Devices, systems, processes, and methods related to 3D printers, including pressurized resin manufacturing of three-dimensional objects.

Abstract

Pressure-supplied dynamic 3D printing (PD3DP) involves 3D printing in which a polymerizable material (typically resin) is delivered under positive pressure as each layer of the object is formed / printed. Such positive pressure can be applied intermittently and even inversely to provide periodic pressure application to assist in resin delivery, placement of the resin in a location suitable for the shape of the object, resin curing, and release of the object from its projection location between the printing of successive layers.

Description

[Technical Field]

[0001] Cross-reference of related applications

[0001] This application claims the benefit of concurrently pending U.S. Provisional Patent Application No. 63 / 450,907 filed 8 March 2023, which is incorporated herein by reference in its entirety. [Background technology]

[0002] background

[0002] 3D printers that digitally print 3D objects are generally available. Examples of such 3D printers include stereolithography (SLA) printers and digital light processing (DLP) printers, which are collectively referred to herein as SLA 3D printers. Such SLA 3D printers produce 3D objects by curing a photosensitive liquid resin using a laser or other energy source. SLA printers can typically produce high-resolution 3D objects with superior surface quality compared to conventional fused deposition modeling (FDM) 3D printers, which produce 3D objects by extruding solid polymer filaments. Other 3D printers / 3D printing methods include selective laser sintering (SLS) printing, which uses a laser to melt the appropriate powder held in a powder bottle, as well as liquid polymer printing vats used in SLA printers, including SLA laser printers, multi-jet fusion (MJF such as HP MJF), selective laser melting (SLM), and direct metal laser sintering (DMLS). These and other exemplary 3D printing systems are generally described at https: / / www.hubs.com / knowledge-base / material-processes-explained / . (Various references discussing specific systems, apparatus, methods and other information are made herein by reference, and all such references, whether or not they appear anywhere in this application, are incorporated herein by reference in whole and in all their teachings and disclosures. The citation of references herein does not constitute an endorsement that such references constitute prior art to this application.)

[0003]

[0003] A 3D printing system typically has an existing permanent print tank, tray, or vat within the build area. (Hereinafter referred to collectively as “existing print vat”. In this context, “print vat” also refers to a vat, tray, or tank on which 3D printing takes place, as opposed to an existing permanent reservoir, vat, or tank (hereinafter referred to as “supply reservoir”). Furthermore, “print area” refers to the area on which 3D printing takes place, and “vat-less print area” refers to a print area that does not have an existing permanent print vat. A 3D printing system typically has a supply reservoir operably connected to an existing permanent print vat within the 3D printer, which holds resin or other 3D printing material and supplies it to the existing permanent print vat for building the object. Such 3D printers have one or more drawbacks, such as lack of precision, material waste, component waste, limitations on the types of materials that can be used, excessive and expensive post-processing, or other disadvantages. [Overview of the project] [Problems that the invention aims to solve]

[0004]

[0004] Therefore, there is an unmet need for 3D printing devices, systems, methods, etc. that offer improved accuracy, faster printing speeds, reduced material waste, and / or a wider range of materials that can be used, compared to existing 3D printers that require a permanent print vat to fabricate an object, such as SLA 3D printers. The present system, process, and method provides a solution to one or more of these needs and / or one or more other advantages. [Means for solving the problem]

[0005] overview

[0005] Described herein are devices, systems, processes, methods, etc., for continuous 3D printing systems that incorporate a pressure-fed 3D dynamic printing (PD3DP) process for dynamically printing products / objects (including exemplary controls, materials, and apparatus specifications). In some embodiments, the object is surrounded (i.e., completely encircled, e.g., a circle, ellipse, variable radius (also positive and negative radius), a variety of variable shapes, and other encirclement patterns), and PD3DP can be performed without any existing vats or immersion containers in the printing area. In some embodiments, for example, a dynamically printed lip about 2 mm high can be incorporated in the first or fairly early layers of the printing process. For example, it can be incorporated when it is desirable to print an unencircled object, and a dynamic shell or other encirclement structure can be fabricated to typically encircle the object in the printing area simultaneously with the object as needed.

[0006]

[0006] In the methods described herein, positive pressure, typically negative pressure, is applied to the resin in the printing area at the level of a newly printed "slice" of the object, and this pressure may be applied at the extrusion stage if extrusion is present, if necessary. Such processes produce a three-dimensional object layer by layer. Each layer of uncured material is formed under positive pressure before curing, if necessary, without an existing vat or any other immersion container. In other words, the 3D dynamic product / object is printed directly by a 3D printer in an open printing area by positive pressure applied to new resin via a build plate or other pressure device, and does not require an existing vat or other permanent immersion pool of resin or other printing material (including an existing vat or other permanent immersion pool that is entirely or partially within the build area) in the build area where the 3D dynamic product is made.

[0007]

[0007] Positive and / or negative pressure is applied to the resin intermittently, typically periodically, layer by layer. Pressure is useful, for example, to move or position the resin (or other 3D printing material) to a desired location within the build area, particularly to the current layer during curing and build. In some embodiments, a pressure projection panel placed between the curing energy source and the resin directly or indirectly presses on the resin / applies positive pressure to the resin, as either the pressure projection panel or the resin moves toward each other—either or both may move. Similarly, a pressure projection panel directly or indirectly recedes from the resin / applies negative pressure to the resin, as either the pressure projection panel or the resin moves toward each other—either or both may move. Pressure can also be applied positively or negatively by the positive or negative flow direction from the pump supplying the resin to the build area and / or the current layer during build. Such positive or negative flow directions can be achieved, for example, by a reversible pump or by switching between two pumps having opposite pumping directions.

[0008]

[0008] The first layer of resin is forcibly coated onto the build plate by pumping. In some embodiments, the polymerizable liquid is the same material delivered to the build plate or subsequent parts under solidification pressure from the build plate, which presses the resin onto the projection plane, and can be, for example, about 65 to 65,000 Pascals. The desired pressure is based, among other things, on material properties, design geometry and PD3DP equipment. The second (or subsequent) layers form interphase boundaries that are polymerized by delivered ultraviolet energy. Typically, due to the movement of the build plate, the layers are delivered under positive pressure, and by building one layer on top of another, a selected layer thickness of about 20 to 1,000 microns can be provided, and typically the 3D object is manufactured layer by layer. The second (or subsequent) layers may be the same or different material to manufacture a multi-material object. Each layer is delivered under pressure to determine its composition and layer thickness. Typically, pressure is applied to all layers of the dynamically created object, but in certain embodiments, pressure may be omitted for one or more layers. Each layer is crosslinked by a photoinitiator initiated with energy that may be provided by UV, laser, or other energy sources. Typically, the layers of printing material do not form interfaces that are completely bonded to each other by pressure alone. The thickness and UV energy of the interface layers can be adjusted, allowing the user to selectively control the build speed.

[0009]

[0009] The amount and rate of resin delivery to the molding area can reduce or eliminate discontinuities, voids, cracks, and other anomalies that affect the quality of the part. Conversely, in the pressurized PD3DP systems and methods described herein, it is also possible to intentionally and selectively incorporate discontinuities, cracks, voids, or other features if the design benefits from them for performance and application purposes.

[0010]

[0010] The devices, systems, processes, methods, etc. of the present invention include one or more of the following aspects, embodiments and / or features: A projection panel comprising a thin, flat panel or plate made of glass, transparent Teflon® (polytetrafluoroethylene), or other suitable material having appropriate flexibility, transparency, and friction properties, wherein curing energy can traverse the panel to cure the resin (or other material) on the opposing side, and the resin can flow across / to the projection panel during PD3DP printing and during resin pressure pumping, including higher pressure pumping. By directly pumping the resin between the build platform and the projection panel at a relatively high positive pressure compared to the surroundings, such as 70, 100, 200, 500, 1000, 10000, 50000, 100000, or 140000 Pascals, higher precision, quality, and speed can be achieved. Conversely, creating a vacuum can help reduce the time required to separate the layers from the projection plate and stabilize the resin's movement. While eliminating the need for a wiper, it also prevents debris and bubbles from adhering to the projection panel. This can be advantageous, for example, because wipers typically operate very slowly to avoid excessive material removal. However, in some embodiments, wipers may be included in the system or process, for example, to create a desirable surface on the object. This allows for rapid replenishment of resin for new layers, improving print performance and reducing print time. Fluid pressure helps separate the object from the projection panel after a given layer has been printed. This can be advantageous, for example, in reducing damage to the object and system during printing. ○ A small amount of resin is substantially constantly moved or maintained across the projection panel, thereby reducing or eliminating adhesion. For example, a textured projection panel for several embodiments to create a relief pattern on the final top surface of a 3D dynamic printed product / object. The projection panels can be rearranged as desired in each layer, as needed.

[0011]

[0011] In the PD3DP process, system, etc. described herein, pressure is applied to a delivered layer of polymerizable material (typically a resin in the form of a liquid, paste, etc.), which is subsequently irradiated through a projection plane. The resin then forms a three-dimensional object within the build area. Thus, in some embodiments, the PD3DP process, system, etc. prints an object by delivering resin to a build area that is selectively and controllly pressurized by a projection plate during the printing process. Irradiating the build area or region is typically achieved by repeatedly adding layers to the surface of the object and pressurizing the resin through the projection plate, while forming a solid polymer for the polymerizable material through an optically transparent surface (typically a projection plate), solidifying the delivered material and determining its thickness (the remainder is squeezed out from the sides of the part and returned to the resin vat).

[0012]

[0012] In some embodiments, the system, device and method, etc., provides a pressure-supplied 3D dynamic printing (PD3DP) system having a pressure projection panel positioned between a curing energy source and an inlet port for 3D printing material in a build area, and may include computer-implemented programming for selectively and periodically pressing the pressure projection panel and the 3D printing material against each other and releasing each other in conjunction with layer-by-layer printing of at least one object in the build area. The build area may include a build plate on the opposite side of the build area from the pressure projection panel, and the projection panel and the build plate are selectively and controllably movable against each other layer by layer in the z-axis according to commands provided to at least one of the projection panel and the build plate, and the projection panel may selectively apply at least one of positive and negative pressure to the resin according to commands when resin can be applied to the layers of the object being printed in the build area.

