifically to 3D printing artificial organs and scaffolds for tissue engineering. [Background technology]

[0003] Generally, it is desirable to produce scaffolds for artificial organs and tissue engineering with a high degree of control and consistency to prevent functional defects. Generally, scaffolds for artificial organs and tissue engineering are formed on a platform, and adhesion of the organ to the platform is a key factor in achieving a successful outcome. One approach to increase adhesion is to chemically modify the platform with chemicals such as salt-based methacrylates. However, this approach is time-consuming, as it requires repeating the chemical process every time a new artificial organ needs to be formed, and inconsistencies in the chemical modifications can result in inconsistencies in the printed product. Summary of the Invention

[0004] One embodiment provides a printing platform for an apparatus for printing 3D models, comprising a base and a mesh on a first side of the base, wherein an adhesive strength of the photocurable ink to the mesh is greater than an adhesive strength of the photocurable ink to an oxygen permeable membrane of the apparatus.

[0005] Another embodiment is an apparatus for printing a 3D model, comprising: a vat configured to store photocurable ink and including an oxygen permeable membrane at a bottom of the vat; and a printing platform including a base and a mesh disposed on a first side of the base, wherein an adhesive strength of the photocurable ink to the mesh is greater than an adhesive strength of the photocurable ink to the oxygen permeable membrane, and wherein the platform is configured to be displaced from the oxygen permeable membrane to form the 3D model from the photocurable ink.

[0006] Yet another embodiment is a method for forming a 3D printed model comprising providing an apparatus including a vat with light curable ink, the vat including an oxygen permeable membrane at a bottom of the vat, and a printing platform including a base and a mesh on a first side of the base, the adhesion strength of the light curable ink to the mesh being greater than the adhesion strength of the light curable ink to the oxygen permeable membrane, and displacing the platform from the oxygen permeable membrane to form a 3D model from the light curable ink.

[0007] Yet another embodiment relates to a platform for an apparatus for printing 3D models. The platform includes a base and a print layer. The base has a first side, the first side of the base having a first surface roughness thereon. The print layer is coupled to the first side of the base and includes a surface. The surface of the print layer is distal from the base and has a second surface roughness greater than the first surface roughness to promote adhesion of the 3D model during printing on the platform.

[0008] And yet another embodiment relates to an apparatus for printing a 3D model. The apparatus comprises a 3D printer assembly and a platform. The 3D printer assembly includes a printer head configured to print a 3D model with a material, a vat or other tank (as used herein, a "vat") configured to store material for use by the printer head, an actuator, and a platform mounting structure coupled to the actuator. The actuator is configured to displace the platform mounting structure along an axis. The platform is coupled to the actuator via the platform mounting structure and configured to receive the material. The platform includes a base and a printing layer. The base has a first side, where the first side of the base has a first surface roughness thereon. The printing layer is coupled to the first side of the base and includes a surface. The surface of the printing layer is distal from the base and has a second surface roughness greater than the first surface roughness to promote adhesion of the 3D model during printing on the platform.

[0009] Yet another embodiment relates to a method of forming a 3D printed model including providing a 3D printer assembly including a printer head configured to print a 3D model with a material, a vat configured to store material for use by the printer head, an actuator, and a platform mounting structure coupled to the actuator. The actuator is configured to displace the platform mounting structure along an axis. The method further includes providing a platform including a base and a print layer. The base has a first side, where the first side of the base has a first surface roughness thereon. The print layer is coupled to the first side of the base and includes a surface. The surface of the print layer is distal from the base and has a second surface roughness greater than the first surface roughness to promote adhesion of the 3D model during printing on the platform. The platform is coupled to the 3D printer assembly, and the 3D printer assembly is coupled to the platform to operate in a manner such that the material is used by the printer head to form the 3D model. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view of an apparatus for printing 3D models. [Diagram 2] FIG. 2 is a perspective view of a platform for an apparatus for printing the 3D model of FIG. [Diagram 3] FIG. 3 is a schematic diagram of a platform according to one embodiment. [Figure 4] FIG. 4 is a schematic diagram of a platform according to one embodiment. [Diagram 5] FIG. 5 is a perspective view of a portion of a printed layer of a platform according to one embodiment. [Figure 6] FIG. 6 is a flow chart of a method of forming a 3D printed model. [Figure 7]FIG. 7 is a flow chart of a method of operating the printer assembly of the apparatus of FIG. 1 according to one embodiment. [Figure 8] FIG. 8 is a perspective view of a 3D model printed on the platform of FIG. 4 according to one embodiment. [Figure 9] FIG. 9 is an illustration of a 3D model on a platform, according to one embodiment. [Figure 10] FIG. 10 is an illustration of a 3D model on a prior art platform. [Figure 11] FIG. 11 is a perspective view of the 3D model. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Reference is made to the accompanying drawings throughout the following detailed description. In the drawings, like numerals typically identify like components unless the context dictates otherwise. The example implementations described in the detailed description, drawings, and claims are not intended to be limiting. Other implementations may be used, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It is readily understood that the aspects of the present disclosure as generally described herein and illustrated in the figures can be arranged, substituted, combined, and designed in a variety of different configurations, all of which are expressly contemplated and made a part of this disclosure.

