3D printing apparatus and method

Abstract

An apparatus and method for forming a three-dimensional object. The apparatus includes a platform on which the three-dimensional object is formed. The apparatus includes an oxygen-acceptable solution having a build surface. The build surface and the platform define a build region therebetween. The apparatus includes a photosensitive liquid disposed in the oxygen-acceptable solution. The density of the oxygen-acceptable solution is greater than the density of the photosensitive liquid. The apparatus includes an optically transparent member. The optically transparent member supports the oxygen-acceptable solution. The apparatus includes an illumination source configured to illuminate the build region through the optically transparent member and the oxygen-acceptable solution to form a solid polymer from the photosensitive solution. The apparatus includes a controller configured to advance the platform in a direction away from the build surface.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Application No. 63 / 069,317, filed August 24, 2020, the entire contents of which are incorporated herein by reference.

[0002] This application relates to a process for eliminating or ameliorating large membrane deformations in oxygen permeable membranes in 3D printing applications. [Background technology]

[0003] Oxygen-permeable membranes are sometimes used in 3D top-down projection printing applications. Summary of the Invention

[0004] The disclosed system and method can address the issues associated with ink-induced deformation of oxygen-permeable membranes in three-dimensional (3D) top-down projection printing processes. The disclosed system and method can enable the use of continuous 3D printing without the need for oxygen-permeable membranes. In addition, the disclosed system and method can solve the problem of membrane deformation for large-area printing, which can be used to print large objects with high resolution.

[0005] At least one aspect of the present disclosure is directed to an apparatus for forming a three-dimensional object. The apparatus includes a platform on which the three-dimensional object is formed. The apparatus includes an oxygen-acceptable solution having a build surface. The build surface and the platform define a build region therebetween. The apparatus includes a photosensitive liquid disposed in the oxygen-acceptable solution. The density of the oxygen-acceptable solution is greater than the density of the photosensitive liquid. The apparatus includes an optically transparent member. The optically transparent member supports the oxygen-acceptable solution. The apparatus includes an illumination source configured to illuminate the build region through the optically transparent member and the oxygen-acceptable solution to form a solid polymer from the photosensitive liquid. The apparatus includes a controller configured to advance the platform away from the build surface.

[0006] Another aspect of the present disclosure is directed to an apparatus for forming a three-dimensional object. The apparatus includes a platform on which the three-dimensional object is formed. The apparatus includes an oxygen-permeable membrane having a build surface. The build surface and the platform define a build region therebetween. The apparatus includes a photosensitive liquid disposed on the oxygen-permeable membrane. The apparatus includes an oxygen-acceptable solution. The oxygen-permeable solution supports the oxygen-permeable membrane. The density of the oxygen-acceptable solution is greater than the density of the photosensitive liquid. The apparatus includes an optically transparent member. The optically transparent member supports the oxygen-acceptable solution. The apparatus includes an illumination source configured to illuminate the build region through the optically transparent member, the oxygen-acceptable solution, and the oxygen-permeable membrane to form a solid polymer from the photosensitive liquid. The apparatus includes a controller configured to advance the platform away from the build surface.

[0007] Another aspect of the present disclosure is directed to a method for forming a three-dimensional object. The method includes providing an oxygen-acceptable solution having a platform and a build surface. The build surface and platform define a build region therebetween. The method includes disposing a photosensitive liquid in the oxygen-acceptable solution. The density of the oxygen-acceptable solution is greater than the density of the photosensitive liquid. The method includes supporting the oxygen-acceptable solution on an optically transparent member. The method includes irradiating the build region through the optically transparent member and the oxygen-acceptable solution to form a solid polymer from the photosensitive liquid. The method includes advancing the platform in a direction away from the build surface.

[0008] Those skilled in the art will appreciate that the summary is illustrative only and is not intended to be limiting in any way. Other aspects, inventive features, and advantages of the devices and / or processes described herein, as defined solely by the claims, will become apparent in the detailed description set forth herein and taken in conjunction with the accompanying drawings.

[0009] The details of one or more implementations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, drawings, and claims. [Brief explanation of the drawings]

[0010] [Figure 1] 1 illustrates an interface between perfluorodecalin and ink, according to one embodiment. [Figure 2] 1 shows the contact angles of water and perfluorodecalin on an AF2400 film, according to one embodiment. [Figure 3] 1 shows the absorption spectrum of perfluorodecalin, according to one embodiment. [Figure 4] 1 shows a plot of the refractive index of perfluorodecalin, water, and air, according to one embodiment. [Figure 5] FIG. 1 shows a schematic diagram of an inverted digital light projection (DLP) system without a solid film interface, according to one embodiment. [Figure 6] 6 illustrates a detailed view of the XZ cross section of the platform in FIG. 5 according to one embodiment. [Figure 7] 1 shows a schematic diagram of a non-compressible oxygen-carrying liquid according to one embodiment. [Figure 8] 1 shows a schematic diagram of membrane deformation under hydrostatic pressure, according to one embodiment. [Figure 9] 1 illustrates a modification of the AF2400 membrane, according to one embodiment. [Figure 10] 10 illustrates membrane deformation across the dotted line shown in FIG. 9 for different hydrostatic pressures on the membrane, according to one embodiment. [Figure 11] 1 illustrates a plot of normalized deformation versus hydrostatic pressure according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] Like reference numbers and designations in the various drawings indicate like elements.