[0013]

[0013] The system can selectively apply both positive and negative pressures. Computer-implemented programming can selectively apply pressure to create an immersion field within at least one of the object or an enclosure shell that completely surrounds the object. The immersion field can contain a liquid 3D printing material up to at least approximately the upper part of the object or the enclosure shell. Computer-implemented programming can selectively apply pressure to create a peripheral bead of the liquid 3D printing material at the upper part of the immersion field. The peripheral bead is in a predetermined position due to surface tension. Computer-implemented programming can selectively direct a 3D printing pattern onto the upper part of the 3D printing material from a curing energy source. For example, by stepwise directing the 3D printing pattern onto the upper part of the 3D printing material from a curing energy source, the object can be continuously shaped layer by layer.

[0014]

[0014] The inlet port can cross through the shaping plate. The pressure projection panel can be transparent, flexible, and low friction. The 3D printing material can be a liquid photosensitive resin that cures into a solid when appropriate activating light from a curing energy source hits it. The curing energy source can be a light delivery source, an ultraviolet light delivery source, a heat delivery source, an iris diaphragm heat radiation source. The PD3DP system can include a thermal management system for rapid cooling and heating by a heat radiation source. The curing energy source can be an electron beam source and can be non-visible directional energy.

[0015]

[0015] Computer-implemented programming can include instructions that combine the pressure applied to the 3D printing material, the layer thickness, the energy delivered to the uncured 3D printing material, and the timing of the release of the shaping plate from the pressure projection panel. The PD3DP system can include a reversible pump for delivering the 3D printing material to the shaping area. Computer-implemented programming can control the reversible pump to deliver the resin to the shaping area at a controlled micrometer level. The resin delivery by the reversible pump can be controlled to control the pressure within the 3D printing material.

[0016]

[0016] The PD3DP system may include a 3D printing material capture system for capturing and repositioning unused 3D printing materials. Computer-implemented programming can instruct a pressure projection panel to press the 3D printing material after a layer of the 3D printing material has been introduced into the shaping area and before directing curing energy to a new layer of the 3D printing material.

[0017]

[0017] The shaping plate can be moved toward and away from the pressure projection panel as part of delivering the 3D printing material to the shaping area and releasing the cured 3D printing material from the pressure projection panel, and positive and negative pressures can be implemented by adding 3D printing material into the shaping area or reversing the direction of its flow. The system PD3DP may lack an existing print vat or a permanent print vat within the shaping area. The PD3DP system can hold at least a partially dynamically printed object printed by the PD3DP system within the shaping area.

[0018]

[0018] Computer-implemented programming can include instructions to print an object and instructions to print the object and not print any surrounding structures. The outer surface of the object may not have unintentional bulges, flashes or ridges extending more than 0.1 mm from the outer surface, and the outer surface of the object may not have surface artifacts extending more than 0.01 mm from the outer surface.

[0019]

[0019] Computer-implemented programming can include instructions to print an object within an enclosure shell that completely encloses the object, including when the non-vertical struts hold the object to the enclosure shell if dynamically created. The dynamically created non-vertical struts can have a diameter of about 200 μm or less. The enclosure shell and the object can be made from the same 3D printing material or can each include different 3D printing materials. The enclosure shell further holds at least one dynamically created auxiliary structure. The auxiliary structure can include piping that directs the printing material from a first location within the surrounding shell to a second location within the surrounding shell. The PD3DP system can be in the process of shaping an object.

[0020]

[0020] The 3D printer system may include a top-down or bottom-up stereolithography (SLA) or digital light projection (DLP) system that can 3D print an object from a photosensitive liquid resin. The PD3DP system may include a plurality of inlet ports that supply 3D printing material to the surrounding shell, each inlet port supplying different or the same 3D printing material. Different 3D printing materials may be different photosensitive resins. The pressure projection panel may be made of glass or transparent polytetrafluoroethylene.

[0021]

[0021] The computer implementation programming may include instructions to pump resin between the build platform and the pressure projection panel at a positive pressure of approximately 70 to 140,000 Pascals. The PD3DP system may include a projection panel cartridge that has or does not have a wiper, or which may include a wiper. The projection panel cartridge may be removable. The PD3DP system may include at least two projection panel cartridges, one having a wiper and the other without a wiper, which may be removable.

[0022]

[0022] In some embodiments, the system, device may include a method of manufacturing or using the PD3DP system shown herein.

[0023]

[0023] Some embodiments include objects printed by a pressure-fed 3D dynamic printing (PD3DP) system as described herein. The objects may be located inside or outside the PD3DP system. The objects may be located inside a surrounding shell within the PD3DP system. The objects do not have to have unintended bumps, flushes, or ridges extending more than 0.1 mm from the outer surface of the objects.

[0024]

[0024] The object may be an open shell such as a drinking glass, or it may be a closed shell or a filter.

[0025]

[0025] In some embodiments, the system, device may include a method that prints an object layer by layer via pressure-supplied 3D dynamic printing (PD3DP), the method of which a) To provide a PD3DP system, b) Printing the target object using PD3DP within the PD3DP system PD3DP printing may include selectively and intermittently pressing and releasing a pressure projection panel against uncured 3D printing material layer by layer to assist in the formation of the object.

[0026]

[0026] The computer implementation programming can instruct the pressure projection panel to press the 3D printing material after a layer of 3D printing material has been introduced into the build area and before curing energy is directed to a new layer of 3D printing material, and can instruct the pressure projection panel to pull away from the 3D printing material after curing energy has been directed to a new layer of 3D printing material. The build plate can be moved toward and away from the pressure projection panel to perform pressing and releasing of the pressure projection panel and the 3D printing material.

[0027]

[0027] The method may further include printing a support wire connecting the enclosing shell and the object, and printing at least one auxiliary structure within the internal space of the enclosing shell. The method may further include removing the object from the PD3DP system or removing the object from the enclosing shell. The system may include a reversible pump, and the method may further include operating the reversible pump in reverse before directing the curing energy to a new layer of the 3D printed material. The reversible pump may be a micro-metering reversible pump.

[0028]

[0028] The current systems, methods, etc. described herein will be discussed in more detail with reference to the following accompanying drawings and embodiments. The PD3DP, which supplies pressure to the projection plate, can be embodied in many different forms, and the embodiments described herein are provided as templates and do not in any way fully represent all aspects of the idea. For example, in some embodiments, the current systems, methods, etc. described herein provide a removable physical projection panel, eliminating the need for a wiper.

[0029]

[0029] These and other aspects, features and embodiments are described herein, including in the following detailed description and accompanying drawings. Unless otherwise specified, all embodiments, aspects, features, etc., can be mixed and adapted, combined and substituted in any desired manner. In addition, various references, including those in cross-references to related applications discussing specific systems, apparatus, methods and other information, are described herein, and all such references are incorporated herein by reference in their entirety and in all teachings and disclosures, regardless of where in this application they may appear. Such references are not necessarily prior art to this application. [Brief explanation of the drawing]

[0030] Brief explanation of the drawing [Figure 1A]

[0030] A front plan view of the pressure-supplied 3D dynamic printing (PD3DP) system described herein is shown. [Figure 1B]

[0030] A perspective view of the pressure-supplied 3D dynamic printing (PD3DP) system described herein is shown. [Figure 1C]

[0030] A perspective view of the pressure-supplied 3D dynamic printing (PD3DP) system described herein is shown. [Figure 2A]

[0031] This specification shows a front plan view of the further pressure-supplied 3D dynamic printing (PD3DP) system described herein. [Figure 2B]

[0031] A perspective view of a further pressure-supplied 3D dynamic printing (PD3DP) system described herein is shown. [Figure 3A]

[0032] This specification provides a high-level flowchart of an exemplary route for performing a pressure-supplied 3D dynamic printing (PD3DP) process using the systems, methods, etc., described herein. [Figure 3B]

[0032] A high-level flowchart of an exemplary route for carrying out a pressure-supplied 3D dynamic printing (PD3DP) process using the systems, methods, etc. of this specification is shown. [Figure 3C]

[0032] A high-level flowchart of an exemplary route for carrying out a pressure-supplied 3D dynamic printing (PD3DP) process using the systems, methods, etc. of this specification is shown. [Figure 3D]

[0032] A high-level flowchart of an exemplary route for carrying out a pressure-supplied 3D dynamic printing (PD3DP) process using the systems, methods, etc. of this specification is shown. [Figure 3E]

[0032] A high-level flowchart of an exemplary route for carrying out a pressure-supplied 3D dynamic printing (PD3DP) process using the systems, methods, etc. of this specification is shown. [Figure 3F]

[0032] A high-level flowchart of an exemplary route for carrying out a pressure-supplied 3D dynamic printing (PD3DP) process using the systems, methods, etc. of this specification is shown. [Figure 4]

[0033] This specification shows a cutaway side view of the build area and specific related structures of the pressure-supplied 3D dynamic printing (PD3DP) system described herein. [Figure 5]

[0034] This specification shows a cutaway side view of the build area and a specific related structure of the pressure-feed 3D dynamic printing (PD3DP) system described herein, where the projection plate is positioned to build the first layer of the object. [Figure 6]

[0035] This specification shows a cutaway side view of the build area and a specific related structure of the pressure-supplied 3D dynamic printing (PD3DP) system described herein, where the first layer of the object is exposed by a light source through a projection plate. [Figure 7]

[0036] This specification shows a cutaway side view of the build area and specific related structures of the pressure-supplied 3D dynamic printing (PD3DP) system described herein, illustrating the separation of the latest layer from the projection plane. [Figure 8]

[0037] This specification shows a cutaway side view of the build area and a specific related structure of the pressure-supplied 3D dynamic printing (PD3DP) system described herein, where the build plate is positioned to create the nth layer of the object. [Figure 9]

[0038] This specification shows a cutaway side view of the build area and specific related structures of the pressure-feed 3D dynamic printing (PD3DP) system described herein, where the final layer of the object is separated from the projection plate. [Figure 10]

[0039] This specification shows a cutaway side view of the build area and specific related structures of the pressure-supplied 3D dynamic printing (PD3DP) system described herein, where the final object and shell are removed manually or by a robotic device. [Figure 11]

[0040] A series of charts illustrates an exemplary overall process flow of a pressure-fed 3D dynamic printing (PD3DP) system. [Figure 12]

