Composite additive and subtractive manufacturing methods and apparatus for photopolymerizable resins

Abstract

According to embodiments of the present invention, a method is provided for fabricating a three-dimensional object by additive manufacturing, the method comprising the steps of: exposing the excess material (13a) on the three-dimensional object to a dose of ablation / laser light (42) sufficient to remove the excess material; exposing the construction surface of the three-dimensional object to ablation / laser light to physically and / or chemically modify the construction surface; and / or exposing a portion of a resin-coated film to a dose of ablation / laser light sufficient to eject resin onto the bottom surface of the three-dimensional object. Related apparatus is also provided.

Description

Technical Field

[0001] Related Applications This application claims priority to U.S. Provisional Application No. 63 / 491,619, filed on March 22, 2023, the disclosure of which is hereby incorporated by reference in its entirety.

[0002] This specification describes additive manufacturing methods and apparatuses, particularly methods and apparatuses for forming three-dimensional objects from a curable resin.

Background Art

[0003] Various additive manufacturing methods for forming 3D objects from a viscous photocurable resin are known. Examples include methods (and corresponding apparatuses) where the resin is applied to a movable light-transmissive film or, by a roller, to the build surface of a growing 3D object to create a continuous resin slice as a "build zone" and a new area of non-polymerized resin (i.e., a "build segment"). Then, patterned light is projected through the film or onto the roller-coated area, either bottom-up or top-down, to continuously polymerize the build segment in this case as well, forming a 3D object (see, e.g., U.S. Pat. Nos. 11,192,302, 10,792,868, 9,862,146, 8,905,739, 5,650,260, and No. 5,637,169, and further see BCN3D's PCT Publication WO2021 / 180997).

[0004] The problem with such methods is that after the 3D object is formed, residual resin remains on its surface in an irregular or non-uniform state and must therefore be removed by a cleaning process such as washing or centrifugation. Often, the higher the viscosity of the resin (and in some applications, a highly viscous resin is preferable), the more vigorous the cleaning process must be. This not only adds an additional (and sometimes time-consuming and very cumbersome) step to the manufacturing process, but the cleaning process itself can damage the 3D object by extracting key chemical components from the object through cleaning solutions, the application of physical force to the object, or a combination thereof. Therefore, there is a need for new additive manufacturing methods using polymerizable resins that do not require a vigorous post-manufacturing cleaning step. [Overview of the Initiative]

[0005] Embodiments of the present invention relate to methods for producing three-dimensional objects by additive manufacturing. In some embodiments, the method includes: (a) forming a construction segment by applying a photopolymerizable resin to a construction surface of a growing three-dimensional object, wherein the application is carried out by a moving roller resin applicator or a moving film resin applicator; (b) forming a new construction surface by exposing the construction segment to patterned light to polymerize the construction segment, wherein the new construction surface has a margin, which holds excess polymerized or nonpolymerized material; (c) exposing the excess material to ablation light (e.g., laser light) at a dose (i.e., exposure pattern, wavelength, intensity, and duration) sufficient to remove the excess material from the margin (e.g., by ablation or melting); and (d) a series of repeating steps (a) to (c) until a three-dimensional object is formed, wherein step (c) is optionally omitted from some of the series of repeating steps but is included in at least some of the series of repeating steps.

[0006] In some embodiments, the excess material includes a polymerized resin.

[0007] In some embodiments, the excess material includes a non-polymerized resin.

[0008] Additional embodiments of the present invention relate to methods for producing three-dimensional objects by additive manufacturing. In some embodiments, the method includes: (a) forming a construction segment by applying a photopolymerizable resin to a construction surface of a growing three-dimensional object, wherein the application is carried out by a moving roller resin applicator or a moving film resin applicator; (b) polymerizing the construction segment by exposing it to patterned light to form a new construction surface; (c) physically and / or chemically modifying the new construction surface by exposing it to ablation light (e.g., laser light); and (d) continuously repeating steps (a) to (c) until a three-dimensional object is formed, wherein step (c) is optionally omitted from some of the continuously repeating steps but is included in at least some of the continuously repeating steps.

[0009] In some embodiments, the exposure step (c) is carried out with a dose (i.e., exposure pattern, wavelength, intensity, and duration) that textures at least a portion (e.g., most) of the new construction surface (e.g., the pattern is configured to enhance the adhesion of the next construction segment to the new construction surface).

[0010] In some embodiments, the photopolymerizable resin comprises an additive (e.g., a thermoplastic material such as nylon powder, natural or synthetic rubber, or ceramic particles), and the exposure step (c) is carried out at a dose (i.e., exposure pattern, wavelength, intensity, and duration) that selectively melts or sintersects the additive on at least a portion (e.g., most) of the new construction surface (e.g., to form a co-continuous secondary material network) and modifies the material properties of the three-dimensional object (e.g., to increase toughness and / or to promote interlayer adhesion, strength, or toughness).

[0011] In some embodiments, the photopolymerizable resin is a dual-cure resin comprising a first polymerizable component and a second polymerizable component, and the exposure step (c) is carried out with a dose (i.e., exposure pattern, wavelength, intensity, and duration) that initiates polymerization of the second polymerizable component on at least a portion (e.g., the majority) of the new construction surface to modify the mechanical properties of the three-dimensional object (in some embodiments, these exposure doses can be patterned spatially and / or temporally to control and modify the spatial distribution of material properties in the three-dimensional object).

[0012] In some embodiments, the exposure step (c) is carried out with a dose (i.e., exposure pattern, wavelength, intensity, and duration) that modifies material properties (e.g., modify the glass transition temperature) on at least a portion (e.g., a large portion) of the new construction surface (e.g., to modify the internal stress within the object and thereby modify the geometry of the final object).

[0013] In some embodiments, the exposure step (c) is carried out with a dose (i.e., exposure pattern, wavelength, intensity, and duration) that activates a surface chemical on at least a portion (e.g., a large portion) of the new construction surface (e.g., to modify the glass transition temperature) (e.g., to promote adhesion, alter surface energy, and / or control the wettability of the resin).

[0014] In some embodiments, the photopolymerizable resin comprises a filler (e.g., pologen or microballoons), and the exposure step (c) is carried out at a dose (i.e., exposure pattern, wavelength, intensity, and duration) that selectively expands the filler on at least a portion (e.g., most) of the new construction surface (e.g., thereby preventing shrinkage and / or warping of the object).

[0015] In some embodiments, the photopolymerizable resin includes a filler (a solid filler, such as a fiber filler, a spherical filler, or an oval filler).

[0016] In some embodiments, the filler is a solid particle filler comprising glass fibers, carbon fibers, aramid fibers, basalt fibers, thermoplastic or thermosetting polymer fibers (e.g., polyamide, cellulose, or nanocellulose fibers).

[0017] In some embodiments, the photopolymerizable resin has a viscosity of 1,000, 2,000, 10,000, or 20,000 centipoise or more at 25 degrees Celsius and 1 atmosphere.