[0012] (Detailed Description) Unless otherwise specified, "a" or "an" means "one or more."

[0013] All numerical designations, e.g., amounts, times and concentrations, including ranges, are approximations which are varied (+) or (-) by increments of 0.05%, 1%, 2%, 5%, 10% or 20%. It is to be understood, although not always explicitly stated, that all numerical designations are preceded by the term "about."

[0014] (Related Applications) The following patent documents, each of which is incorporated herein by reference in its entirety, may be useful in understanding this application: U.S. Patent Application Publication No. 2022-0370188, U.S. Patent Application Publication No. 2022-0389374, U.S. Patent Application Publication No. 2022-0356433, U.S. Patent Application Publication No. 2022-0371268, U.S. Patent Application Publication No. 2022-0354954, U.S. Patent Application Publication No. 2022-0355541, ... These are PCT Patent Application International Publication No. WO2022 / 236030, International Publication No. WO2022 / 236061, International Publication No. WO2022 / 236119, International Publication No. WO2022 / 236116, International Publication No. WO2022 / 236125, International Publication No. WO2022 / 236103, and International Publication No. WO2022 / 046719.

[0015] The embodiments described herein generally relate to an apparatus and method for 3D printing a 3D model. In a preferred embodiment, the 3D model is an artificial organ or a portion thereof, or a tissue engineering scaffold. The tissue engineering scaffold may be used to form an artificial organ or a portion thereof, or may be used for other applications. In some embodiments, the tissue engineering scaffold may be used to support the growth of one or more cell types and may be intended for implantation into a subject, including a human subject. For ease of reference, an "artificial organ" as used herein may include artificial organs and portions thereof, as well as tissue engineering scaffolds. Thus, for example, a process for producing an artificial organ may also be used to produce a tissue engineering scaffold, unless otherwise indicated. The apparatus and methods described herein use a platform and a 3D printer assembly that includes a print layer to ensure adhesion of the 3D model to the platform during the printing process.

[0016] Artificial organs can be used for transplantation, educational and research purposes, and for investigating the viability of transplanted organs. Due to limited organ donation, ethical concerns, and the high costs of procuring and handling organs, there is a demand for artificial organs for both transplantation and research purposes. 3D printing technology can be used to form artificial organs or tissue scaffolds. Typically, 3D printed artificial organs are formed on a platform that has been chemically modified to increase adhesion, for example by chemically modifying the platform with a chemical such as a salt methacrylate. However, this process can increase the time required to form the artificial organ, as the platform needs to be cleaned and chemically modified again between the formation of each artificial organ. This cleaning and / or chemical treatment can be complicated or costly, depending on the manufacturing requirements and processes. Furthermore, once formed, the artificial organ may need to go through additional processes to clean any chemical residues that may lead to damage to the artificial organ. Finally, current methods used to form artificial organs have a low success rate, in part due to imprecision that occurs during formation. For example, the position of the material used for the artificial organ may change during the formation of the artificial organ due to poor adhesion to the platform. Poor adhesion is a significant issue in applications that require high precision or resolution, such as printing analogues of fine biological structures. Examples of such structures include small blood vessels and subbronchial structures of the lung, bronchioles and alveoli.

[0017] In contrast, the apparatus and methods for forming 3D models as described herein, including forming the 3D model on a platform including a base and a print layer, can provide one or more advantages including: (1) reducing the time required to form multiple 3D models; (2) increasing adhesion between the 3D model and the platform during the formation process; (3) increasing accuracy and resolution compared to other methods; (4) forming 3D models that are substantially defect-free; and (5) forming large, heavy 3D models that cannot be printed by other methods.

[0018] Referring to FIG. 1, an apparatus 100 for printing 3D models according to some embodiments is shown. The apparatus may be similar to the 3D printing apparatus disclosed in PCT Patent Application Publication No. WO2022 / 046719, US Patent Application Publication No. 2022-0055289 and US Patent Application Publication No. 2022-0356433, each of which is incorporated herein by reference in its entirety. In particular, the apparatus may be similar to the apparatus illustrated in FIG. 2 of US Patent Application Publication No. 2022-0356433 or FIG. 5 of International Publication No. WO2022 / 046719.

[0019] The apparatus 100 includes a container, such as a vat 106, for storing a photosensitive liquid, such as a photocurable ink. The container, such as the vat 106, may include an oxygen permeable membrane 105 on its bottom surface. The oxygen permeable membrane 105 may be formed from a fluoropolymer, such as polytetrafluoroethylene or perfluoro. The oxygen permeable membrane 105 has a molecular weight of at least 100×10 -10 cm 3 (STP)cm / (cm 2 s cmHg) or at least 200 × 10 -10 cm 3 (STP)cm / (cm 2 s cmHg) or at least 400 × 10 -10 cm 3 (STP)cm / (cm 2 s cmHg) or at least 600 × 10 -10cm 3 (STP)cm / (cm 2 s cmHg) or at least 800 × 10 -10 cm 3 (STP)cm / (cm 2 s cmHg) or at least 1000 × 10 -10 cm 3 (STP)cm / (cm 2 s cmHg) or at least 1200 × 10 -10 cm 3 (STP)cm / (cm 2 s cmHg) or at least 1400 × 10 -10 cm 3 (STP)cm / (cm 2 s cmHg) or at least 1600 × 10 -10 cm 3 (STP)cm / (cm 2 s cmHg). In some embodiments, the oxygen permeable membrane 105 may be formed from TEFLON AF1600® or TEFLON AF2400® fluoropolymer.