[0041] This specification provides exemplary high-level printer software logic for a pressure-fed 3D dynamic printing (PD3DP) process using the systems, methods, etc. [Figure 13]

[0042] Further exemplary high-level printer software logic for pressure-fed 3D dynamic printing (PD3DP) processes using the systems, methods, etc., described herein is presented. [Figure 14A]

[0043] This specification shows a series of drawings illustrating the open-shell printing process of the pressure-supplied 3D dynamic printing (PD3DP) system described herein. [Figure 14B]

[0043] A series of drawings illustrating the open-shell printing process of the pressure-supplied 3D dynamic printing (PD3DP) system described herein are shown. [Figure 14C]

[0043] A series of drawings illustrating the open-shell printing process of the pressure-supplied 3D dynamic printing (PD3DP) system described herein are shown. [Figure 15A]

[0044] A series of drawings illustrating the closed-shell printing process for the pressure-supplied 3D dynamic printing (PD3DP) system described herein are shown. [Figure 15B]

[0044] A series of drawings illustrating the closed-shell printing process for the pressure-supplied 3D dynamic printing (PD3DP) system described herein are shown. [Figure 15C]

[0044] A series of drawings illustrating the closed-shell printing process for the pressure-supplied 3D dynamic printing (PD3DP) system described herein are shown. [Figure 16A]

[0045] This specification shows a series of diagrams illustrating the closed-shell printing process of the pressure-supplied 3D dynamic printing (PD3DP) system described herein. [Figure 16B]

[0045] A series of drawings showing enlarged views of the closed-shell printing process of the pressure-supplied 3D dynamic printing (PD3DP) system described herein are shown. [Figure 16C]

[0045] A series of drawings showing enlarged views of the closed-shell printing process of the pressure-supplied 3D dynamic printing (PD3DP) system described herein are shown. [Figure 16D]

[0045] A series of drawings showing enlarged views of the closed-shell printing process of the pressure-supplied 3D dynamic printing (PD3DP) system described herein are shown. [Figure 17A]

[0046] This specification shows a hollow pyramidal object with the pipe and manifold broken off, as detailed by the pressure-fed 3D dynamic printing (PD3DP) system described herein. [Figure 17B]

[0046] The image shows a hollow pyramidal object with the pipe and manifold broken off, as shown in detail from the pressure-supplied 3D dynamic printing (PD3DP) system described herein. [Figure 18A]

[0047] This specification shows a drinking glass printed from resin delivered vertically from the main resin inlet to the immersion field using a pressure-fed 3D dynamic printing (PD3DP) system. [Figure 18B]

[0047] The drinking glass printed from resin delivered vertically from the main resin inlet to the immersion field by the pressure-feed 3D dynamic printing (PD3DP) system described herein is shown. [Figure 18C]

[0047] The drinking glass printed from resin delivered vertically from the main resin inlet to the immersion field by the pressure-feed 3D dynamic printing (PD3DP) system described herein is shown. [Figure 19A]

[0048] This specification shows drinking glasses in different states of the printing process of the pressure-feed 3D dynamic printing (PD3DP) system described herein. [Figure 19B]

[0048] A drinking glass is shown, illustrating different states of the printing process of the pressure-feed 3D dynamic printing (PD3DP) system described herein. [Figure 20]

[0049] The resin is pumped through the build plate into an immersion field for the manifold, and, under pressure applied by the projection plane, forms a resin field-based support for a pressure-supplied 3D dynamic printing (PD3DP) system as described herein. [Figure 21A]

[0050] This document shows a filter fabricated using the pressure-supplied 3D dynamic printing (PD3DP) system described herein. [Figure 21B]

[0050] A filter fabricated by the pressure-supplied 3D dynamic printing (PD3DP) system described herein is shown. [Figure 22][000111] Shows a pressure-supplied 3D dynamic printing (PD3DP) system having a wiper as part of the projection panel cartridge. [Figure 23] [000112] Shows a pressure-supplied 3D dynamic printing (PD3DP) system having a wiper as part of the projection panel cartridge. [Modes for carrying out the invention]

[0031] Detailed explanation

[0051] The system and method include PD3DP printing, in which a polymerizable material (typically resin) is delivered under positive pressure as each layer of the object is formed / printed. Such positive pressure can be applied intermittently and then reversed to provide periodic pressure that assists in resin delivery, placement of the resin in a location suitable for the shape of the object, curing of the resin, and release of the object from projection locations between the printing of successive layers.

[0032]

[0052] Figures 1A–1C and 2A–2B, as well as other drawings herein, illustrate examples of the systems and methods herein, including those in which an immersion field is formed. In these examples, two 3D dynamic printed products are manufactured simultaneously in the build area, and each of them has a consumer-quality finish exterior, i.e., a smooth surface with substantially no significant surface artifacts such as undesirable bumps, flashes, ridges, etc., from the resin extruded from the build process, i.e., more than 0.1 mm, 0.01 mm, or even 0.001 mm, where “undesirable” means an unintended / unintended part of the input design.

[0033]

[0053] In Figure 1, polymerizable resin from the reservoir (117) is delivered by a resin delivery pump (118) through a resin delivery pipe (119). The polymerizable resin reaches the build plate, which may also be called the build platform (113), and is pumped to the build plate. The resin can flow over the sides of the build platform (13), collect in the resin return system (128), and is transported back to the resin reservoir via a return pipe (129). Positive pressure is applied to the resin on the build platform by a projection panel (125) being brought close by a Z-axis motor (114) and lowering the projection panel (125) onto the resin. This can extrude the resin along the sides (132). The projection panel (125) is controlled by a pressure-regulating spring (18), and the object or part is formed by projecting an image or printed pattern downward from a light source such as a projector (134) (or other suitable energy source), and by projecting UV energy (134) through the projection light shroud (17) to manufacture an outer 3D enclosure, a guy wire horizontal support, and an inner 3D dynamic printed product (a tugboat in this example).

[0034]

[0054] Figure 2 shows another diagram illustrating resin delivered to the build area (244) from the build plate or platform (209) to form the shell and object, flowing through a nozzle (245) to the build plate (209), over the side (201) and into a gutter (242). The build plate (209) is supported by a Z-axis positioning system (210). A projection panel (221) is fitted to a projection panel mount (24) made of FEP or other material, so that the projection panel contacts the top of the shell and applies pressure (250), trapping the resin on the top of the shell by surface tension (232), and allowing excess resin to flow down the side of the shell (252). Light from the projector (234) is collimated, and a light pattern is projected (223, 253) through the light shroud (203) to the projection panel (221), onto the build plate (209) where the outer 3D dynamic printed product and support are made, and the shell (232) is filled with resin (216).

[0035]

[0038] An exemplary printing process is shown in block diagram AI (Figure 3), and an exemplary discussion of materials and work sequence is given in the following paragraphs (and elsewhere in this specification).

[0036]

[0039] Figure 3A outlines that the initial steps for starting printing include lowering the build plate, loading the desired code, and pumping resin or similar material into the build plate to create a “self-supporting pool” held in place by surface tension at the edges of the build plate.

[0037]

[0040] Figure 3B: The projection plane is positioned at a certain distance from the build plate. This is typically 1 to 100 microns. Here, the immersion field is the remaining pool of resin that has been pressurized to a single layer thickness.

[0038]

[0041] Figure 3C: It is possible to make the resin settle.

[0039]

[0042] Figure 3D: The resin layer is exposed to the slice pattern for a predetermined amount of time.

[0040]

[0043] Figure 3E. The separation process involves placing the build plate below the previous layer and moving it down to a certain level (typically 1000-5000 μm). At this point, the resin is simultaneously pumped to release the vacuum and facilitate delamination.

[0041]

[0044] Figure 3F: The build plate is placed below the height of the previous layer and is typically raised by 1-4 μm. Simultaneously, the pump is operated in reverse to remove the resin and release the pressure.

[0042]

[0045] Figure 3G: It is possible to make the resin settle.

[0043]

[0046] Figure 3H: The resin is exposed to a layer slice pattern.

[0044]

[0047] Figure 3I: The process returns to step D, the resin is exposed, and the next layer is created.

[0045]

[0048] Exemplary versions of the entire process are also shown in Figures 4-10.

[0046]

[0049] In Figure 4, the first layer is prepared for deposition. The light source (401) is on a transparent backing plate (409) having an anti-friction coating or laminate film on the bottom (410). The resin is pumped (414a) from a metering pump (402) towards the build plate via an inlet pipe that rises into the build area to form the resin coating (408), flows downward by gravity over the edges (406) across the build plate (407) into a gutter (404), where it falls through an outlet (412) and flows into a capture unit or reservoir (not shown) (413). The resin passes through the build platform - for example, via internal piping - which may be handled by a thermal management system to maintain an optimal operating temperature specific to resin production. As described, resin flows over the build platform, forming a layer of resin whose thickness depends on the physical properties of the resin, such as surface tension and viscosity, as well as other factors, thus creating the first layer of the 3D dynamic printed product.

[0047]

[0050] In Figure 5, the thickness of the layer resin is set before curing (polymerization). The layer thickness can be set as needed, for example, typically 1 μm to a maximum of 100 μm, and layers of 200 μm or more can be used for faster output. The system build plate is positioned at an appropriate distance from the projection plane to form the first layer. The projection plate is positioned to build the first layer. Pressure is applied as the build plate (509) is raised until it presses against the projection plate (510), which may be a glass plate or a light source and other suitable friction and transparency properties against the resin. The resin is pumped into the build area between the build platform and the projection panel, in which case the resin is forced down into a metering pump (502) to reverse the direction of the resin and return it to the reservoir (514b). In addition to providing a layer of the 3D dynamic printed product, the pressure can push bubbles and debris out of the build area.

[0048]

[0051] In Figure 6, the first layer is exposed by a light source (601) through a transparent projection plate, and the flow of resin is blocked by fixing a pump (614c) and curing the first layer (616). The image of the first (or subsequent) layer of the 3D dynamic printed product is projected to form the desired shape, which may include the object and a resin-filled shell of one layer thickness. The resin and / or energy source may be selected to cure - solidify in the light spectrum of the projector. For example, a wavenumber of 405 nm is used for many SLA / DLP resins. A small amount of residual pressure helps to reduce or effectively remove adhesion of newly formed objects to the projection panel.