[0018] In some embodiments, the photopolymerizable resin has a viscosity of 100,000 centipoise to 1,000,000 or 2,000,000 centipoise or more at 25 degrees Celsius and 1 atmosphere.

[0019] In some embodiments, the coating step is carried out by a bottom-up or top-down additive manufacturing apparatus.

[0020] In some embodiments, the applying step is performed by a moving roller resin applicator.

[0021] In some embodiments, the applying step (a) is performed by a moving film resin applicator (e.g., the moving film is a light-transmissive film, and patterned light and optionally ablation light are projected through the moving film).

[0022] In some embodiments, the ablation light is laser light.

[0023] In some embodiments, the laser light is a dose absorbed by the extra material and / or the new build surface in a single-photon absorption process or a multi-photon absorption process.

[0024] In some embodiments, the laser light is delivered as a shaping beam to the extra material and / or the new build surface.

[0025] In some embodiments, the laser light is delivered as a continuous wave or pulsed laser beam to the extra material and / or the new build surface.

[0026] In some embodiments, the method further includes detecting the current characteristics of the ablation light (e.g., focal field, focal distance, wavelength, intensity), comparing the current characteristics with the desired characteristics (e.g., focal field, focal distance, wavelength, intensity), and changing the ablation light so that the current characteristics more closely correspond to the desired characteristics.

[0027] Additional embodiments of the present invention are directed to three-dimensional objects made by the methods described herein.

[0028] Additional embodiments of the present invention are directed to an apparatus for additively manufacturing a three-dimensional object from a photopolymerizable resin. The apparatus includes: (a) a construction platform on which a growing three-dimensional object can be created, the object having construction segments, the construction segments including edges and a construction surface, the construction platform; (b) an applicator configured to apply a photopolymerizable resin to the construction surface to form a new construction segment including a new edge and a new construction surface, the applicator including a moving roller resin applicator or a moving film resin applicator; (c) a resin supply configured to apply a photopolymerizable resin to the applicator; (d) a first additional light source configured to polymerize the photopolymerizable resin on the construction segment; and (e) a second subtractive light source configured to deliver a dose of light to the edge and / or the construction surface and includes.

[0029] In some embodiments, the subtractive light source includes an ultraviolet (UV) light source, a vacuum UV light source, a deep UV light source, and / or a high-intensity infrared (IR) light source.

[0030] In some embodiments, the subtractive light source includes a laser (e.g., a gas laser, a solid laser, a fiber laser, a liquid laser, or a semiconductor laser).

[0031] In some embodiments, the applicator includes a moving roller resin applicator.

[0032] In some embodiments, the applicator includes a moving film resin applicator.

[0033] In some embodiments, the moving film resin applicator is light transmissive and the first light source projects through the moving film resin applicator.

[0034] In some embodiments, the subtractive light source projects through the moving film resin applicator.

[0035] In some embodiments, the negative light source does not project through the moving film resin applicator (for example, by positioning it on the opposite side of the moving film resin applicator from the additional light source, or by positioning it adjacent to the moving film resin applicator so that the moving film resin applicator is not located between the construction platform and / or the growing three-dimensional object).

[0036] In some embodiments, the apparatus further includes a detector operably coupled to a rejection light source and configured to detect the current characteristics of the rejection light (e.g., focal field, focal length, wavelength, intensity), and a controller operably coupled to the detector and the rejection light source and configured to compare the current characteristics with desired characteristics (e.g., focal field, focal length, wavelength, intensity) and to change the rejection light so that the current characteristics more closely correspond to the desired characteristics.

[0037] In some embodiments, the rejection (e.g., laser) light source includes a continuous-wave light source or a pulsed laser light source, a single-beam light source or a multi-beam light source, a self-contained laser or an optical fiber laser, and / or a single-wavelength light source or a multi-wavelength light source.

[0038] In some embodiments, the rejective (e.g., laser) light source further includes a laser trepanning system, an XY stage for scanning or raster scanning of the laser beam, a beam expander, mirrors, focusing lenses and / or Z-focusing elements such as air assist, motorized focusing mechanisms, additional optical elements including optical fiber elements, diffractive optical elements and / or beam splitters, beam focusing elements (e.g., f-theta lenses, motor-driven z-focusing elements, etc.), and / or beam shaping elements (e.g., refractive beam shaping elements, diffractive beam shaping elements, laser beam integrators, axicons for generating Bessel beams, cylindrical lenses, and pairs of anamorphic prisms for making the beam circular, etc.).

[0039] While polymer laser ablation is discussed in S. Ravi-Kumar et al., "Procedia Manufacturing", 34, 316-327 (2019), incorporating polymer laser ablation into the methods and apparatus described herein is neither proposed nor disclosed.

[0040] A method for producing a three-dimensional object by additive manufacturing is also provided, which includes (a) forming a three-dimensional object on a construction platform; (b) positioning a resin-coated film beneath the three-dimensional object, wherein the resin-coated film may be in contact with the three-dimensional object, or a gap may exist between the resin-coated film and the three-dimensional object; (c) exposing a portion of the resin-coated film to sufficient laser radiation (e.g., UV, visible, or IR laser light using a secondary light source) to eject at least a portion of the resin onto the bottom surface of the three-dimensional object; (d) polymerizing the ejected resin on the bottom surface of the three-dimensional object by exposing it to chemical radiation or chemical light using an additive light source; and (e) continuously repeating steps (b) to (d). The ejection of the resin can be achieved using a number of methods, including a direct jetting method or a blister transfer method.

[0041] The above and other objects and aspects of the present invention will be described in more detail in the drawings and the specification described herein later. All disclosures of U.S. patent documents referenced herein are incorporated herein by reference. [Brief explanation of the drawing]