[0020] The apparatus includes a radiation source beneath a container, such as vat 106. The radiation source is configured to irradiate a light-sensitive liquid, such as a photocurable ink, thereby converting the light-sensitive liquid into a solid polymer, such as a photocured and / or crosslinked polymer, to form the 3D model.

[0021] The apparatus 100 includes a platform 116 configured to be immersed in a container, such as a vat 106, and then translationally displaced from an oxygen permeable membrane 105 at a bottom surface of the container, such as a vat 106, while a 3D model is being formed. A radiation source irradiates a portion of a light-sensitive liquid, such as a photocurable ink, thereby resulting in the formation of a layer of a solid polymer, such as a photocured and / or crosslinked polymer, between the platform and the oxygen permeable membrane from the portion of the light-sensitive liquid, such as a photocurable ink.

[0022] The platform 116 includes a base 118. The base 118 has a first side or surface 120. During formation of the 3D model, the first side or surface 120 may be parallel or essentially parallel to the oxygen permeable membrane 105 at the bottom of a container, such as the vat 106.

[0023] A first side or surface 120 of the base 118 is covered by a mesh or mesh material, such as mesh 128 in FIG. 4. As used herein, "mesh" refers to an open textured woven, knitted or knotted material with holes that may or may not be evenly spaced. A mesh material, such as mesh 128, has a high surface area. To form a 3D model, the adhesion strength between a light-sensitive liquid, such as a light-curable ink, and the mesh may be greater than the adhesion strength between an oxygen-permeable membrane and the light-curable ink at the bottom of a container, such as vat 106. Similarly, the adhesion strength between an oxygen-permeable membrane and a light-sensitive liquid, such as a light-curable ink, at the bottom of a container, such as vat 106, may be greater than the adhesion strength with a solid polymer, such as a photocured and / or crosslinked polymer formed from a light-sensitive liquid, such as a light-curable ink, by irradiation from a radiation source below a container, such as vat 106.

[0024] The mesh material, such as mesh 128 on the first side 120 of the base 118, may be a mesh formed from a metal, such as titanium, copper or aluminum, or a polymer, such as cellulose. Non-limiting examples of mesh materials may include hook and loop material, Velcro®, cellulose paper, and metallic titanium mesh.

[0025] In some embodiments, the first surface 120 of the base 118 may have a surface roughness that facilitates attachment of a mesh material, such as mesh 128. In some embodiments, the mesh material, such as mesh 128, may be attached to the base 118 using a layer of adhesive between the first surface 120 of the base 116 and the mesh material. In some embodiments, the mesh material, such as mesh 128, may be attached to the base 118 using a layer of adhesive between the first surface 120 having a surface roughness and the mesh material.

[0026] The base 118 may be formed from a number of materials, for example, the base 118 may be formed from a metal, such as aluminum, titanium, steel, a polymer, such as a plastic or resin, or any other suitable material used to form a base.

[0027] The base 118 further includes a second base side 122. The second base side 122 is opposite the first base side 120. The platform 116 includes a mounting arm 124. The mounting arm 124 is coupled at one end to the second base side 122. The mounting arm 124 extends from the second base side 122 to a distal end. The platform 116 includes a mounting structure 126. The mounting structure 126 is coupled to a distal end of the mounting arm 124. In this manner, the platform 116 is coupled to the mounting structure 126.

[0028] In some embodiments, the first base side 120 may have a first base side surface roughness (e.g., a first surface roughness). In some embodiments, the first base side surface roughness of the first base side 120 may be the surface roughness of a material used to form the base 118. In some embodiments, the first base side surface roughness is defined by a hook and loop material. The hook and loop material is configured to generate adhesion. The base 118 further includes a second base side 122. The second base side 122 is opposite the first base side 120. The platform 116 includes an assembly arm 124. The assembly arm 124 is coupled to the second base side 122 at one end. The assembly arm 124 extends from the second base side 122 to a distal end. The platform 116 includes an assembly structure 126. The assembly structure 126 is coupled to a distal end of the assembly arm 124. In this manner, the platform 116 is coupled to the mounting structure 126 .

[0029] The mounting structure 126 is coupled to the mounting structure rod 114. In this manner, the mounting structure 126 is coupled to the platform mounting structure 110 and the platform 116 is coupled to the 3D printer assembly 102. In operation, as the actuator 108 moves, the mounting structure rod 114 displaces, displacing the mounting structure 126. As the mounting structure 126 displaces, the platform 116 displaces vertically and / or in a direction perpendicular to the surface of the photocurable ink in the vat 106 (or the surface of the oxygen permeable membrane 105 on the bottom surface of the vat 106) and parallel to the platform mounting axis 112. The platform 116 may be displaced to move toward and away from the vat 106.