[0049]

[0052] Figure 7 shows the separation of the layer from the projection plane. During the separation phase, the build plate is lowered by a short distance along the Z-axis (in this specification, “lowered” and “raised” are used to indicate the increase or decrease in the relative distance between the projection panel and the build plate along the Z-axis) to separate the flexible (or non-flexible, depending on the resin used) projection plane from the cured resin layer (717). While lowering in this manner, resin can be pumped into the build area to assist in the separation of the projection panel from the 3D dynamic print product, which can be particularly useful if any adhesion of the 3D dynamic print product to the projection panel occurs. The layer thickness can be set as needed, for example typically to about 1 μm, 3 μm, 5 μm, 10 μm, 25 μm, 50 μm and up to about 100 μm, and layers of 200 μm or more can also be used for faster output. As the build plate descends, the expansion of the pumped (714a) resin assists in rapid separation, reducing the risk of wear and damage to the projection plate due to counter-fluid pressure. Pressure measurement and volume calculations can be used to reduce the amount of resin displaced by pressure or vacuum. As a result, a resin column is obtained that maintains contact with the projection plate with minimal or no overflow. It also protects the print itself from vacuum or cupping action. Alternatively, excess resin can be pumped to displace bubbles or debris from the build area.

[0050]

[0053] In Figure 8, the build plate is positioned to manufacture the Nth layer of the part / object (818). In this figure and embodiment, the object (ship) (818) is formed layer by layer simultaneously with the surrounding dynashell (820). In other embodiments, the dynashell (820) may be omitted, especially if the object is in an enclosing shape. In Figure 8, the object (818) is supported by horizontal guy wires (819) attached between the inner wall of the shell and the object (818). Other supports, such as vertical supports to the build plate or oblique supports attached to the object from the inner wall of the shell, may also be manufactured.

[0051]

[0054] In Figure 8, a resin immersion field can be created over the outer upper part of the periphery of the Dynashell (820), thereby creating a periphery bead of resin held in place by surface tension. Typically, the bead extends about 0.5 to 5 mm beyond the periphery, based on the resin viscosity. This depends on the chemical properties of the resin and projection plate, as well as environmental conditions in the build area, such as temperature. If necessary, the next layer can be formed in this immersion field. As the build platform is raised to a position with a desired layer thickness subtracted from the previous position, the resin continues to be pumped under pressure into the build area. Such a thickness can be caused by the fluid pressure ram effect of the Z motor pressing the object onto the projection plate. By reducing the pressure, the movement and acceleration of Z can be increased while shortening the settling time. This resin pumping can be configured to remove and eliminate debris, bubbles, and other undesirable materials, for example, by displacing excess resin. The Dynashell (820) remains filled with resin. Excess resin pumped into the system eventually flows into a capture channel and then into a resin return system (814b). If necessary, such resin can be filtered and returned to the reservoir for reuse. Due to the resin bead, the outer perimeter of the geometric shape of the next layer can be increased by the same amount as the bead radius, thus giving the material design engineer the ability to gradually form larger layers horizontally.

[0052]

[0055] In Figure 8, the object is supported by horizontal guy wires installed between the shell's inner wall and the object. Other supports can be manufactured, such as conventional vertical supports fabricated from bottom to top, or oblique supports attached to the object from the shell's inner wall.

[0053]

[0056] Figure 9 shows the separation of the final layer, similar to Figure 7. Once the printing process is complete, the build platform is positioned to facilitate the removal of the 3D dynamic printed product. During separation, the semi-flexible projection plane (if appropriate for use with the respective compatible resin) bends slightly to allow the separation process to proceed.

[0054]

[0057] In Figure 10, the final object and shell (1021) are removed manually or by a robotic device. The PD3DP product (1021) is removed from the build platform by, for example, lightly pressing the bottom of the shell with a flat tool. Strong adhesion between the 3D dynamic printed product and the build platform (build plate) is usually not necessary for the manufacturing process or for any issues with this system. To reduce excess resin spillage, the pump (2) can be operated in reverse (14b) to flush out the resin contained in the Dynashell. Optionally, a cleaning solution can be pumped through the system to remove uncured liquid resin from all surfaces and tubes.

[0055]

[0058] Next, the 3D dynamic printed product containing the object can undergo post-processing as needed, for example, removal of the support, and then, if necessary, cleaning and final curing in a UV bath. If one of the products is a surrounding shell (sometimes called a dynamic shell) or other suitable shape, such product can be reused in future printing processes as needed by installing a printer of a suitable design.

[0056]

[0059] In Figure 11, the overall process flow is shown by a series of charts. For example, when the pump is turned on and the resin is flowing, the positive pressure on the resin is low. When the build plate is lifted to the projection plane, the resin pressure increases and the frame is subjected to positive load pressure. At this stage, the direction of the pump flow can be reversed. Curing takes place in the next phase, followed by separation, where the flow direction is reversed again to the positive direction, the build plate is inverted, and the resin pressure and frame load are removed.

[0057]

[0060] An exemplary PD3DP software logic is shown in Figure 12.

[0058]

[0061] In Figure 12A, the slicer receives a 3D model file as input. Resin-specific parameters such as viscosity, curing strength, elasticity, maximum pump speed, and layer height are also set automatically or manually according to the printer settings.

[0059]

[0062] In Figure 12B, the slicer cuts the model into multiple layers corresponding to static or dynamic layer height settings.

[0060]

[0063] In Figure 12C, the layers are analyzed for printability, and appropriate print settings are set based on the geometric shape and parameters of the layers from A. Image processing is also performed for light uniformity, anti-aliasing, and any other digital-to-analog quality improvement methods.

[0061]

[0064] In Figure 12D, the motion sequences of all motors, pumps, solenoids, valves, etc., are set based on parameters from A.

[0062]

[0065] In Figure 12E, the resin parameters A and layer analysis E are interpreted and converted into machine settings. These include maximum / minimum projector output, pressure, etc.

[0063]

[0066] In Figure 12F, the image is saved using lossless compression.

[0064]

[0067] In Figure 12G, the calculated sequence of motion is converted into instructions and instruction payloads. These may include G-code, STEP, open-loop or closed-loop parameters, or other standardized or custom machine-interpretable instructions.

[0065]

[0068] In Figure 12H, the parameter data is saved in key-based format.

[0066]

[0069] In Figure 12I, the image, instructions, and metadata are stored in the printer's data payload.

[0067]

[0007] In Figures 13A to C, the printer receives data from the slicer via a network or physical data SD / TF, USB, etc.

[0068]

[0071] In Figure 13D, pixel data is loaded into the projector via digital communication such as parallel or serial data communication.

[0069]

[0072] In Figure 13E, the motor controller interprets the command and follows the programmed printing sequence.

[0070]

[0073] In Figure 13F, other print settings are interpreted and used to program various aspects of the layer sequence. The behavior of specific movement commands can be modified, and discontinuous settings such as temperature, pressure limits / targets, and projector output can be set.

[0071]

[0074] This PD3DP will also be discussed in more detail in this specification with reference to the attached drawings, and embodiments of the concept will be shown. These embodiments are intended to convey the scope of the PD3DP system, method, etc.

[0072]

[0075] Moving on to some further general considerations of methods, systems, etc., in this specification, in certain embodiments of PD3DP, the first layer of material is delivered to or in contact with a build plate made of any material, after positive pressure is introduced between the resin and the part, and since transparency is not required - UV energy is delivered from top to bottom. This step may be advantageous for overall process performance, as pressure is applied to the delivered resin supported by the build plate. Thus, the build plate has high rigidity and can remain stationary without movement during printing. Furthermore, the build plate may be textured or surface modified to facilitate adhesion of the first layer or to preferentially texture the surface of the part. The final removal of the part can be considered in this process, as the part is finally removed when the PD3DP printing is complete, while the object will be adhered to the build plate.

[0073]

[0076] In some embodiments, the pressure applied to the delivered material is a set of product features that provide layer control of the delivered material and force the material layer to solidify upon delivery to either the build plate or the previous material layer. The PD3DP process pressure applied to the fluid layer under compression is determined by the following formula: P = F / A (1) (In the equation, P = pressure, F = normal force, A = the area on which the force is applied. This formula is based on the definition of pressure as force per unit area over which a force is applied. When a fluid is under compression and held down at its edges by surface tension, the pressure at a given depth can be calculated as follows: P=P o +pgh (2) (In the formula, P = pressure at a specific depth, P o = atmospheric pressure, p = density of a fluid or viscous material. g = acceleration due to gravity, (h = depth of the material) This shows that there is a material pressure gradient across the material interface as a function of material depth. Thus, the surface tension restraining the material having viscosity "X" under a compressive load is equal to P, which is the sum of the terms provided above.

[0074]

[0077] In the PD3DP process, there is an additional term for the overall pressure P, i.e., after the "as-received" material is delivered in situ to the shaping plate during the printing process of the finished part, the projection plate provides a positive force P applied to the shaping surface. a to provide. The resulting overall pressure P T is equivalent to the following. P T = P a + P o + pgh (3) (where P T = the pressure at a specific depth, P a = the pressure applied by the projection plane, P o = the atmospheric pressure, p = the density of the fluid, viscous material, g = the acceleration due to gravity, h = the depth of the material)

[0075]

[0078] In the PD3DP process, pressure is applied to each layer in a layer-by-layer process. An external compressor is not used. Applying pressure during material delivery is inherent within the 3D shaping process. In most embodiments, the pressure supplied is independent of the shaping speed. This is because the process pressure is supplied on the order of milliseconds in response to the contact of the projection panel.

[0076]

[0079] In some embodiments, a plurality of channels are formed and the photoinitiating resin can be delivered under pressure P through one or more of the channels. T

[0077]

[0080] In some embodiments, a plurality of materials are pressured P into a UV energy layer that will include a multi-material layer. T ​It can be delivered below.

[0078]

[0081] In some embodiments, the method is specific, and pressure P T The steps can be repeated to create areas with different functions from the bulk of the parts to be delivered below.

[0079]

[0082] In some embodiments, multiple materials can be delivered to the fabrication surface or part, and these materials are combined under pressure P to give the geometric shape of the solidified part.