[0042] [Figure 1A] This figure schematically illustrates a prior art method and apparatus in which a new construction segment is exposed to patterned light. [Figure 1B]Figure 1A schematically shows a prior art method and apparatus in which a new construction segment is polymerized and advanced toward the resin applicator film. [Figure 2A] This figure schematically illustrates the method and apparatus described herein, in which a new construction segment is exposed to patterned light. [Figure 2B] Figure 2A schematically illustrates the method and apparatus in which a new construction segment is polymerized and advanced away from the resin applicator film. [Figure 2C] Figures 2A and 2B schematically illustrate the method and apparatus used, in which excess material on the edges of a new construction segment is removed by laser light from a second (laser) light source. [Figure 2D] Figures 2A and 2B schematically illustrate the method and apparatus used, in which excess material on the edges of a new construction segment is removed by laser light from a second (laser) light source. [Figure 2E] Figures 2A and 2B schematically illustrate the method and apparatus used, in which excess material on the edges of a new construction segment is removed by laser light from a second (laser) light source. [Figure 2F] Figures 2A to 2E schematically illustrate the method and apparatus in which the construction surface of a new construction segment is treated by a second laser light source. [Figure 2G] Figures 2A to 2E schematically illustrate the method and apparatus in which the construction surface of a new construction segment is treated by a second laser light source. [Figure 2H] Figures 2A–2G schematically show the method and apparatus, with the new construction segment ready for exposure to patterned light (i.e., repetition of the steps shown in Figure 2A). [Figure 3] This figure schematically illustrates an alternative embodiment of the method and apparatus described herein, in which the second laser light source is positioned so that it does not need to be projected through a film resin applicator. [Figure 4A]This figure schematically illustrates additional alternative embodiments of the method and apparatus described herein, in which the film applicator advances across the construction surface of a growing three-dimensional object by lateral movement of the carrier platform (dashed arrow), lateral movement of the film applicator carrier assembly (dashed arrow), or both. [Figure 4B] This figure shows an embodiment of Figure 4A in which excess material on the leading edge of a new construction segment is removed by laser light from a second light source. [Figure 4C] This figure shows the embodiment shown in Figures 4A-4B, where the construction surface of a new construction segment is being processed by a second laser light source. [Figure 4D] Figures 4A to 4C show embodiments in which excess material on the trailing edge of a growing three-dimensional object is removed by laser light from a second light source. [Figure 5A] This figure schematically illustrates an alternative embodiment of the present invention, in which the device is configured to eject resin from a resin-coated film onto a three-dimensional object using laser light. [Figure 5B] This figure schematically shows the embodiment of Figure 5A after the laser beam has been ejected onto a three-dimensional object. [Modes for carrying out the invention]

[0043] The present invention will be described in more detail below with reference to the accompanying drawings illustrating embodiments of the invention. However, the present invention can be carried out in many different forms and should not be construed as being limited to the embodiments described herein, and these embodiments are provided to make this disclosure thorough and complete and to fully convey the scope of the invention to those skilled in the art.

[0044] In this specification, the term "and / or" includes any possible combination of one or more of the enumerated items relating to the subject, as well as the absence of any combination when interpreted as an alternative ("or").

[0045] 1. Additive manufacturing resins and equipment resin To carry out the present invention, any suitable resin containing monomer and / or prepolymer components that can be cured by chemical rays or chemical light, particularly UV light, can be used. Examples include, but are not limited to, those described in U.S. Patents 9,360,757 and 9,211,678 by DeSimone et al. In some embodiments, the resin includes, but is not limited to, dual-cure resins, including those described in U.S. Patents 9,676,963 and 9,598,606 by Rolland et al.

[0046] In some embodiments, the resin includes a high-viscosity resin. For example, in some embodiments, the resin has a viscosity of 1,000 or 2,000, 10,000, 20,000 centipoise or more, and a maximum of 100,000 or 200,000 centipoise or more, at 25 degrees Celsius and 1 atmosphere (i.e., “standard conditions”). In some embodiments, the resin has a viscosity of 100,000 centipoise to 1,000,000 or 2,000,000 centipoise or more, at 25 degrees Celsius and 1 atmosphere.

[0047] In some embodiments, the resin contains a substantial amount of filler (e.g., at least 10, 20, 30, or 40 volume percent filler, up to 80 volume percent filler). Preferred fillers include, but are not limited to, solid fiber fillers, spherical fillers, oval fillers, etc. In some embodiments, the filler is a solid particle filler, but is not limited to, glass fibers, carbon fibers, aramid fibers, basalt fiber fillers, thermoplastic and thermosetting polymer fibers (e.g., polyamide, cellulose, or nanocellulose fibers, etc.). See, for example, V. Dhand et al., "A short review on basalt fiber reinforced polymer composites," Composites Part B: Engineering 73, 166-180 (2015), and A. Dufresne, "Nanocellulose: a new ageless bionanomaterial," Materials Today 16, 220-227 (June 2013). In some embodiments, the filler includes pologen or microballoon filler, such as those described in Poelma's U.S. Patent No. 11,292,186.

[0048] Applicator device with additional light source The methods described herein can be carried out by various additive manufacturing apparatuses as basic apparatuses, which are further modified to include a second removeive or ablation light source and additional features described herein. Examples of suitable basic apparatuses, but not limited to them, include coating a movable light-transmitting film with resin and further coating the construction surface of the growing 3D object from the film with resin to form continuous resin slices that constitute "construction zones," thereby forming new construction segments. In some embodiments, the film may be an oxygen-permeable semi-permeable film. Patterned light is then projected from a first light source (i.e., an additive light source) into the construction segments (through the film, in some embodiments) in a bottom-up or top-down manner to repeatedly and sequentially polymerize the construction segments and form a 3D object. Examples of such apparatuses are disclosed in U.S. Patent No. 10,792,868 (Carbon, Inc.), No. 9,862,146 (DSM), No. 8,905,739 (TNO), No. 5,650,260 (Teijin), and No. 5,637,169 (3D Systems), as well as in PCT Publication WO2021 / 180997 (BCN3D). In some embodiments, the apparatus may be such that a roller, rather than a light-transmitting film, applies resin to the construction platform or growing 3D object. All disclosures in these references are incorporated herein by reference as a whole.

[0049] Ablation light source Suitable reductive or ablation light sources for use in combination with the above-described apparatus include, but are not limited to, laser light sources, ultraviolet (UV) light sources, vacuum UV light sources, deep UV light sources, and high-intensity infrared (IR) light sources, and combinations thereof.

[0050] Examples of suitable laser-removal light sources, though not limited to these, include gas lasers (e.g., CO2 lasers, helium-neon lasers, argon lasers, krypton lasers, or excimer lasers), solid-state lasers (e.g., ruby ​​lasers, Nd:YAG lasers), fiber lasers (e.g., ytterbium or erbium-doped fiber lasers), liquid lasers (also known as dye lasers, including tunable lasers), or semiconductor lasers (e.g., diode lasers, quantum cascade lasers, optically pumped semiconductor lasers, etc.). Specific examples include CO2 lasers; excimer lasers such as KrF 248nm, ArF 193nm, XeCl, or XeF; and YAG lasers such as 355nm frequency 3x YAG and 266nm frequency 4x YAG.

[0051] The laser light source can include a continuous-wave light source or a pulsed laser light source. In some embodiments, short-pulse lasers, including nanosecond, picosecond, and femtosecond pulsed lasers, are preferred to reduce the heat-affected zone (HAZ). The laser light source may be a single-beam light source or a multi-beam light source, a self-standing laser or an optical fiber-based laser, and may include a single-wavelength light source or a multi-wavelength light source. The laser light source can be selected based on the resin to be coated so that the resin absorbs single or multiple photons in order to control, for example, speed, resolution, and / or HAZ.

[0052] A laser light source can take any of a variety of configurations and may include any of the various features known in the art. For example, a laser light source may include a laser trepanning system and apparatus. A laser light source may include an XY stage for scanning or raster scanning of the laser beam, a beam expander, mirrors, focusing lenses, and / or air assists, a Z-focusing element such as an electric focusing mechanism, additional optical elements such as optical fibers, diffractive optical elements, and beam splitters; elements for focusing the laser beam, including but not limited to f-theta lenses and motor-driven z-focusing elements; laser beam shaping elements such as refractive beam shaping elements, diffractive beam shaping elements, laser beam integrators, axicons for generating Bessel beams, cylindrical lenses, and pairs of anamorphic prisms for making the beam circular, etc. A light source may include combinations of the above elements known in the art.