[0030] In some embodiments, the photosensitive fluid, such as a photocurable ink, may contain one or more monomers and / or polymers, one or more crosslinkers, and monomers to be crosslinked upon irradiation from a radiation source, such as a radiation source below the vat 106. The photosensitive fluid, such as a photocurable ink, may further include a photoinitiator to initiate a crosslinking reaction upon irradiation from the radiation source, a reaction that may result in the formation of a solid polymer, such as a photocured and / or crosslinked polymer, from the photosensitive fluid. The photosensitive fluid, such as a photocurable ink, may also include a dye that absorbs radiation from the radiation source. The photosensitive fluid, such as a photocurable ink, may also include 10% to 90% water.

[0031] In some embodiments, the photosensitive fluid, such as a photocurable ink, may be a photosensitive fluid disclosed in one or more of U.S. Patent Application Publication No. 2022-0370188, U.S. Patent Application Publication No. 2022-0356433, U.S. Patent Application Publication No. 2022-355541, U.S. Patent Application Publication No. 2022-389374, U.S. Patent Application Publication No. 2022-0371268, U.S. Patent Application Publication No. 2022-0354954, each of which is incorporated by reference in its entirety. In some embodiments, the photosensitive fluid, such as a photocurable ink, may be a bio-ink, which may be biocompatible. In some embodiments, a photosensitive fluid such as a photocurable ink can be used to print a 3D model, which may be a bioscaffold such as those disclosed in one or more of U.S. Patent Application Publication No. 2022-0370188, U.S. Patent Application Publication No. 2022-0356433, U.S. Patent Application Publication No. 2022-355541, U.S. Patent Application Publication No. 2022-389374, U.S. Patent Application Publication No. 2022-0371268, U.S. Patent Application Publication No. 2022-0354954. In some embodiments, the 3D model may be an artificial organ (e.g., a lung, a liver, a kidney, a heart, a portion of a heart, etc., or a scaffold for tissue engineering).

[0032] The apparatus 100 can be used to print a 3D model. In some embodiments, the apparatus is used to print a 3D model that is an artificial organ (e.g., a lung, a liver, a kidney, a heart, a portion of a heart, etc., or a scaffold for tissue engineering). The apparatus 100 includes a 3D printer assembly 102 (e.g., a digital light projection assembly, a stereolithography assembly, a selective laser melting assembly, etc.). The 3D printer assembly 102 includes a printer head 104. The printer head 104 is configured to utilize a material (e.g., a hydrogel, a resin, etc.) to form a 3D model. In some embodiments, the printer head 104 can be a plurality of UV lights that react with the material and change the material from a liquid state to a solid state. In some embodiments, the printer head 104 can be an extruder configured to extrude the material to form the 3D model. The 3D printer assembly 102 includes a vat 106. The vat 106 is coupled to the printer head 104. In some embodiments, the vat 106 can be fluidly coupled to the printer head 104. Vat 106 is configured to store material for use by print head 104. Vat 106 may be coupled (e.g., attached, affixed, adhesively attached, affixed) to a cartridge dispenser. The cartridge dispenser is configured to refill vat 106 once the material in vat 106 has been used. In some embodiments, vat 106 can be refilled manually.

[0033] The printer assembly 102 includes an actuator 108 (e.g., a linear actuator, a linear screw actuator, a pneumatic actuator, etc.). The printer assembly 102 includes a platform mounting structure 110. The platform mounting structure 110 is operatively coupled to the actuator 108. During operation, the actuator 108 displaces the platform mounting structure 110 along a platform mounting axis 112. The platform mounting structure 110 includes at least one mounting structure rod 114. The mounting structure rod 114 may reside along the platform mounting axis 112. The mounting structure rod 114 is coupled to the actuator 108 such that the mounting structure rod 114 displaces along the platform mounting axis 112 as the actuator 108 operates.

[0034] The device 100 includes a platform 116. Referring to FIGS. 1 and 2, the platform 116 according to one embodiment is shown. The platform 116 includes a base 118. The base 118 may be formed of a metal (e.g., aluminum, titanium, steel, etc.), plastic, resin, or any other suitable material used to form a base. The base 118 includes a first base side 120. In some embodiments, the first base side 120 may have a first base side surface roughness (e.g., a first surface roughness, etc.). In some embodiments, the first base side surface roughness of the first base side 120 may be the surface roughness of the material used to form the base 118. In some embodiments, the first base side surface roughness is defined by a hook and loop material. The hook and loop material is configured to generate a fastening property. The base 118 further includes a second base side 122. The second base side 122 is opposite the first base side 120. The platform 116 includes a mounting arm 124. The mounting arm 124 is coupled at one end to the second base side 122. The mounting arm 124 extends from the second base side 122 to a distal end. The platform 116 includes a mounting structure 126. The mounting structure 126 is coupled to the distal end of the mounting arm 124. In this manner, the platform 116 is coupled to the mounting structure 126.