[0080]

[0083] In some embodiments, the polymer may be polymerizable by free radical polymerization.

[0081]

[0084] In some embodiments, the resin or second-phase material may be heated or cooled to facilitate flow onto the build surface—before the projection site applies pressure to the layer.

[0082]

[0085] In some embodiments, the polymerizable liquid is catalyzed in situ before being exposed to UV or another form of crosslinking-promoting energy. The situ chemical reaction is an example of this in applications.

[0083]

[0086] In some embodiments, catalytic photoinitiators are added to the non-catalyst resin before it is subjected to pressure from the projection plane. These can be cationic polymers and acid catalysts.

[0084]

[0087] In some embodiments, the pressure applied by the projection plane can be assisted by incorporating acoustic or ultrasonic energy to support the compaction step. Acoustic or ultrasonic energy may be applied to the material reservoir, transport line or channel, or to the build plate.

[0085]

[0088] In some embodiments, acoustic or ultrasonic energy can be combined within the PD3DP platform to create solidified, void-free compressed polymers or composite printed structures or multiphase polymer compounds. By incorporating acoustic or ultrasonic energy into the projection plate, the following can be achieved: (1) reducing internal friction to facilitate compression of the composite material; (2) enabling precise control of the solidification process with high frequency, ensuring that the material is properly heated and compacted; and (3) improving mechanical properties - the induced high-frequency load improves the mechanical properties of the material, such as hardness and fracture toughness.

[0086]

[0089] Acoustic systems in 3D printing focus on part solidification, and the approach described herein ensures that a well-dispersed multiphase system is prepared before fabrication. Furthermore, acoustic input to the material, which reaches its maximum potential upon delivery, can contribute to surface smoothing of the part in all parts—whether it be a single resin under photoinitiated curing or a multiphase composite material fabricated over a wide range of individual layer thicknesses.

[0087]

[0090] Acoustic or ultrasonic energy-based material preparation can support the in-situ mixing and processing of multiphase material systems. Mixing 3D materials of different phases has always been challenging. The ability to mix multiple materials in-situ using acoustic energy opens up new possibilities for 3D printing. Within this process range, it is possible to manufacture multifunctional materials from a second phase such as graphene, carbon nanotubes, or ceramic nanocomposites. This unique high-energy mixing technology, which does not transfer energy to the materials (the mixture), opens up new possibilities in electronics, aerospace, energy, and medical devices, to name a few.

[0088]

[0091] In some embodiments, mixing two or more materials (some polymers, ceramics, and metals) in a dynamic mixer (active mixer) such as an impeller or blade that provides mixing at, for example, between 1, 10, 100, 500, 1000, or 2000 rpm requires energy to blend. For example, in printing techniques that deposit materials layer by layer, the ability to dynamically adjust (change) the morphology of the material makes it possible to create complex structures and shapes with varying topology and function. Using the PD3DP process, precise parts can be printed / fabricated by converting liquid materials (polymers), carbon-based materials (fibers, sol-gel plateslets, whiskers, etc.), and ceramics layer by layer from 3D CAD data without the use of tools, resulting in solid cross-section composite materials.

[0089]

[0092] In some embodiments utilizing the dynamic mixing of multiple materials, novel functionalities can be developed in medical devices with embedded features and functions, including, to name a few, battery anodes, cathodes and stack designs, functional surfaces including filtration, and electronically inductively printed hardware.

[0090]

[0093] In some embodiments, a fluid pressure separator integrated in-line with the PD3DP printer can function to separate primary and secondary (or beyond) material supply to the print surface "zone," thereby imparting area-specific material properties to the continuous printed part. The fluid pressure separator acts as a barrier between loops, allowing each to operate independently. The primary function of the fluid pressure separator is to prevent interference between different materials and improve the overall efficiency of the system.

[0091]

[0094] In some embodiments, the fluid pressure mixing primary loop typically includes a single source of printing solution at room temperature, although the temperature may be heated or cooled depending on the printing architecture.

[0092]

[0095] In some embodiments, one or more fluid pressure mixing secondary loops deliver fluids of a different material from the primary loop to individual zones within a component where these properties are required. This can be locally cured (UV, heat, etc.) and delivered at varying flow rates or pressures depending on the desired specific zone or system. Fluid pressure separators mitigate any interference between the flow and pressure of the primary loop and the performance of the secondary loop, which can lead to non-uniform flow, zone interference, or reduced efficiency. In some embodiments, the loops then operate independently by (1) physically separating the flow paths by separate chambers for each loop, and (2) reducing pressure imbalances by equalizing the pressure between the loops, preventing high pressure in one loop from affecting the pressure in the secondary loop.

[0093]

[0096] Separating fluid pressure loops achieves several advantages, including (1) improved system efficiency as each loop can operate at its optimal flow rate, pressure, and mixing; (2) enhanced system control as individual zones can be controlled more precisely with less interference from other components of the system; (3) the ability to use more material in manufacturing; and (4) reduced wear on a single system.

[0094]

[0097] In some embodiments, fluid pressure separation can improve the local thermal and mechanical performance of PD3DP printed structures. For example, electronic packaging typically has multiple components related to the overall design, some of which generate more heat than others. The locations of these components require higher heat transport characteristics and are usually composed of a second-phase material having excellent thermal conductivity to achieve the heat transport operating parameters. In such cases, a second loop material with high thermal conductivity can be preferentially supplied to meet the design criteria.

[0095]

[0098] There are many materials that can be used by PD3DP printers and processes. The range of materials includes polymerizable fluids or liquids, catalytic polymerizable liquids, photocurable silicones, photocurable urethanes, hydrogels, ceramic green state materials, high-performance thermosetting resins, algae-fungi with photocurable binders, and photocurable biomaterials.

[0096]

[0099] Acid-catalyzed polymers: While acid-catalyzed or cationic polymerizable liquids may be used, free radical polymerization may be the most commonly used material in the embodiments. Acid-catalyzed polymers are materials that undergo polymerization in the presence of an acid catalyst. These polymers are widely used as binders and adhesives due to their excellent performance properties, such as high shear strength, low viscosity at room temperature, and good water resistance. They can be formulated with various types of monomers, such as acrylics, olefins, styrene-acrylates, vinyl esters, epoxys, urethanes, silicones, and other specialty resins. Acid-catalyzed polymers are suitable for use in PD3DP printing applications because they offer several advantages over conventional thermoplastics. Typically, an ionic or nonionic photoacid generator is included in the acid-catalyzed polymerizable liquid, which may, but is not limited to, sulfonium salts, iodonium salts, such as triphenylsulfonium hexafluorophosphate and diphenyliodide hexafluoroarsenate. Furthermore, these polymers can be easily modified by changing the type or amount of crosslinking agent, allowing for fine-tuning of the properties of the final material. Some specific examples of acid-catalyzed polymers include (a) poly(methyl methacrylate) (PMMA), (b) epoxy resins, and (c) silane-derived polymers containing reactive groups that can react with hydroxyl (-OH), carboxyl (-COOH), or amino (-NH2) functional groups on their surface.

[0097] [000100] Photocurable urethanes: Photocurable polyurethanes can typically be cured using ultraviolet (UV) or visible light with a composition consisting of a urethane monomer, a photoinitiator, a chain extender, an antioxidant, and a crosslinking agent. The urethane monomer provides the skeletal structure, while the photoinitiator initiates the curing process when exposed to UV light. The crosslinking agent helps to create a network within the polymer, improving its mechanical properties. Photocurable polyurethanes have many applications, including (1) medical devices including printed scaffolds for bioprinting and tissue engineering, as well as implantable medical devices such as heart valves and orthopedic implants, (2) bioprinting to create organs such as livers and kidneys, as well as cell and bacterial cultures, and (3) custom metamaterials with tough and elastic properties for special applications such as bone repair.

[0098] [000101] Liquid crystalline polymers: This class of materials may be derived from esters, ester-imides and ester-amide oligomers and are used as high-temperature thermosetting resins using several suitable photoinitiators such as benzophenone, fluoroenone and others that initiate polymer networks by crosslinking upon exposure to UV energy.

[0099] [000102] Photocurable Silicones: Photocurable silicone resins are a class of materials that combine the advantages of both silicone rubber and photoresists, offering a diverse set of properties. These resins can be cured using light energy, typically ultraviolet (UV) radiation, and contain organic components known for their ease of processing. The resulting cured products exhibit the characteristic properties of silicone rubber, such as flexibility, elasticity, and thermal stability, while also offering the advantage of being processed by photopolymerization technology. Their wide range of applications includes adhesives, coatings, mold making, medical implants, and optoelectronic devices. Photocurable silicone resins can be classified into two main categories based on their curing mechanism: (1) Cationic curable silicone resins rely on the addition of a cationic initiator system to induce a polymerization reaction when exposed to UV light, and generally utilize higher energy sources such as deep ultraviolet lamps to achieve complete curing. (2) Free radical curable silicone resins utilize free radical initiators to promote polymerization when exposed to UV light.

[0100] [000103] Free radical curable silicone resins typically cure with lower energy sources such as visible light or LED systems. Applications of photocurable silicone resins include: (1) Adhesion and coating technologies: Due to their excellent adhesive properties, photocurable silicone resins can be used as adhesives and coatings in various industries such as automotive, electronics, and medical devices. (2) Mold making and casting: Photocurable silicone resins can be used as mold materials to manufacture complex shapes and structures, particularly in the manufacture of microfluidic devices. (3) Medical implants: Biocompatible photocurable silicone resins can be used to manufacture medical implants such as stents and catheters that integrate flexible and biocompatible materials. (4) Optoelectronic devices: Photocurable silicone resins can be incorporated into optoelectronic devices such as solar cells and sensors to improve their optical and electrical properties.

[0101] [000104] Multiphase composites: Multiphase composites typically consist of a core (liquid, solid) polymer material and a reinforcing material such as chopped or continuous fibers, graphene, carbon nanotubes, ceramic materials, bioceramics, or clay. These composites offer higher strength and rigidity compared to unreinforced polymers and can replace metals such as aluminum. Some common types of composites used in PD3DP printing include (1) short fiber reinforced composites, including ABS composites, epoxy resin composites, nylon composites, and polylactic acid composites; and (2) particle reinforced composites, including filler biopolymers, acrylics, polystyrenes, and nylon composites.