[0053] Suitable laser light sources and / or components that may be included in the rejection light sources described herein include U.S. Patent No. 6,864,459 (Lawrence Livermore), No. 8,673,745 (Hamamatsu Photonics; multiphoton absorption), No. 9,701,564 (Corning), No. 10,058,953 (Trumpf), No. 10,300,555 (Trumpf), No. 10,312,659 (Coherent), No. 10,343,237 (IPG Photonics), No. 10,444,597 (Coherent), No. 11,014,194 (Coherent), No. 11,364,572 (IPG Photonics), and No. 11,534,858 (IPG Further details are provided in Photonics, No. 11,548,093 (Coherent), and U.S. Patent Publication No. US2022 / 0390713 (Trumpf, "optical arrangement with an f-theta lens"), and U.S. Patent Publication No. US2022 / 0360036 (Trumpf), all of which are incorporated herein by reference as if they were all described in full. See also S. Ravi-Kumar et al., "Laser Ablation of Polymers: A Review," Procedia Manufacturing 34, 316-327 (2019).

[0054] In addition to the above, suitable remover laser light sources and / or components are commercially available from companies such as Coherent, INC., 5100 Patrick Henry Drive, Santa Clara, CA 95054 USA; IPG Photonics, 50 Old Webster Road, Oxford, MA 01540 USA; TRUMPF SE+Co.KG, Johann-Maus-Strasse 2, 71254 Ditzingen, Germany; AMPLITUDE LASER GROUP, Cite de la Photonique, 11 Ave. de Canteranne, 33600, Pessac, France; and LASERAX USA, 2401 Parkman Rd.NW, Warren, OH 44485 USA.

[0055] Apparatus having a combined cooperative additional light source and a removal light source As an introduction, Figures 1A to 1B show prior art apparatuses, and their embodiments may be included in the apparatus of the present invention. A first embodiment of the apparatus of the present invention is shown in Figures 2A to 2E, and this series of figures illustrates one embodiment of the method described herein. A second embodiment of the apparatus is shown in Figure 3, and a third embodiment of the apparatus is shown in Figures 4A to 4D, and again, this series of figures illustrates one embodiment of the method described herein. A fourth embodiment of the apparatus is shown in Figures 5A to 5B, and this series of figures illustrates one embodiment of the method described herein. Throughout these figures, common features are referred to by the same reference numerals. In these figures, the apparatus is shown in a “bottom-up” configuration, but it should be noted that the orientation of these apparatuses can be reversed or “inverted” to a “top-down” orientation.

[0056] In summary, the apparatus for additionally manufacturing three-dimensional objects from the photopolymerizable resin described herein is: (a) A construction platform 11 capable of fabricating a growing three-dimensional object 12, wherein the object has a construction segment 13, and the construction segment includes an edge 13a and a construction surface 13b, (b) An applicator 30, described later, configured to apply a photopolymerizable resin 21 to the construction surface to form a new construction segment including the edge and the construction surface, wherein the applicator includes a moving roller or a moving film resin applicator, (c) A resin supply unit 31 configured to apply a photopolymerizable resin to the applicator, (d) A first additional light source 41 configured to polymerize the resin within the construction segment, (e) A second rejection light source 42 configured to deliver a dose of light to the edges and / or construction surfaces It can include...

[0057] In various figures, excess material or residual resin 12a adhering to the edge 13a is shown and will be discussed further below in relation to the method.

[0058] In some embodiments, the applicator includes a movable roller resin applicator (not shown), such as that described in U.S. Patent No. 11,192,302 (Carbon, Inc.), the disclosure of which is incorporated herein by reference in whole.

[0059] In other embodiments, such as those shown in Figures 2A to 4D, the applicator includes a moving film resin applicator. Examples of such applicators are disclosed in U.S. Patent No. 10,792,868 (Carbon, Inc.), No. 9,862,146 (DSM), No. 8,905,739 (TNO), No. 5,650,260 (Teijin), No. 5,637,169 (3D Systems), and PCT Publication WO2021 / 180997 (BCN3D). In some embodiments, the moving film is light-transmitting, and a first light source is projected through the moving film. The elements may be directly and physically connected to each other, or indirectly connected via a common support or chassis 55. In some embodiments, a second rejection light source is projected through the moving film (e.g., shown in Figures 2A to 2H). On the other hand, in other embodiments, the second rejection light source does not project through the moving film, for example, as shown in Figures 3 and 4A-4D, by positioning it on the opposite side of the moving film from the first light source, or by positioning it adjacent to the moving film so that the moving film is not located between the carrier platform and / or the growing object. Such an applicator may include, in some embodiments, a moving film drive assembly, such as a roller 33 for advancing the moving film, a rigid and light-transmitting backing 34 for supporting the moving film, a support frame 35 (not shown in some embodiments), and a platform drive 36 operably connected to the carrier platform. For the purpose of clarity, some components are not shown in some figures (for example, the controller 10 is shown only in Figure 2A, and the resin supply unit 31 is not shown in Figures 4A-4D, but will be evident from the patent incorporated above by reference).

[0060] The controller 10 can be operably connected to the first light source 41 and the second light source 42, the moving film drive assembly (or moving roller drive), and the platform drive 36. The controller is configured (in hardware and / or software) to implement the methods described herein.

[0061] In some embodiments, the laser source further comprises a sensing system for measurement (e.g., to maintain beam quality). As schematically shown in Figure 2A, such a sensing system may include a detector 51 configured for insertion into and out of the beampath (by moving the beam or moving the detector), or an integrated beam splitter can be used to generate a dedicated beam for the sensor. The sensor(s) (including multiple sensors) can detect the beam's focus, wavelength, intensity, or a combination thereof. The sensor(s) may be operably coupled to a controller 10, which is operably coupled to the above-described rejection light source 42 to provide a feedback system for adjusting the laser beam's focus, wavelength, and / or intensity when deviations from desired or preset parameters are detected.

[0062] Although not shown in the illustration, the apparatus may include a system for managing gases, particles, etc., generated by the elimination process. Such a system, implemented according to well-known techniques, may include a work chamber sealing the apparatus, an inert gas (e.g., nitrogen, argon) supply unit for flushing the chamber (or associated work area) during the process, and / or a cleaning fluid (e.g., aqueous liquid) supply unit for flushing the associated work area during the process, vents and / or drains, and sensors for detecting the levels of gases and / or particles generated by the elimination process via a connected controller.

[0063] method The apparatus described above can be used to perform various methods. These methods are further described below. These methods can be performed independently of each other or in combination, as will also be further described below.