[0035] The mounting structure 126 couples to the mounting structure rod 114. In this manner, the mounting structure 126 is coupled to the platform mounting structure 110 and the platform 116 is coupled to the 3D printer assembly 102. In operation, as the actuator 108 moves, the mounting structure rod 114 displaces, displacing the mounting structure 126. As the mounting structure 126 displaces, the platform 116 displaces in a direction perpendicular to the bat 106 and parallel to the platform mounting axis 112. The platform 116 may displace and move toward and away from the bat 106.

[0036] 3 and 4, a platform 116 according to one embodiment is shown. The platform 116 includes a print layer 128. The print layer 128 is configured to receive a 3D model during a printing process. The print layer 128 is coupled to the first base side 120 at one end. The print layer 128 includes a print layer surface 130. The print layer surface 130 is distal from the first base side 120 of the base 118. The print layer 128 may be formed from a hook and loop material, Velcro, cellulose paper, metal titanium mesh, or any similar suitable material that adheres when pressed together. The print layer surface 130 has a print layer surface roughness (e.g., a second surface roughness, etc.) that is determined by the material used to form the print layer 128. The print layer surface roughness of the print layer surface 130 promotes adhesion of the 3D model to the print layer 128 of the platform 116. In some embodiments, the print layer surface roughness is measured using a profilometer (such as a Taylor Hobson surface roughness tester). The profilometer measures the distance between the microscopic peaks and bottoms of the print layer surface 130 over the entire area of ​​the print layer surface 130. The surface roughness is approximately 0.5 micrometers (μm) to 20 μm (including, for example, 0.475 μm, 0.5 μm, 1.0 μm, 5 μm, 10 μm, 15 μm, 20 μm, 21 μm, etc.). In some embodiments, the print layer surface roughness is greater than the first base side surface roughness. The print layer surface roughness may be in the range of 50% to 300% greater than the first base side surface roughness (e.g., including 47.5%, 50%, 75%, 100%, 125%, 150%, 175%, 200%, 225%, 250%, 275%, 300%, 315%, etc.).

[0037] Referring to FIG. 5, a perspective view of a portion of the printed layer 128 is shown. In some embodiments, the printed layer 128 may be formed on the first base side 120. The printed layer 128 may be formed in a complex mesh pattern (e.g., a woven pattern, etc.). The printed layer 128 includes a plurality of first printed strips 132. Each of the plurality of first printed strips 132 is placed parallel to each other in a direction parallel to the printed layer transverse axis 134 of the first base side 120. The printed layer 128 includes a plurality of second printed strips 136. Each of the plurality of second printed strips 136 is placed on the plurality of parallel first printed strips 132 in a direction parallel to the printed layer longitudinal axis 138 and perpendicular to the plurality of first printed strips 132. In some embodiments, the printed layer 128 is formed by placing multiple layers of the plurality of first printed strips 132 on the plurality of second printed strips 136. Specifically, the plurality of first printed strips 132 are laid down on a preceding layer of the plurality of second printed strips 136 in a direction parallel to the print layer transverse axis 134 and perpendicular to the plurality of second printed strips 136. The plurality of second printed strips 136 are laid down on a preceding layer of the first printed strips 132 in a direction parallel to the print layer longitudinal axis 138 and perpendicular to the plurality of first printed strips 132. As each layer of the plurality of first printed strips 132 and the plurality of second printed strips 136 is laid down, the plurality of first printed strips 132 adhere to the plurality of second printed strips 136.

[0038] In some embodiments, the printed layer 128 is formed and bonded to the first base side 120. The printed layer 128 may include a coating material (e.g., powdered titanium, etching material, sandblasted titanium, etc.). Specifically, once the printed layer 128 is formed, a coating material may be applied to the printed layer 128 (e.g., spot coating, sprinkling, dusting, sandblasting, etching, etc.) to help promote adhesion. For example, powdered titanium may be spot coated onto the printed layer 128. In some embodiments, the printed layer 128 may be sterilized. For example, the printed layer 128 may be applied with a sterilant (e.g., saline) that sterilizes the printed layer surface 130. In some embodiments, once the printed layer 128 is bonded to the first base side 120, there is no need to replace the printed layer 128 between the formation of 3D models.

[0039] Returning now to FIG. 3 , in some embodiments, the platform 116 includes an adhesive layer 140 (e.g., epoxy glue, glue, hook and loop, Velcro, barbed shapes, rivet-like objects, etc.). The adhesive layer 140 is interposed between the first base side 120 and the printed layer 128. The adhesive layer 140 is configured to bond the printed layer 128 to the base 118. In some embodiments, the adhesive layer 140 bonds the printed layer 128 to cover the entire first base side 120 and further prevents the printed layer 128 from detaching from the first base side. In operation, the adhesive layer 140 is applied to the first base side 120. A plurality of first printed strips 132 are placed on the adhesive layer 140 to initiate the formation of the printed layer 128. The printed layer 128 is formed as described above. The adhesive layer 140 is allowed to dry to facilitate bonding of the printed layer 128 to the first base side 120 of the platform 116. In some embodiments, the adhesive layer 140 is integrated into the first base side 120 and is formed from a hook and loop material that adheres the printed layer 128. For example, the printed layer 128 may be formed from a hook and loop material and the first base side 120 may be formed from a hook and loop material. When the printed layer 128 is pressed onto the first base side 120, the hook and loop of the printed layer 128 mates with the hook and loop of the first base side 120 to bond the printed layer 128 to the base 118.