[0102] [000105] Bio-based resins and composite materials: Bio-based resins refer to materials derived from natural sources or materials designed to mimic biological tissues. These resins have great potential for creating biocompatible, biodegradable, and sustainable devices, membranes, filters, scaffolds, etc. These materials are biocompatible, biodegradable, and sustainable overall. Examples include: (1) Collagen, a protein abundant in animal connective tissue. It is used as a scaffold material in tissue engineering, providing a structural support for growing new cells. Collagen-based PD3DP prints can be used in regenerative medicine, wound healing, and dental applications. (2) Alginate, a naturally occurring polysaccharide extracted from seaweed. It is used as a biocompatible and biodegradable material for temporary implants such as wound dressings and drug delivery vehicles. PD3DP-printed alginate constructs can be applied to tissue engineering, drug delivery, and sustained-release systems. (3) Plant-derived polymers, such as polylactic acid (PLA), polyhydroxybutyrate (PHB), polyhydroxyaldanoate (PHA), poly-3-hydroxybutyrate (P3HB), poly-4-hydroxybutyrate (P4HB), polyhydroxyvalerate (PHV), polyhydroxyhexanoate (PHH), polyhydroxyoctanoate (PHO) and their copolymers, as well as other plant-derived polymers synthesized from renewable resources such as corn starch and soybean oil, to name just a few. This class of materials is considered a non-acid-catalyzed polymer and is derived from sources such as corn or other carbohydrate precursors, making them an environmentally friendly alternative to conventional plastics. These biodegradable polymers can be used in a variety of PD3DP printing applications, including medical devices, packaging, sports and consumer goods. (4) Decellularized extracellular matrix (ECM), bioscaffolds or cell-free matrices can function as templates for tissue repair and regeneration, especially when the original tissue is damaged or lost. (5) Bio-ink is a special ink formulation designed specifically for 3D bioprinting.These consist of living cells suspended in a supporting matrix such as collagen or gelatin, which allows the cells to maintain their viability and function during the printing process. Bio-ink based PD3DP prints can be used in tissue engineering, organ modeling, and personalized medicine.

[0103] [000106] Photocurable epoxy: Photocurable epoxy that can be printed with PD3DP typically consists of a combination of monomers, initiators and other additives. These materials are photopolymerized and can be used in various PD3DP printing technologies, such as the PD3DP process. Some key components of photocurable epoxy include monomers such as 4'-pentyl-4-cyanobiphenyl to improve the dispersion and rheological properties of the resin. Initiators include benzophenone and others that play a crucial role in inducing polymerization reactions. They absorb light energy, generate free radicals, and result in polymer formation. Inert fillers or additives can be incorporated into the resin to improve specific properties such as mechanical strength or flexibility. Applications of PD3DP-printed photocurable epoxy extend to a variety of industries, including: (1) Orthodontics: Photocurable compositions have been developed for the manufacture of clear orthodontic devices; (2) Flexible materials: Epoxy-based compositions have been made for the manufacture of flexible material-based objects.

[0104] [000107] Photocurable ceramic preforms: The composition of photocurable ceramic preforms involves the use of pre-ceramic polymers having editable and designable molecular structures suitable for various PD3DP printing processes. These precursors undergo a series of chemical reactions during the sintering or firing process to form dense, high-quality ceramic materials. Some examples of renewable photopolymer resins include bio-based acrylates, which have been developed for processes similar to the PD3DP process. Applications of PD3DP-printed photocurable ceramic materials extend to various industries such as energy storage devices like batteries and capacitors, solar cells, and smart glass. The unique properties of these materials make them ideal for creating complex geometric shapes and intricate designs that are difficult or impossible to achieve with conventional manufacturing methods.

[0105] [000108] Hydrogels: Photocurable hydrogels typically consist of a crosslinked network formed by photoinitiated polymerization of a monomer solution containing water. These hydrogels exhibit excellent swelling behavior and can be tuned to meet specific targets with respect to mechanical properties, degradation rates and biological responses. The main components of photocurable hydrogels include (1) monomers such as methacrylic acid (MA), ethylene glycol dimethacrylate (EGDMA), and N,N'-methylenebis(acrylamide) (MBAA) which are commonly used in the synthesis of photocurable hydrogels; (2) crosslinking agents such as EGDMA and MBAA which facilitate the formation of the interconnected network structure of the hydrogel; (3) photoinitiators such as Irgacure 2959 and LAPOX which are essential for initiating the polymerization process upon exposure to light; and (4) water content which plays a crucial role in determining the final properties such as the swelling capacity and mechanical strength of the hydrogel.

[0106] [000109] The applications of PD3DP printed hydrogel materials are diverse and extend to various fields such as tissue engineering, drug delivery systems, and soft robotics. Some potential applications include (1) biomedical implants designed to mimic the mechanical properties and biocompatibility of natural tissues and suitable for use in medical implants; (2) drug delivery hydrogel scaffolds designed to release drugs at a controlled rate and enable targeted therapy for specific diseases; and (3) soft robots fabricated from hydrogels that can be used to develop soft robotic actuators that can adapt to different environments and perform tasks requiring delicate manipulation.

[0107] [000110] Many embodiments of the system, process, etc., utilize polymerizable fluids or liquids. The PD3DP process enables the supply of pressure to any suitable UV energy polymerizable liquid in the present concept. The liquid or resin may comprise monomers and initiators such as free radical initiators. Examples include acrylics, styrenes and styrene derivatives, olefins, acrylamides, alkenes, maleic anhydride, alkynes, polyfunctional monomers, polyethylene glycol (PEG), diglycyl etherbisphenol A epoxy or other epoxy systems, vegetable oil polymers, biopolymers derived from any natural resource, and composite materials thereof comprising a liquid phase and at least one other phase material. [Examples]

[0108] Examples [000111] Example 1: Open-shell PD3DP printed beverage container and plug. [000112] In this embodiment, an open-shell drinking glass is 3D dynamically printed to demonstrate the usefulness of the PD3DP process, where the dynamic shell is fabricated in open air and is the finished product. The drinking glass is fabricated by being immersed in the fabrication envelope by the overflowing resin collected in a resin storage reservoir. In our embodiment, the separation support is printed in a partition style during printing.

[0109] [000113] In Figure 14, a series of drawings illustrate an exemplary open-shell printing process.

[0110] [000114] In order to start printing the open-shell 3D drinking glass (1412a) and threaded plug (1412b), the build plate entrance is covered with a layer of resin (1421) and the resin is spilled downward (1429) onto the build plate (1410).

[0111] [000115] The dynamically created resin immersion field (1418) enables a molding process that supplies resin to spread over the top of the shell, with the bead perimeter formed and constrained by surface tension.

[0112] [000116] The inward flow of resin into each layer is pumped (1427) to flow downward (1427) in the direction of the build plate (1429) so as to completely fill the glass when it is built (1426).

[0113] [000117] A transparent projection plate (1414) located above the immersion field allows UV exposure (1417) to the support formed during the printing process.

[0114] [000118] The open-shell drinking glass and plug are completed in this case with a removable plug that can be screwed in when printing is complete (1424).

[0115] [000119] Example 2: Closed-shell PD3DP printing of a pyramid [000120] In this embodiment, the 3D pyramid is printed within a closed shell that is formed as the printing progresses. In this method, the resin delivery channels are formed either inside or outside the structure that enables resin delivery. The advantage is that the resin delivery can be constructed so that the part is formed to selectively deliver resin and to enable complex structures such as pyramidal structures and tubular structures.

[0116] [000121] Figure 15 shows the overall closed-shell PD3DP printing process.

[0117] [000122] In Figure 15(A), the build plate is shown in the home position (1518) with the transparent projection plate (1509) above it. Due to the resin coating on the build plate (1506), the build plate moves to the first layer position (1517) and the resin spills over the edges (1519). The immersion field is created as layers are built (1502, 1503, 1504), allowing the pyramid to progress through the build cycle.

[0118] [000123] Figure 15(B) shows a magnified view of the printing of the first layer. In this image, a dynamically printed distribution manifold (1501) indicating that the dipping is the first coating on the build plate is in contact with the resin (1519) covering the build plate, giving detail of the build plate position (1517) in the first layer.

[0119] [000124] Figure 15(C) shows both a side view and a top view of the printing process as it progresses. In the image on the left, the holes passing through the plate can be seen through the transparent projection plate. The hollow pyramid (1507) is dynamically printed through a series of immersion fields created in process (1504).

[0120] [000125] Figure 16 is an enlarged view of the fabrication process when a dynamically PD3DP printed closed shell is made.

[0121] [000126] In Figure 16, the build plate (1603) supports a dynamically printed resin distribution manifold (1602), and the figure being printed (1604) is placed on the printed manifold (1611) with the attached printed resin tubes facing upwards on the sides (1605, 1607).

[0122] [000127] In Figure 16, the next layer is created by a resin immersion field, which is made to hold the resin on the projection surface due to the surrounding surface tension (1609), and the image is projected onto the plate from this position and cured by exposing the photosensitive resin to UV light (1610).

[0123] [000128] Figure 17 shows the resulting hollow pyramid or target material (1707), and the target material separation pipe and manifold are shown in detail (1711).

[0124] [000129] Example 3: Closed-shell PD3DP printing of a drinking glass [000130] In this embodiment, the PD3DP printed beverage container is printed within a closed shell that is formed during part construction. In this method, channels are formed within the structure to deliver resin to locations where the object being built is moving, or to locations located outside the structure. This embodiment demonstrates the construction of a drinking glass in which the resin is pumped from the center outwards, and each continuous layer hardens to form the part while remaining a thin-walled structure.

[0125] [000131] In Figure 18, a drinking glass (1802) is printed from resin delivered vertically (1832) from the main resin inlet (1833) to the immersion field (1807). Once in the immersion field (1807), it is immersed, compressed by the projection plane (1806), and flows out of the immersion field (1831).

[0126] [000132] In Figure 18, for special features, the resin is delivered via an inlet port through dynamically printed piping (manifold, uptube) (1839) to a dynamically made resin tube (1838) that rises upward to the immersion field (1807).

[0127] [000133] In this projection plane (1806), pressure is applied to the immersion field (1807) to push out excess resin from the field (1831), which then moves down to the part, to the build plate, flows over the build plate (1837), and away from it (1811).