[0064] The first method for producing a three-dimensional object by additive manufacturing as described herein is: (a) A step of forming a structured segment by applying a photopolymerizable resin to the construction surface of a growing three-dimensional object, wherein the application is carried out by a moving roller resin applicator or a moving film resin applicator. (b) A step of exposing the construction segment to patterned light to polymerize the construction segment and form a new construction surface, wherein the new construction surface has a margin, and the margin holds excess polymerized or nonpolymerized material, (c) Exposing the excess material to ablation light (e.g., laser light) in a dose (i.e., exposure pattern, wavelength, intensity, and duration) sufficient to remove the excess material from the edges (e.g., by ablation or melting), (d) A step in which steps (a) to (c) are continuously repeated until the three-dimensional object is formed, wherein step (c) is optionally omitted in some of the continuously repeated steps, but is included in at least some of the continuously repeated steps. Includes.

[0065] Such methods are schematically illustrated in a series of steps schematically shown in Figures 2A-2E, 3, 4A, 4B, and 4D. Note that, when performing the methods shown in Figures 2A-2D, the laser removes not only the resin on the portion but also the resin on the carrier film in some embodiments. For clarity, this feature is omitted from the figures. It should also be noted that the laser penetration depth can be controlled by selecting a combination of the laser wavelength and the absorption values ​​of the additives and resin components at that laser wavelength, according to well-known techniques. Resin components may have an inherent absorption at their laser wavelength. If not, dyes or pigments can be selected to achieve the desired value. A specific value for the penetration depth is set far below the expected resin thickness (approximately several tens of micrometers) and aims to maximize energy density and avoid radiation transmission. The penetration depth is selected to optimize or achieve the state and behavior of the resin removed from the surface.

[0066] A second method for producing a three-dimensional object by additive manufacturing as described herein is: (a) A step of forming a structured segment by applying a photopolymerizable resin to the construction surface of a growing three-dimensional object, wherein the application is carried out by a moving roller resin applicator or a moving film resin applicator. (b) Exposing the constructed segment to patterned light to polymerize the constructed segment and form a new constructed surface, (c) Exposing the new construction surface to ablation light (e.g., laser light) to physically and / or chemically modify the new construction surface, (d) A step in which steps (a) to (c) are continuously repeated until the three-dimensional object is formed, wherein step (c) is optionally omitted in some of the continuously repeated steps, but is included in at least some of the continuously repeated steps. Includes.

[0067] Such methods are schematically shown in Figures 2F to 2G and Figure 4C. It should be noted that this second method can be carried out independently of the first method described above, or in combination with it, as schematically shown in Figures 2A to 2H and Figures 4A to 4D.

[0068] In some embodiments of the second method, the exposure step (c) is carried out with a dose (i.e., exposure pattern, wavelength, intensity, and duration) that textures at least a portion (e.g., most of) of the new construction surface (e.g., the pattern is configured to enhance the adhesion of the next construction segment to the new construction surface).

[0069] In some embodiments of the second method, the photopolymerizable resin comprises an additive (e.g., a thermoplastic material such as nylon powder, natural or synthetic rubber, or ceramic particles), and the exposure step (c) is carried out at a dose (i.e., exposure pattern, wavelength, intensity, and duration) that selectively melts or sintersects the additive in at least a portion (e.g., a majority) of the new construction surface (e.g., to form a co-continuous secondary material network) and modifies the material properties of the three-dimensional object (e.g., to increase toughness and / or to promote interlayer adhesion, strength, or toughness).

[0070] In some embodiments of the second method, the photopolymerizable resin is a dual-cure resin comprising a first polymerizable component and a second polymerizable component, and the exposure step (c) is carried out with a dose (i.e., exposure pattern, wavelength, intensity, and duration) that initiates polymerization of the second polymerizable component on at least a portion (e.g., a large portion) of the new construction surface to modify the mechanical properties of the three-dimensional object (e.g., in the green step and / or final step) (in some embodiments, these exposure doses can be patterned spatially and / or temporally to control and modify the spatial distribution of material properties in the three-dimensional object).

[0071] In some embodiments of the second method, the exposure step (c) is carried out with a dose (i.e., exposure pattern, wavelength, intensity, and duration) that modifies the material properties (e.g., modify the glass transition temperature) (e.g., modify the internal stresses within the object, thereby modifying the geometry of the final object) in at least a portion (e.g., most of) of the new construction surface.

[0072] In some embodiments of the second method, the exposure step (c) is carried out with a dose (i.e., exposure pattern, wavelength, intensity, and duration) that activates a surface chemical on at least a portion (e.g., a large portion) of the new construction surface (e.g., to modify the glass transition temperature) (e.g., to promote adhesion, modify surface energy, and / or control the wettability of the resin).

[0073] In some embodiments of the second method, the photopolymerizable resin comprises a filler (e.g., pologen or microballoons), and the exposure step (c) is carried out at a dose (i.e., exposure pattern, wavelength, intensity, and duration) that selectively expands the filler on at least a portion (e.g., most of) of the new construction surface (e.g., thereby preventing shrinkage and / or warping of the object).

[0074] In some embodiments of all the methods described above, the coating step is carried out by a bottom-up or top-down additive manufacturing apparatus, by a moving roller resin applicator, and / or by a moving film resin applicator (for example, the moving film is a light-transmitting film, and patterned light and optionally ablation light are projected through the moving film).

[0075] A third method for producing a three-dimensional object by additive manufacturing as described herein is: (a) The step of forming a three-dimensional object on a construction platform, (b) A step of positioning a resin-coated film beneath a three-dimensional object, wherein the resin-coated film may be in contact with the three-dimensional object, or a gap may exist between the resin-coated film and the three-dimensional object. (c) Exposing a portion of a resin-coated film to laser radiation sufficient to eject at least a portion of the resin onto the bottom surface of a three-dimensional object (e.g., UV, visible, or IR laser light using a secondary light source), (d) A step of polymerizing the ejected resin on the bottom surface of a three-dimensional object by exposing it to chemical rays or chemical light using an additional light source, (e) A step in which steps (b) to (d) are repeated in succession. Includes.

[0076] In some embodiments of all the methods described above, the laser light is a dose absorbed by the excess material and / or the new construction surface in a single-photon absorption process or a multi-photon absorption process, the laser light being delivered to the excess material and / or the new construction surface as a shaping beam, and / or the laser light being delivered to the excess material and / or the new construction surface as a continuous wave or pulsed laser beam.

[0077] In some embodiments of all the methods described above, the method may further include the steps of: detecting the current characteristics of the ablation light (e.g., focal field, focal length, wavelength, intensity); comparing the current characteristics with desired characteristics (e.g., focal field, focal length, wavelength, intensity); and changing the ablation light so that the current characteristics correspond more closely to the desired characteristics.