[0040] Referring to FIG. 6, a flow chart of a method 200 for forming a 3D printed model according to one embodiment is provided. At 202, a 3D printer assembly (such as 3D printer assembly 102) is provided. The 3D printer assembly includes a printer head configured to use material to print a 3D model, a vat configured to store material for use by the printer head, an actuator, and a platform mounting structure operably coupled to the actuator. The actuator is configured to displace the platform mounting structure along an axis. At 204, a platform (such as platform 116) is provided. At 206, the platform is coupled to the 3D printer assembly. In some embodiments, the platform includes an attachment arm (such as attachment arm 124) that couples to an attachment structure (such as attachment structure 126) of a platform mounting structure (such as platform mounting structure 110) of the 3D printer assembly.

[0041] At 208, the 3D printer assembly is operated to print the 3D model. Referring to FIG. 7, a flow chart of a method of operating the 3D printer assembly 208 according to one embodiment is shown. At 302, a vat (such as vat 106) is filled with material. In some embodiments, the vat is filled with liquid hydrogel material. In some embodiments, the vat is filled with liquid resin material. The vat may be filled manually or with a cartridge dispenser. In some embodiments, the cartridge dispenser dispenses the material into the vat. At 304, an actuator is operated to lower a platform into the vat. The actuator is operated to actuate, which displaces a mounting structure rod (such as mounting structure rod 114) along an axis (such as platform mounting axis 112). As the mounting structure rod displaces along the axis, the platform mounting structure to which the platform is coupled is displaced as well. In some embodiments, the platform is displaced into the vat such that the platform is submerged in the material. In some embodiments, the platform is displaced into proximity with the vat and the printer head. At 306, the printer head operates to form the 3D model. In some embodiments, the printer head can emit a plurality of ultraviolet rays (e.g., ultraviolet light beams) onto the platform that cause the material to change from a liquid state to a solid state. In some embodiments, the printer head extrudes the material onto the platform. The printer head can include a nozzle through which the material is extruded. As the printer head operates to form the 3D model, the actuator operates to raise the platform off the vat to provide a gap between a bottom surface of the vat and the 3D model being formed. In some embodiments, the 3D model is formed by multiple layers of material. For example, the printer head operates to form a first layer of the 3D model on the platform. The printer head forms a second layer of the 3D model on the first layer.The process is repeated until the 3D model is formed, hi some embodiments, the 3D model is submerged in the material during the formation process.

[0042] At 308, the platform including the formed 3D model is separated from the 3D printer assembly. In some embodiments, the mounting structure is separated from the platform mounting structure such that the platform is separated from the 3D printer assembly. At 310, the 3D model is separated from the platform. In some embodiments, the 3D model is manually separated using a separation tool so as not to damage the platform or the 3D model. In some embodiments, once the 3D model is detached from the platform, the platform may be resalted and reattached to the 3D printer assembly so that the method 300 can be repeated. In this manner, the time for the process of forming a large number of 3D models is reduced. For example, after the formed 3D model is removed from the platform, the platform may be quickly resalted and reattached to the 3D printer assembly.

[0043] Referring to FIG. 8, a perspective view of a portion of a 3D model 312 printed on the platform 116 is shown according to an embodiment. A portion of the 3D model 312 (e.g., a first layer of material) adheres to the print layer surface 130 as the printer head 104 transforms the material from a liquid state to a solid state. In some embodiments, the portion of the 3D model is the first layer of the 3D model 312 formed on the platform. The first layer of the 3D model 312 adheres to the print layer surface 130. Referring to FIG. 9, the adhesion of the portion of the 3D model 312 to the print layer is shown. As can be seen from the edge feature 314 of the 3D model 312, the adhesion of the 3D model 312 to the platform 116 is promoted. In particular, the edge feature 314 is substantially smooth and free of defects. This indicates that as the 3D model 312 is formed, the portion of the 3D model 312 adheres to the print layer surface 130 without sliding, moving, shifting, falling, etc., while the 3D model 312 is formed. The substantial adhesion of the portion of the 3D model 312 to the print layer promotes an accurate 3D model that is substantially free of defects once the 3D model is formed. In some embodiments, the adhesion of the portion of the 3D model to the print layer is greater than the adhesion of the material bonded to the portion of the 3D model 312. For example, as the 3D model 312 is being formed, a second layer of material is formed on the portion of the 3D model 312 formed on the print layer 128 of the platform 116. As the second layer of material forms, a force is applied to the portion of the 3D model 312. Due to the adhesion of the portion of the 3D model 312 to the print layer being greater than the force applied by the second layer, the portion of the 3D model 312 does not detach from the platform 116. In some embodiments, the portion of the 3D model 312 does not move, shift, slide, etc. due to the applied force.