[0128] [000134] Figure 19(A) shows a drinking glass (1925) in different states of the PD3DP printing process.

[0129] [000135] In Figure 19(A), the molding plate (1915) has two inlet ports, one of which supplies to the manifold (1933) and the other supply pipe (1913) which goes upward to the immersion field (1916).

[0130] [000136] In Figure 19(A), dynamically constructed resin supply pipes and manifolds (1913) transport the resin to the immersion field (1916), where the projection plate (1922) applies pressure to the UV-exposed layer to create a solid layer, and any excess resin flows down the sides of the object and spills onto the build plate (1939).

[0131] [000137] In Figure 19(B), the resin was supplied using dynamically manufactured resin tubes (1938) to fill the immersion field (1916). Excess resin spilled from the build plate (1911) and flowed downward (1935).

[0132] [000138] In Figure 19(19B), at the end of the molding process for the drinking glass, the molding plate (1915) is lowered with the completed drinking glass attached, while the dynamically manufactured resin supply pipe and manifold (1913) are separate components from the molding plate (1915) and the immersion field (1916).

[0133] [000139] Example 4: Barb fitting for open shell PD3DP printing [000140] In this embodiment, an open-shell PD3DP print of a multi-port barb fitting (2001) is 3D dynamically printed.

[0134] [000141] In Figure 20, the resin is pumped through the molding plate (2010) into an immersion field for the manifold (2018), and, under pressure applied by the projection plane (2016), forms a resin field base support (2003).

[0135] [000142] In Figure 20, the molding process is continued by pumping resin into the immersion field of the lower half of the barb fitting (2017), with a projection plane (2016) applying pressure to each new layer and curing with UV light.

[0136] [000143] In Figure 20, the upper half of the barb fitting is PD3DP printed (2014) from the immersion field, and the barb fitting transitions from four ports to a single port.

[0137] [000144] Example 5: PD3DP filter and filtration device. [000145] PD3DP printing for filters and filtration devices has become a significant need and market. For example, PD3DP printing for water treatment and purification membrane separators has increased rapidly over the past decade. Researchers have begun evaluating 3D printed materials for membrane separation, water treatment, and purification process applications. This stems from the global problem of water scarcity, and solutions may include new membrane technologies (spacers, modules, membrane fabrication), new oil / water separation approaches, and filters for dye capture and catalysts. In water purification, water permeates through a membrane where contaminants such as plastic particles, oil droplets, and solutes are removed by the membrane.

[0138] [000146] By manufacturing a near-ideal porous structure, properties including improved durability, resistance to breakage, antimicrobial and antibacterial properties, and high flow rate at low cost and improved durability can be obtained. Some problems that hinder large-scale adoption include the limited solution of layer height. This is a particularly important limitation for directly fabricating membranes where the layer height and pore diameter of most membranes are at the micron level.

[0139] [000147] Films manufactured with PD3DP have solidification, which results in better mechanical performance. The material and specific PD3DP printing technology determine the resulting properties and performance of the film. Mechanical strength is an important parameter, and PD3DP filters and films must be able to withstand high pressure loads in a variety of harsh environments. This is especially true for wastewater or saline water where pH levels may be extreme or where various impurities are present in the solution.

[0140] [000148] We investigated 3D printed materials for membrane separation, water treatment, and purification process applications. One need is the global shortage of water resources, and solutions may include new membrane technologies (spacers, modules, and membrane fabrication), new oil / water separation approaches, filters for dye capture and catalysts, etc. PD3DP filters and membranes may be useful for such purposes. For example, the applicant used a resin of 1000 cp (0.001 Pa·s / cp) or 1 Pa·s and 0.1 m with each layer of 0.001 m. 2 The film was printed over the area. To calculate the effects of the overall printing speed and pressure, the applicant used the following: Volume (V) = Area (A) * Depth (h) = 0.1 m 2 *0.001m = 0.0001m 3

[0141] [000149] The flow rate (laminar flow) in a narrow gap is determined by the Hagen-Poiseuille equation for laminar flow in a narrow gap between parallel plates. Flow rate (Q)=Δp / (12μ*h)*A 2 (In the formula, Δp = pressure difference across the plate (1000 Pa), μ = viscosity of liquid (1 Pa·s), h = gap thickness (0.001 m), A = Plate area (0.1 m²) 2 ) Substitution of value: Q = 1000 Pa / (12 * 1 Pa·s * 0.001 m) * (0.1 m) 2 ) 2 = 83.3333m 3 / s

[0142] [000150] To calculate the filling time, divide the volume by the flow rate to find the time required to fill the gap. Filling time (t) = Volume (V) / Flow velocity (Q) = 0.0001m 3 / 83.3333m 3 / s =0.000012 seconds

[0143] [000151] This calculated time step is due to the small area, shallow depth, and relatively high pressure. Incorporating factors such as surface roughness, uneven pressure, and temperature will have a significant impact on the filling rate - estimates are up to 1000 times. This indicates that pressure changes directly affect the flow rate, which in turn directly affects the overall filling time and printing speed.

[0144] [000152] This has a more direct impact on the overall filling time and print throughput.

[0145] [000153] Figures 21A-21B show filters fabricated by the pressure-supplied 3D dynamic printing (PD3DP) system described herein. In Figures 21A-21B, canister 2a holds filters 3a, 3b, and the fluid to be filtered passes through port 2b.

[0146] [000154] Example 5: Mixed Mode PD3DP System [000155] In this embodiment, the PD3DP system performs both pressurized PD3DP printing and surface tension PD3DP printing, which are referred to herein as “mixed mode”. Mixed mode PD3DP printing may include the integration of at least one projection panel cartridge for: (1) a pressure projection panel for pressurized PD3DP printing, and (2) a wiper for surface tension printing (in some embodiments, the wiper may be located elsewhere than the projection panel cartridge). This may be advantageous for manufacturing the object, as the wiper may be useful for surface tension-based delivery of the 3D printing material, thereby further facilitating separation from the build plate. Examples include unattached bracing wires, delicate 3D printed films, and filters.

[0147] [000156] In Figure 22, the base plate stand (2218) supports the mounting bracket (2255) attached to the stand.

[0148] [000157] In Figure 22, the electric wiper motor (2245) moves across the z direction (2231).

[0149] [000158] In Figure 22, as the wiper moves across the part, excess resin spills (2251) over the dynamically created shell / object (2252) to the build plate (2253) and back into the resin capture unit (2254).

[0150] [000159] In Figure 22, in the midspan, the wiper moves across a dynamically created shell / object (2252) (2244) in a tightly controlled interface (2235) that terminates at a projected plane frame (2233).

[0151] [000160] In Figure 22, the layer is hardened by energy delivered from the projection source (2223).

[0152] [000161] In Figure 23, the wiper moves across the shell / target (2350), and at the end of one wipe, the wiper is at the stopping position of one swipe (2349).

[0153] [000162] In Figure 23, the projection source (2323) delivers energy through the transparent projection panel (2346) to harden the layer.

[0154] [000163] All terms used herein are used in their ordinary sense unless the context or definition explicitly indicates otherwise. Unless explicitly indicated otherwise, the use of “or” herein includes “and” and vice versa. Non-restrictive terms should not be construed as restrictive unless explicitly stated or clearly indicated in the context (for example, “include,” “have,” and “contain” typically mean “include without limitation”). Singular nouns in the claims, including “one (a),” “one (an),” and “it,” include plural nouns unless explicitly stated or clearly indicated in the context.

[0155] [000164] Unless otherwise specified, any adjectives herein, such as “substantially” and “about,” that modify a condition or relational feature of one or more features of an embodiment indicate that the condition or feature is defined within a tolerance acceptable to the operation of the embodiment for the intended use.

[0156] [000165] The scope of this device, system and method includes both the concepts of means and function and steps and function. However, the claims should not be interpreted as indicating a means-function relationship unless the word “means” is specifically described in the claims, and should be interpreted as indicating a means-function relationship unless the word “means” is specifically described in the claims. Similarly, the claims should not be interpreted as indicating a step-function relationship unless the word “step” is specifically described in the claims, and should be interpreted as indicating a step-function relationship unless the word “step” is specifically described in the claims.

[0157] [000166] From the above, it will be understood that although specific embodiments have been discussed herein for illustrative purposes, various modifications may be made without departing from the spirit and scope of the discussion herein. Accordingly, systems and methods, etc., including all such modifications and all substitutions and combinations of the subject matter described herein, are not limited by the drawings herein. Accordingly, these and other aspects, features and embodiments are described herein. Unless otherwise specified, all embodiments, aspects, features, etc., may be mixed and adapted, combined and substituted in any desired manner. In addition, any references, including those in cross-references to related applications, that discuss specific systems, apparatus, methods and other information are described herein, and all such references, regardless of where in this application they appear, are incorporated herein by reference in whole and in all teachings and disclosures.

Claims

1. A pressure-supplied 3D dynamic printing (PD3DP) system having a pressure projection panel positioned between a curing energy source and an inlet port for 3D printing material in the build area, The process includes a computer implementation program for selectively and periodically pressing the pressure projection panel and the 3D printing material against each other and releasing them from each other within the build area, in conjunction with the layer-by-layer printing of at least one object within the build area. Pressure-feed 3D dynamic printing (PD3DP) system.

2. The pressure-supplied 3D dynamic printing (PD3DP) system according to claim 1, wherein the build area includes a build plate on the opposite side of the build area from the pressure projection panel, the projection panel and the build plate are selectively and controllably movable relative to each other layer by layer in the z-axis according to a command provided to at least one of the projection panel and the build plate, and the projection panel selectively applies at least one of positive and negative pressure to the resin according to the command when resin is applied to the layers of the object being printed in the build area.

3. The pressure-supplied 3D dynamic printing (PD3DP) system according to claim 2, wherein both the positive pressure and the negative pressure are selectively applied.

4. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 3, wherein the computer implementation programming selectively applies pressure to create an immersion field within the object or at least one of a surrounding shell completely enclosing the object, the immersion field containing liquid 3D printing material up to at least approximately the top of the object or the surrounding shell.