[0078] Examples of the apparatus and method of the present invention will be described in more detail. Referring to Figure 2A, the apparatus of the present invention may include a construction platform 11 on which a growing three-dimensional object 12 having edges 12a and a construction surface 12b is fabricated. A moving film resin applicator 30 includes a resin supply unit 31, a film 32, rollers 33, and a rigid and light-transmitting backing 34, which moves the resin 21 to the appropriate position so that the three-dimensional object 12 comes into contact with the resin 21. An additional light source 41 emits light or chemical rays through the light-transmitting backing 34 and the film 32 to polymerize the photopolymerizable resin 21. In this embodiment, an exclusionary light source 42 and an exclusionary photosensor 51 are located below the applicator 30 and below the film 32. In addition, in this embodiment, the controller 10 is configured to operate various components of the apparatus, including, but not limited to, a platform drive 36 capable of moving the platform 11 vertically and / or horizontally, an additional light source 41, and / or a removal light source 42. The controller 10 can operate in the same manner as any of the other apparatuses and methods described herein.

[0079] Referring to Figure 2B, light or chemical rays from the additional light source 41 interact with the photopolymerizable resin 21, causing the resin 21 to solidify and thus produce a solid construction segment 13 that can be attached to the three-dimensional object 12 and has edges 13a and a construction surface 13b. As shown in Figure 2B, the edges 13a of the construction segment 13 hold excess material (excess resin or partially or completely cured excess polymer).

[0080] Referring to Figures 2C to 2E, in some embodiments, the ablationary light source 42 (e.g., a laser) is located beneath the three-dimensional object 12, the applicator 30, and the film 32 coated with resin 21. In Figure 2C, the ablationary light source 42 delivers a dose of light through the resin 21 and the film 32 to ablate (remove) excess material on the edge 13a of the construction segment 13. In some embodiments, when the dose of light passes through the resin 21 on the film 32, a portion of the resin 21 on the film 32 is also ablated. In Figure 2D, when the construction segment 13 is located on the film 32, the ablationary light source 42 delivers a dose of light through the resin 21 and the film 32 to ablate excess material on the edge 13a. In Figure 2E, the ablationary light source 42 delivers a dose of light through the film 32 but not through the resin 21 to ablate excess material on the edge 13a of the construction segment 13. For example, the removal light source 42 can deliver the dose after the addition light source 41 solidifies the construction segment 13 into a three-dimensional object, and after the construction platform lifts the construction segment 13 from the film 32, but before the new resin 21 is positioned beneath the three-dimensional object 12.

[0081] Figures 2F to 2G schematically show the three-dimensional object 12 after ablation of excess material. In certain embodiments, the extirpative light source 42 can emit ablation light (e.g., laser light) to physically and / or chemically modify the construction surface 12b. For example, the construction surface 12b can be modified to facilitate adhesion of the construction surface 12b to the next layer by altering or removing a portion of the solid polymer in the construction surface 12b (e.g., texture the surface) or by modifying the fillers within the polymer (e.g., melting or sintering glass or fillers, activating reactive fillers, etc.). In another embodiment, a portion of the solid polymer in the construction surface 12b is removed while leaving the fillers unmodified. In addition, in other embodiments, the ablation light can be used to improve toughness and / or reduce anisotropy in the construction surface 12b. In Figure 2F, the remover light source 42 delivers a dose of light through the resin 21 and the film 32 to physically and / or chemically modify the construction surface 12b, thereby also removing and / or modifying a portion of the resin 21 on the film 32. In Figure 2G, the remover light source 42 delivers a dose of light through the film 32 but not through the resin 21 to physically and / or chemically modify the construction surface 12b. For example, the remover light source 42 can deliver a dose after the additive light source 41 solidifies the construction segment 13 into a three-dimensional object and the construction platform lifts the construction segment 13 from the film 32, but before the new resin 21 is positioned beneath the three-dimensional object 12.

[0082] Figure 2H shows a larger three-dimensional object 12 immediately after ablation of excess material as shown in Figures 2C-2E, and / or after modification of the construction surface as shown in Figures 2F-2G. In addition, in some embodiments, ablation of excess material as shown in Figures 2C-2E is not required, and the exfoliative light source 42 is used only to modify the construction surface, as shown in Figure 2D. In Figure 2H, the three-dimensional object 12 can then be brought into contact with additional resin 21 to repeat the process and continue growing the three-dimensional object 12.

[0083] Figure 3 shows an alternative configuration of the remover light source 42 that can be used in several embodiments. In this configuration, the remover light source 42 is positioned above the three-dimensional object 12, the applicator 30, and the resin 21 on the film 32, and optionally above the construction platform 11. In such a case, excess material on the edge 13a of the construction segment 13 can be ablated from above the object 12. In this configuration, the remover light source 42 may not be able to modify the construction surface 13b. However, the remover light source 42 can modify or ablate an upward surface (e.g., the upper surface 13c of the construction segment 13). In some embodiments, the remover light source 42 can be present both below and above the three-dimensional object 12, the applicator 30, and the resin 21 on the film 32.

[0084] Referring to Figures 4A to 4D, in some embodiments, the construction platform 11 and / or the film applicator 30 can be moved laterally (translated) during the printing process. For example, in Figure 4A, the film applicator 30 moves across the growing three-dimensional object 12 via the lateral movement of the carrier platform 11 (see dashed arrow), the lateral movement of the film applicator 30, or both, and the remover light source 42 is positioned to the side of the film applicator 30. Lateral movement can also be used in embodiments where the remover / laser light source 42 is positioned in other locations, including below the film 32 and the three-dimensional object 12 or above the applicator 30 and / or the construction platform 11.

[0085] Figure 4B shows the embodiment of Figure 4A after the construction platform 11 and / or film applicator 30 have been moved laterally. The construction platform 11 and the three-dimensional object 12 have been moved beyond the edge of the film applicator 30. Excess material on the leading edge 12a of the new construction segment 12 can be removed by ablation laser radiation from the second light source 42. Figure 4C shows the embodiments of Figures 4A-4B in which the ablation light source 42 has been moved further laterally so that the construction surface 13b of the new construction segment 13 is irradiated by the second laser light source without passing through the resin 21. Figure 4D shows the embodiments of Figures 4A-4C in which excess material on the trailing edge of the growing three-dimensional object is removed by laser light from the second ablation light source 42.

[0086] The method of the present invention allows for the removal of excess resin, including excess resin at part borders and edge meniscus, in situ (see, for example, Figures 2A-2E) or ex-situ (see, for example, Figure 3 or Figures 4A, 4B, and 4D) by laser ablation, thus enabling the fabrication of objects without the need for additional cleaning and / or sanding / polishing.

[0087] In the method of the present invention, the laser penetration depth can be modified based on, for example, the laser's field of view and the structure of the three-dimensional object. For example, a relatively short penetration depth may be ensured if there is a structure underneath or adjacent to excess material. However, a longer penetration depth may be permissible if the laser is guided to avoid hardened areas, or if the transmitted beam energy is low enough to avoid unintended damage.

[0088] In some embodiments, occlusion can be reduced or eliminated by using a small field of view with a full-field lens to cover the construction area, or by using a small field of view and a scanning stage smaller than the construction area to cover the construction area. In some embodiments, occlusion can be reduced by using a larger field of view but achieving the desired result using a scanning system and complex patterning. In some cases, a multi-module scanning laser system can be used, allowing the laser to be positioned below, above, and / or to the side of the film applicator and construction platform.