[0044] In contrast, referring to FIG. 10, the adhesion of a 3D model to a currently existing ceramic platform 400 is shown. As can be seen in FIG. 10, the edges of the 3D model on the ceramic platform are not substantially smooth. This is due to poor adhesion of the 3D model to the platform. For example, as the 3D model is being formed, the 3D model begins to move and slide on the platform. Due to the poor adhesion, the formed 3D model may contain substantial defects or may lead to poor formation of the 3D model.

[0045] 11, a 3D model 312 is shown. In an exemplary embodiment, the 3D model is an artificial organ. The 3D model 312 includes an adhesive side 316 (e.g., an outer surface, etc.). The adhesive side 316 bonds the 3D model 312 to the print layer 128 of the platform 116. In some embodiments, the adhesive side 316 includes a surface roughness. The surface roughness may be substantially similar to the print layer surface roughness (e.g., the second surface roughness, etc.). In some embodiments, the adhesive side 316 is a substantially smooth surface. In some embodiments, the surface roughness is determined by the following equation (Equation 1):

[0046]

number

[0047] where the surface thickness is the thickness of the layer that adheres to the print layer surface 130 and the angle θ is the angle at which the printer head 104 applies the material. The surface thickness can be in the range of 16 micrometers (μm) to 30 μm (including, for example, 15.2 μm, 16 μm, 20 μm, 24 μm, 28 μm, 30 μm, 31.5 μm, etc.) and the angle can be in the range of 0° to 90° (including, for example, 0°, 15°, 30°, 45°, 60°, 75°, 90°, etc.). The surface roughness of the adhesive side 316 can be in the range of 0.5 micrometers (μm) to 20 μm (including, for example, 0.475 μm, 0.5 μm, 1.0 μm, 5 μm, 10 μm, 15 μm, 20 μm, 21 μm, etc.).

[0048] As used herein, terms such as "coupled" refer to the joining of two components directly or indirectly to one another. Such joining may be immovable (e.g., permanent) or movable (e.g., removable or releasable). Such joining may be achieved with the two components or the two components and any additional intermediate components integrally formed with one another as a single unit, and the two components or the two components and any additional intermediate components are attached to one another.

[0049] As used herein, terms such as "fluidly coupled" mean that two components or objects have a pathway formed between them through which a fluid, such as air, gas, or liquid, can flow with or without interference from the components or objects.

[0050] It is important to point out that the construction and arrangement of the various systems shown in the various exemplary implementations are merely illustrative and not limiting in nature. All changes and modifications that come within the spirit and / or scope of the described implementations are desired to be protected. It should be understood that some features may not be required and that implementations lacking various features may be contemplated as falling within the scope of the present disclosure, the scope of which is defined by the following claims. When the term "part" is used, the item can include a portion of the item and / or the entire item unless specifically stated otherwise.

[0051] Similarly, the term "or," when used to connect lists of elements, is used in its inclusive sense (and not its exclusive sense) so that it means one, some, or all of the elements in the list. Connecting terms such as the phrase "at least one of X, Y, and Z" are otherwise understood with the context as being used to generally convey that an item, term, etc. may be either X, Y, Z, X and Y, X and Z, Y and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z), unless specifically stated otherwise. Thus, such connecting terms are generally not intended to imply that some embodiments require that at least one of X, at least one of Y, and at least one of Z each be present, unless otherwise indicated.

[0052] Additionally, the use of numerical ranges herein (e.g., W1 to W2, etc.) includes the maximum and minimum values ​​unless otherwise indicated (e.g., W1 to W2 includes W1 and includes W2, etc.). Additionally, numerical ranges (e.g., W1 to W2, etc.) do not necessarily require that intermediate values ​​be included within the range of values ​​(e.g., W1 to W2 can include only W1 and W2, etc.), unless otherwise indicated.