5. The computer implementation programming selectively applies pressure to create a peripheral bead of liquid 3D printing material on top of the immersion field, the peripheral bead being held in place by surface tension, according to claim 4, for the pressure-supplied 3D dynamic printing (PD3DP) system.

6. The computer implementation programming selectively directs the 3D print pattern from the curing energy source to the top of the 3D print material in the pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 5.

7. The computer implementation programming selectively directs the 3D printing pattern from the curing energy source to the top of the 3D printing material in stages, thereby continuously forming the target object layer by layer, according to claim 2 of the pressure-supplied 3D dynamic printing (PD3DP) system.

8. The inlet port traverses the build plate in the pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 7.

9. The pressure projection panel is transparent, according to any one of claims 1 to 8, for the pressure-supplied 3D dynamic printing (PD3DP) system.

10. The pressure projection panel is flexible, according to the pressure-supplied 3D dynamic printing (PD3DP) system of any one of claims 1 to 9.

11. The pressure projection panel is low friction, according to the pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 10.

12. The pressure projection panel is transparent, flexible, and low-friction, according to any one of claims 1 to 11, for the pressure-supplied 3D dynamic printing (PD3DP) system.

13. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 12, wherein the 3D printing material is a liquid photosensitive resin that hardens and becomes solid when exposed to appropriate activation light from the curing energy source.

14. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 13, wherein the curing energy source is a light delivery source.

15. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 14, wherein the curing energy source is an ultraviolet light delivery source.

16. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 15, wherein the curing energy source is a heat delivery source.

17. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 16, wherein the curing energy source is an iris diaphragm heat radiation source.

18. The pressure-supplied 3D dynamic printing (PD3DP) system according to claim 17, comprising a thermal management system for rapid cooling and heating by the heat radiation source.

19. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 18, wherein the curing energy source is an electron beam source.

20. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 19, wherein the curing energy source delivers non-visible directional energy.

21. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 20, wherein the computer implementation programming includes instructions for combining the pressure applied to the 3D printing material, the layer thickness, the energy delivered to the uncured 3D printing material, and the timing of the release of the build plate from the pressure projection panel.

22. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 21, comprising a reversible pump for delivering the 3D printing material to the build area.

23. The pressure-supplied 3D dynamic printing (PD3DP) system according to claim 22, wherein the computer implementation programming controls the reversible pump to deliver resin to the build area at a controlled micrometer level.

24. The pressure-supplied 3D dynamic printing (PD3DP) system according to claim 23, wherein the computer implementation programming controls the resin delivery by the reversible pump to control the pressure within the 3D printing material.

25. A pressure-feed 3D dynamic printing (PD3DP) system according to any one of claims 1 to 24, comprising a 3D material capture system for capturing and repositioning unused 3D printing material.

26. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 25, wherein the computer implementation programming instructs the pressure projection panel to press the 3D printing material after the layer of the 3D printing material has been introduced into the build area and before curing energy is directed to the new layer of the 3D printing material.

27. A pressure-supplied dynamic 3D printing (PD3DP) system according to any one of claims 1 to 9, wherein the build plate is moved toward and away from the pressure projection panel as part of the delivery of 3D printing material to the build area and the release of cured 3D printing material from the pressure projection panel.

28. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 27, wherein the positive pressure and negative pressure are achieved by adding 3D printing material to the build area or by reversing the direction of its flow.

29. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 28, which lacks an existing print vat within the build area.

30. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 29, which lacks a permanent print vat within the build area.

31. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 30, further holding within the build area an object printed by the PD3DP system, at least partially dynamically printed.

32. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 31, wherein the computer implementation programming includes instructions for printing an object.

33. The pressure-fed 3D dynamic printing (PD3DP) system according to claim 32, wherein the computer implementation programming includes instructions to print an object and not to print any surrounding structures.

34. The pressure-fed 3D dynamic printing (PD3DP) system according to claim 33, wherein the outer surface of the object does not have any unintended bumps, flushes, or ridges extending more than 0.1 mm from the outer surface.

35. The pressure-supplied 3D dynamic printing (PD3DP) system according to claim 34, wherein the outer surface of the object does not have surface artifacts extending beyond 0.01 mm from the outer surface.

36. The pressure-fed 3D dynamic printing (PD3DP) system according to claim 35, wherein the surface artifact is at least one of an unintended bump, flash, or ridge.

37. The pressure-fed 3D dynamic printing (PD3DP) system according to claim 32, wherein the computer implementation programming includes instructions to print the object within a surrounding shell that completely encloses the object.

38. A pressure-supplied 3D dynamic printing (PD3DP) system according to claim 37, wherein dynamically generated non-vertical guy wires hold the object in the surrounding shell.

39. The pressure-supplied 3D dynamic printing (PD3DP) system according to claim 38, wherein the dynamically produced non-vertical guy wires have a diameter of approximately 200 μm or less.

40. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 37 to 39, wherein the surrounding shell and the object are made from the same 3D printing material.

41. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 37 to 39, wherein the surrounding shell and the object each comprise different 3D printing materials.

42. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 41, wherein the surrounding shell further holds at least one dynamically manufactured auxiliary structure.

43. The pressure-supplied 3D dynamic printing (PD3DP) system according to claim 42, wherein the auxiliary structure includes piping that guides the printing material from a first location within the enclosing shell to a second location within the enclosing shell.

44. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 43, relating to the process of creating the aforementioned object.

45. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 44, comprising a top-down stereolithography (SLA) or digital light projection (DLP) system capable of 3D printing the object from a photosensitive liquid resin.

46. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 45, comprising a bottom-up stereolithography (SLA) or digital light projection (DLP) system capable of 3D printing the object from a photosensitive liquid resin.

47. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 46, comprising a plurality of inlet ports for supplying 3D printing material to the surrounding shell, each inlet port supplying a different 3D printing material.

48. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 47, comprising a plurality of inlet ports for supplying 3D printing material to the surrounding shell, each inlet port supplying the same 3D printing material.

49. The pressure-supplied 3D dynamic printing (PD3DP) system according to claim 48, wherein the different 3D printing materials are different photosensitive resins.

50. The pressure projection panel is made of glass or transparent polytetrafluoroethylene, according to any one of claims 1 to 49, for a pressure-supplied 3D dynamic printing (PD3DP) system.

51. The pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 50, wherein the computer implementation programming includes instructions to pump resin between the build platform and the pressure projection panel at a positive pressure of approximately 70 to 140,000 Pascals.

52. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 51, which does not have a wiper.

53. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 52, comprising a wiper.

54. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 53, comprising a projection panel cartridge including a wiper.

55. The projection panel cartridge is removable, in the pressure-supplied 3D dynamic printing (PD3DP) system according to claim 54.

56. A pressure-fed 3D dynamic printing (PD3DP) system according to any one of claims 1 to 55, comprising at least two projection panel cartridges, one having a wiper and the other without a wiper being removable.

57. The computer implementation programming instructs the printing of multiple objects and multiple surrounding shells in the pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 1 to 56.

58. A method comprising manufacturing the system described in any one of claims 1 to 57.

59. A method comprising using the system described in any one of claims 1 to 57.

60. Object printed by pressure-fed 3D dynamic printing (PD3DP).

61. The object according to claim 60, located within the pressure-supplied 3D dynamic printing (PD3DP).

62. The object according to claim 61, which is not located within the surrounding shell in the PD3DP system.

63. The object according to claim 61, located within the surrounding shell in the PD3DP system.

64. The object according to any one of claims 61 to 63, wherein it does not have any unintended protrusions, flushes, or ridges extending more than 0.1 mm from the outer surface of the object.

65. The object according to any one of claims 61 to 64, which is an open shell.

66. The object according to claim 65, wherein the open shell is a drinking glass.

67. The object according to any one of claims 61 to 66, which is a closed shell.

68. A filter, the object according to any one of claims 61 to 67.

69. A method for printing an object layer by layer via pressure-supplied 3D dynamic printing (PD3DP), a) To provide a PD3DP system, b) Printing the target object using PD3DP within the PD3DP system A method comprising selectively and intermittently pressing and releasing a pressure projection panel onto uncured 3D printing material layer by layer to assist in the formation of the object.

70. The method according to claim 69, wherein the computer implementation programming instructs the pressure projection panel to press the 3D printing material after the layer of the 3D printing material has been introduced into the build area and before curing energy is directed to the new layer of the 3D printing material.

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

72. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 69 to 71, wherein the build plate is moved toward and away from the pressure projection panel to perform the pressing and release of the 3D printing material.

73. A pressure-supplied 3D dynamic printing (PD3DP) system according to any one of claims 69 to 72, wherein the PD3DP system does not have an existing print vat within the build area.

74. The method further comprises simultaneously PD3DP printing a surrounding shell around the object, according to any one of claims 69 to 73, for a pressure-supplied 3D dynamic printing (PD3DP) system.

75. a) Printing the guy wires that connect the surrounding shell and the target object. The method according to claim 74, further comprising:

76. The method according to claim 74 or 75, further comprising PD3DP printing at least one auxiliary structure within the internal space of the surrounding shell.

77. The method according to claim 76, wherein the auxiliary structure includes a pipe for guiding printing material from a first location within the enclosing shell to a second location within the enclosing shell, and the method further includes feeding the printing material through the pipe from the first location within the enclosing shell to the second location during the printing of the enclosing shell and the object.

78. The method according to claim 76, wherein the auxiliary structure includes a manifold.

79. The method according to claim 76, wherein the auxiliary structure includes at least one of a baffle, a partition, an angled support, and stacked objects.

80. The method according to claim 79, wherein the baffle, partition, angled support or stacked object is supported by vertical anchors.

81. The method according to claim 77, wherein the piping includes at least one of a pipe, elbow, splitter, joint, reservoir, expansion chamber, limiter, flow-through gap, ballast chamber, concentric geometric shape, diffusion plate, or on-demand valve.

82. The method according to any one of claims 69 to 81, further comprising removing the object from the PD3DP system.

83. The method according to any one of claims 74 to 82, further comprising removing the object from the surrounding shell.

84. The method according to any one of claims 69 to 83, wherein the PD3DP system includes a reversible pump, and the method further includes operating the reversible pump in reverse before directing curing energy to the new layer of the 3D printed material.

85. The method according to claim 84, wherein the reversible pump described above is a micro-metering reversible pump.

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