[0089] In some embodiments, the removal of excess resin is achieved by using a narrow laser UV alignment tolerance between the partial boundary and the laser scanning system. By adding a mechanical vision function (e.g., a camera), laser alignment with respect to the partial boundary can be facilitated, and such a function can therefore be included in the apparatus of the present invention.

[0090] In some embodiments, laser ablation can be used to remove fibers protruding from a partial surface. When the fibers are glass fibers, in some cases, CO2 or DUV lasers can yield the best results. The use of such techniques can enable the use of longer glass fibers in some objects, thereby providing desirable properties in the final three-dimensional object.

[0091] In some embodiments, the use of laser ablation can provide a more accurate or precise construction surface than can be achieved with a UV curing system alone, or it can enable the use of a less precise additional optical system. In this case, the cured resin can be ablated, which may require higher pulse energy.

[0092] Referring to Figures 5A to 5B, a third method for producing a three-dimensional object by additive manufacturing includes: (a) forming a three-dimensional object 12 on a construction platform 11; (b) positioning a resin-coated film 32 beneath the three-dimensional object 12, wherein the resin-coated film 32 may be in contact with the three-dimensional object 12, or a gap may exist between the resin-coated film 32 and the three-dimensional object 12; (c) exposing a portion of the resin-coated film 32 to sufficient laser radiation (e.g., UV, visible, or IR laser light using a secondary light source 42) to eject at least a portion of the resin 21 onto the bottom surface 12b of the three-dimensional object 12; (d) exposing the ejected resin 21a on the bottom surface 12b of the three-dimensional object 12 to chemical radiation or chemical light using an additional light source 41 to polymerize the ejected resin; and (e) continuously repeating steps (b) to (d). In some cases, the laser radiation in step (c) is patterned laser radiation, which creates a pattern in the ejected resin. However, in some embodiments, an additional light source 41 that cures the ejected resin is patterned. In some embodiments, both light sources can use patterned light.

[0093] In some embodiments, the ejected resin 21a is transferred to a three-dimensional object 12 using a direct jet ejection, thereby causing the laser pulse to evaporate the resin 21 and transfer it to the bottom surface 12b of the three-dimensional object 12. In other embodiments, a "blister transfer" method is used, in which the laser pulse focused by the film 32 can create a blister (not shown), and the appearance of the blister generates a transfer impulse for the ejection of the resin 21.

[0094] Additionally manufactured objects The methods described above allow for the fabrication of various different three-dimensional objects. Depending on the choice of resin, the objects may be rigid, flexible, or elastic. The objects may include three-dimensional grids, such as strut grids, surface grids, and combinations thereof. The objects may include electrical connectors, mechanical connectors, or fluid connectors, helmet liners and midsoles, body pads, cushions such as those for bedding or seats, housings for mechanical or electrical components such as aerospace or automotive body panels and piping, and so on.

[0095] Table 1 below shows some non-limiting examples of specific embodiments and use cases of the methods and apparatus described herein.

[0096] [Table 1] JPEG2026511152000003.jpg255161 JPEG2026511152000004.jpg255161

[0097] The above is illustrative of the present invention and should not be construed as limiting the invention. The present invention is defined by the following claims, and the equivalents of the claims are also included within that scope.

Claims

1. A method for producing a three-dimensional object by additive manufacturing, (a) A step of forming a structure by applying a photopolymerizable resin to the construction surface of a growing three-dimensional object, wherein the application is carried out by a moving roller resin applicator or a moving film resin applicator, (b) A step of exposing the construction segment to patterned light to polymerize the construction segment and form a new construction surface, wherein the new construction surface has a margin, and the margin holds excess polymerized or nonpolymerized material, (c) Exposing the excess material to ablation light (e.g., laser light) in a dose (i.e., exposure pattern, wavelength, intensity, and duration) sufficient to remove the excess material from the edges (e.g., by ablation or melting), (d) A step in which steps (a) to (c) are continuously repeated until the three-dimensional object is formed, wherein step (c) is optionally omitted in some of the continuously repeated steps, but is included in at least some of the continuously repeated steps. Methods that include...

2. The method according to claim 1, wherein the excess material includes a polymerized resin.

3. The method according to claim 1 or 2, wherein the excess material includes a nonpolymerized resin.

4. A method for producing a three-dimensional object by additive manufacturing, (a) A step of forming a structure by applying a photopolymerizable resin to the construction surface of a growing three-dimensional object, wherein the application is carried out by a moving roller resin applicator or a moving film resin applicator, (b) Exposing the construction segment to patterned light to polymerize the construction segment and form a new construction surface, (c) Exposing the new construction surface to ablation light (e.g., laser light) to physically and / or chemically modify the new construction surface, (d) A step in which steps (a) to (c) are continuously repeated until the three-dimensional object is formed, wherein step (c) is optionally omitted in some of the continuously repeated steps, but is included in at least some of the continuously repeated steps. Methods that include...

5. The method according to claim 4, wherein the exposure step (c) is carried out with a dose (i.e., exposure pattern, wavelength, intensity, and duration) that textures at least a portion (e.g., most) of the new construction surface (e.g., the pattern is configured to enhance the adhesion of the next construction segment to the new construction surface).

6. The photopolymerizable resin contains additives (for example, thermoplastic materials such as nylon powder, natural or synthetic rubber, or ceramic particles), The method according to claim 4 or 5, wherein the exposure step (c) is carried out at a dose (i.e., exposure pattern, wavelength, intensity, and duration) that selectively melts or sintersects the additive in at least a portion (e.g., most of) of the new construction surface (e.g., to form a co-continuous secondary material network) and modifies the material properties of the three-dimensional object (e.g., to increase toughness and / or to promote interlayer adhesion, strength, or toughness).

7. The photopolymerizable resin is a dual-cure resin containing a first polymerizable component and a second polymerizable component. The method according to any one of claims 4 to 6, wherein the exposure step (c) is performed at a dose (i.e., exposure pattern, wavelength, intensity, and duration) that initiates polymerization of the second polymerizable component on at least a portion (e.g., a large portion) of the new construction surface to modify the mechanical properties of the three-dimensional object (in some embodiments, these exposure doses may be patterned spatially and / or temporally to control and modify the spatial distribution of material properties in the three-dimensional object).

8. The method according to any one of claims 4 to 7, wherein the exposure step (c) is carried out at a dose (i.e., exposure pattern, wavelength, intensity, and duration) that modifies material properties (e.g., modify the glass transition temperature) in at least a portion (e.g., a large portion) of the new construction surface (e.g., to modify the glass transition temperature).

9. The method according to any one of claims 4 to 8, wherein the exposure step (c) is carried out at a dose (i.e., exposure pattern, wavelength, intensity, and duration) that activates a surface chemical on at least a portion (e.g., most of) the new construction surface (e.g., to modify the glass transition temperature).