[0053] Additional Embodiments 1. A platform for a device for printing 3D models, comprising: a base having a first surface roughness on a first side; A platform comprising: a printing layer bonded to a first side of the base, wherein a surface of the printing layer distal to the base has a second surface roughness greater than the first surface roughness to promote adhesion of a 3D model being printed on the platform. 2. The platform of embodiment 1, wherein the base is formed from a metal. 3. The platform of embodiment 1, wherein one of the first surface roughness or the second surface roughness includes hooks and the other of the first surface roughness or the second surface roughness includes loops, which adhere when pressed together. 4. The platform of embodiment 1, further comprising an assembly arm extending from a second side of the base opposite the first side. 5. The platform of embodiment 1, wherein the second surface roughness is 50% to 300% greater than the first surface roughness. 6. The platform of embodiment 1, further comprising an adhesive layer interposed between the base and the printed layer, the adhesive layer bonding the printed layer to the base. 7. The platform of embodiment 4, further comprising an attachment structure coupled to the assembly arm at one end of the assembly arm distal from the base, the attachment structure configured to couple the platform to a 3D printer assembly. 8. An apparatus for printing 3D models, comprising: a printer head configured to print a 3D model using the material; a vat configured to store material for use by the printer head; An actuator, and a 3D printer assembly including a platform mounting structure coupled to an actuator, the actuator configured to displace the platform mounting structure along an axis; a platform coupled to the actuator via a platform mounting structure and configured to receive a material, the platform having a base with a first side thereon having a first surface roughness; a platform including a printing layer coupled to a first side of the base, a surface of the printing layer distal from the base having a second surface roughness greater than the first surface roughness to promote adhesion of a 3D model printed on the platform; An apparatus comprising: 9. The platform will also: an assembly arm extending from a second side of the base opposite the first side of the base; an assembly structure coupled to the assembly arm at an end of the assembly arm distal from the base, the assembly structure being coupled to the platform assembly structure; 9. An apparatus for printing a 3D model as described in embodiment 8, comprising: 10. An apparatus for printing a 3D model as described in embodiment 8, wherein the first surface roughness and the second surface roughness include hooks or loops that adhere when pressed together. 11. An apparatus for printing a 3D model as described in embodiment 8, wherein the platform further includes an adhesive layer interposed between the base and the printing layer, the adhesive layer bonding the printing layer to the base. 12. An apparatus for printing a 3D model as described in embodiment 8, wherein the material stored in the vat is a hydrogel. 13. An apparatus for printing a 3D model as described in embodiment 8, wherein the second surface roughness of the print layer is 50% to 150% greater than the first surface roughness of the base. 14. An apparatus for printing a 3D model as described in embodiment 8, wherein the base is made of metal. 15. A method of forming a 3D printed model, comprising: a printer head configured to print a 3D printed model using the material; a vat configured to store material for use by the printer head; An actuator, and a platform mounting structure operably coupled to the actuator, the actuator configured to displace the platform mounting structure along an axis; providing a 3D printer assembly including: a base having a first side thereon having a first surface roughness; a printing layer bonded to a first side of the base, a surface of the printing layer distal to the base having a second surface roughness greater than the first surface roughness to promote adhesion of a 3D printed model on the platform; providing a platform comprising: coupling the platform to a 3D printer assembly; operating the 3D printer assembly in a manner such that material is bonded to the platform to form a 3D model; A method comprising: 16. The method of embodiment 15, wherein the platform further comprises an adhesive layer interposed between the base and the print layer, the adhesive layer bonding the print layer to the base. 17. The method of embodiment 15, further comprising providing a material on the printing layer of the platform such that the adhesion force between the first material layer and the printing layer is greater than the adhesion force of a second material layer disposed on the first material layer to prevent the first material layer from detaching from the printing layer. 18. The method of embodiment 15, wherein the formed 3D model includes a roughness on an outer surface of the 3D model that is substantially similar to the roughness of the second surface. 19. The method of embodiment 15, wherein the 3D model formed is an organ formed from a hydrogel. 20. The Platform further: an assembly arm extending from a second side of the base opposite the first side of the base; an assembly structure coupled to the assembly arm at an end of the assembly arm distal from the base, the assembly structure being coupled to the platform assembly structure; 16. The method of embodiment 15, comprising:

[0054] Although certain preferred embodiments have been referred to above, it is understood that the invention is not so limited. Those skilled in the art will recognize that various modifications can be made to the disclosed embodiments, and that such modifications are intended to fall within the scope of the invention.

[0055] All publications, patent applications and patents cited herein are hereby incorporated by reference in their entirety.

Claims

1. 1. A method for forming a 3D printed model, comprising: a vat with photocurable ink, the vat including an oxygen permeable membrane at the bottom of the vat; providing an apparatus comprising: a printing platform including a base and a mesh on a first side of the base, the mesh having hooks or loops for coupling a 3D printed model to the base, the mesh further comprising a photocurable ink having a greater adhesive strength to the mesh than to the oxygen permeable membrane; and displacing a platform from the oxygen permeable membrane to form a 3D model from the photocurable ink.

2. The method of claim 1 , wherein the base is formed from a metal.

3. The method of claim 1 , wherein the platform further includes an assembly arm extending from a second side of the base opposite the first side.

4. The method of claim 1 , wherein the platform further comprises an adhesive layer interposed between the base and the mesh, the adhesive layer bonding the print layer to the base.

5. The method of claim 1 , wherein the first side of the base has a surface roughness to promote adhesion of the mesh to the base.

6. The method of claim 1 , wherein the 3D model is a bioscaffold.

7. The method of claim 2, wherein the platform further includes an assembly arm extending from a second side of the base opposite the first side.

8. The method of claim 2, wherein the platform further includes an adhesive layer interposed between the base and the mesh, the adhesive layer bonding the print layer to the base.

9. The method described in claim 3, wherein the platform further includes an adhesive layer interposed between the base and the mesh, the adhesive layer bonding the print layer to the base.

10. The method of claim 2, wherein the first side of the base has a surface roughness to promote adhesion of the mesh to the base.

11. The method of claim 3, wherein the first side of the base has a surface roughness to promote adhesion of the mesh to the base.

12. The method of claim 4, wherein the first side of the base has a surface roughness to promote adhesion of the mesh to the base.

13. The method described in claim 2, wherein the 3D model is a bioscaffold.

14. The method described in claim 3, wherein the 3D model is a bioscaffold.

15. The method described in claim 4, wherein the 3D model is a bioscaffold.

16. The method described in claim 5, wherein the 3D model is a bioscaffold.

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