10. The photopolymerizable resin comprises a filler (e.g., pologen or microballoons), The method according to any one of claims 4 to 9, wherein the exposure step (c) is carried out at a dose (i.e., exposure pattern, wavelength, intensity, and duration) that selectively expands the filler on at least a portion (e.g., most of) the new construction surface (e.g., thereby preventing contraction and / or warping of the object).

11. The method according to any one of claims 1 to 10, wherein the photopolymerizable resin includes a filler (for example, a solid filler including a fiber filler, a spherical filler, an oval filler, etc.).

12. The method according to claim 11, wherein the filler is a solid particle filler comprising glass fibers, carbon fibers, aramid fibers, basalt fibers, thermoplastic or thermosetting polymer fibers (e.g., polyamide, cellulose, or nanocellulose fibers).

13. The method according to any one of claims 1 to 12, wherein the photopolymerizable resin has a viscosity of 1,000, 2,000, 10,000, or 20,000 centipoise or more at 25 degrees Celsius and 1 atmosphere.

14. The method according to any one of claims 1 to 13, wherein the photopolymerizable resin has a viscosity of 100,000 centipoise to 1,000,000 or 2,000,000 centipoise or more at 25 degrees Celsius and 1 atmosphere.

15. The method according to any one of claims 1 to 14, wherein the coating step is carried out by a bottom-up or top-down additive manufacturing apparatus.

16. The method according to any one of claims 1 to 15, wherein the coating step is performed by a moving roller resin applicator.

17. The method according to any one of claims 1 to 15, wherein the coating step (a) is carried out by the moving film resin applicator (for example, the moving film is a light-transmitting film, and the patterned light and optionally the ablation light are projected through the moving film).

18. The method according to any one of claims 1 to 17, wherein the ablation light is laser light.

19. The method according to claim 18, wherein the laser light is a dose absorbed by the excess material and / or the new construction surface in a single-photon absorption process or a multi-photon absorption process.

20. The method according to claim 18 or 19, wherein the laser beam is delivered as a shaping beam to the excess material and / or the new construction surface.

21. The method according to any one of claims 18 to 20, wherein the laser light is delivered as a continuous wave or pulsed laser beam to the excess material and / or the new construction surface.

22. The steps include detecting the current characteristics of the ablation light (e.g., focal field, focal length, wavelength, intensity), The steps include comparing the current characteristics with desired characteristics (e.g., focal field, focal length, wavelength, intensity), The steps include changing the ablation light so that the current characteristics correspond more closely to the desired characteristics, and The method according to any one of claims 1 to 21, further comprising:

23. A three-dimensional object manufactured by the method described in any one of claims 1 to 22.

24. An apparatus for additionally manufacturing three-dimensional objects from photopolymerizable resins, (a) A construction platform capable of fabricating a growing three-dimensional object, wherein the object has construction segments, and the construction segments include edges and construction surfaces, (b) An applicator configured to apply a photopolymerizable resin to the construction surface to form a new construction segment including a new edge and a new construction surface, the applicator comprising a moving roller resin applicator or a moving film resin applicator, (c) A resin supply unit configured to apply the photopolymerizable resin to the applicator, (d) A first additional light source configured to polymerize the photopolymerizable resin on the construction segment, (e) A second rejection light source configured to deliver a dose of light to the edge and / or the construction surface A device equipped with the following features.

25. The apparatus according to claim 24, wherein the rejection light source includes an ultraviolet (UV) light source, a vacuum UV light source, a deep UV light source, and / or a high-intensity infrared (IR) light source.

26. The apparatus according to claim 24 or 25, wherein the rejection light source includes a laser (for example, a gas laser, a solid-state laser, a fiber laser, a liquid laser, or a semiconductor laser).

27. The apparatus according to any one of claims 24 to 26, wherein the applicator includes the movable roller resin applicator.

28. The apparatus according to any one of claims 24 to 26, wherein the applicator includes the movable film resin applicator.

29. The apparatus according to claim 28, wherein the movable film resin applicator is light-transmitting, and the first light source is projected through the movable film resin applicator.

30. The apparatus according to claim 29, wherein the removal light source is projected through the moving film resin applicator.

31. The apparatus according to claim 29, wherein the rejecting light source does not project through the moving film resin applicator (for example, by positioning it on the opposite side of the moving film resin applicator from the additional light source, or by positioning it adjacent to the moving film resin applicator so that the moving film resin applicator is not located between the construction platform and / or the growing three-dimensional object).

32. A detector operably connected to the rejection light source and configured to detect the current characteristics of the rejection light (e.g., focal field, focal length, wavelength, intensity), A controller operably connected to the detector and the rejecting light source, configured to compare the current characteristics with desired characteristics (e.g., focal field, focal length, wavelength, intensity) and to change the rejecting light so that the current characteristics correspond more closely to the desired characteristics. The apparatus according to any one of claims 24 to 31, further comprising:

33. The aforementioned rejection (e.g., laser) light source Continuous wave light source or pulsed laser light source, Single-beam light source or multi-beam light source, Self-standing lasers or fiber-optic lasers, and / or Single-wavelength light source or multi-wavelength light source The apparatus according to any one of claims 24 to 32, including the apparatus described in any one of claims 24 to 32.

34. The aforementioned rejection (e.g., laser) light source Laser trepanning system, XY stage for scanning a laser beam or raster scanning, Beam expander, mirror, focusing lens, and / or air assist, Z-focus adjustment elements such as motorized focus adjustment mechanism, Additional optical elements including optical fiber elements, diffractive optical elements, and / or beam splitters, Beam focusing elements (e.g., f-theta lenses, motor-driven z-focusing elements, etc.), and / or Beam shaping elements (e.g., refractive beam shaping elements, diffractive beam shaping elements, laser beam integrators, axicons for generating Bessel beams, cylindrical lenses, and pairs of anamorphic prisms for making beams circular) The apparatus according to any one of claims 24 to 33, further comprising:

35. A method for manufacturing a three-dimensional object by additive manufacturing, (a) The step of forming a first three-dimensional object on a construction platform, (b) A step of positioning a resin-coated film beneath the three-dimensional object, wherein optionally there is a gap between the resin-coated film and the three-dimensional object; (c) Exposing a portion of the film coated with the resin to laser radiation (e.g., UV, visible, or IR laser light) sufficient to eject at least a portion of the resin onto the bottom surface of the three-dimensional object, (d) A step of exposing the resin on the bottom surface of the three-dimensional object to chemical rays or chemical light to polymerize the resin, (e) Optionally, the steps (b) to (d) are repeated in succession to form a second three-dimensional object. Methods that include...

36. The method according to claim 35, wherein the laser radiation in step (c) is a patterned laser radiation.

37. The method according to claim 35 or 36, wherein the chemical beam or chemical light in step (d) is a patterned chemical beam or chemical light.

38. The method according to any one of claims 35 to 37, wherein in step (c), the resin is ejected using a blister transfer method.

39. The method according to any one of claims 35 to 37, wherein in step (c), the resin is ejected using a direct jet method.

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