[0012] Oxygen-inhibition layers (e.g., dead zones) can control the thickness of printed cured layers in 3D printing applications. Solid film interfaces with high oxygen permeability (e.g., AF2400) can be used to control photopolymerization inhibition. These solid film interfaces can be chemically inert and UV-transparent. However, these oxygen-permeable films can pose problems when 3D printing large cross-sections at high resolution. When printing with high UV intensity, the dead zone thickness can decrease, resulting in window adhesion defects. Window adhesion defects can prevent the printed object from moving freely. The 3D-printed object may collapse and fall into the vat before the printing process is complete. In addition, when printing with large ink volumes, the hydrostatic pressure of the ink can cause vertical film deflection, causing the polymerization surface to move out of the projector's focal plane. This can result in the object being printed with lower output intensity and lower resolution. Therefore, process improvements are needed for 3D objects with large cross-sections while maintaining high resolution.

[0013] Rapid and accurate additive manufacturing (AM) can be important in organ fabrication and 3D scaffold printing. Three-dimensional printing can materialize computer-aided design (CAD) models by slicing the virtual 3D model and photopolymerizing the object layer by layer. Stereolithography (SL) techniques can be used as a platform for top-down UV laser rasterization exposure. Digital light projection (DLP) can eliminate laser rasterization and enable bottom-up photopolymerization of UV-curable polymers in a single exposure. In all of these techniques, photopolymerization can be inhibited by atmospheric oxygen. Oxygen inhibition can occur in the build window, resulting in the formation of a dead zone. The dead zone may include areas where oxygen inhibition is dominant and photopolymerization does not occur. For the ambient air below the window, the dead zone can be calculated using Equation 1:

[0014]

number

[0015] where C is the proportional value, Φ is the luminous flux per area per time, and α PI+Ab is the absorbance peak of the photoinitiator and absorber, and D e represents the monomer reactivity with the photoinitiator. Φ or α PI+Ab Increasing the dead zone thickness can decrease the oxygen concentration. When the dead zone thickness is between 20 μm and 30 μm, the dead zone is negligibly small, and the cross-linked polymer may adhere to the film, causing defects or collapsing the printed object.

[0016] To overcome the adhesion defects caused by the small dead zone thickness, the oxygen permeable membrane may be replaced with an oxygen-carrying solution (e.g., an oxygen-carrying liquid) that has a higher density than the bioink. The oxygen-carrying liquid has a density of 1.917 g / cm 3 Perfluorodecalin (PFD) (C), an oxygen-soluble compound with a density of 0.01 and an oxygen solubility of 40.5 ml O2 / 100 ml liquid, 10 F 18 ) is included. Figure 1 shows the interface between PFD and ink. The high density of PFD makes this oxygen-carrying liquid very robust for forming a two-phase system (e.g., for aqueous inks). Figure 2 shows the contact angle of water and PFD on an AF2400 film. In addition, PFD has robust wetting properties with the AF2400 film, which improves adhesion between PFD and AF2400. Figure 3 shows the absorption spectrum of PFD. The absorbance of PFD at 365 nm and 405 nm is 0.07 and 0.03, respectively. PFD can be used as a replacement for solid oxygen-permeable membranes.

[0017] Figure 4 shows a plot of the refractive index of perfluorodecalin, water, and air. Because it has a higher refractive index (1.36) than air, the projected image may require correction to compensate for the smaller size of the object. The refractive index of PFD can be between 1.3 and 1.4. The refractive index of water (e.g., deionized water, DI water, etc.) can be between 1.3 and 1.4. The refractive index of air can be approximately 1. The refractive indices can be measured at standard temperature and pressure.

[0018] FIG. 5 shows a schematic diagram of an inverted digital light projection (DLP) system 500 without a solid membrane interface. An oxygen-carrying liquid may be used with or without a solid membrane in the polymerization vat. As an alternative to using a solid membrane with an inverted DLP 3D printer, a Volumetric™ 3D printer can be modified by eliminating the bottom membrane and replacing it with a dense oxygen-carrying liquid. To maintain a constant oxygen concentration during printing, the dense oxygen-carrying liquid may be circulated using a peristaltic pump at a flow rate of 10 μL / min.

[0019] A system 500 for forming a three-dimensional object may include a platform 502 (e.g., a printing platform) on which the three-dimensional object is formed. The three-dimensional object may include an artificial organ (e.g., an artificial lung, an artificial heart, an artificial kidney, an artificial liver, etc.). The system 500 may include an oxygen-carrying liquid 604 (e.g., an oxygen-carrying liquid) having a build surface. The oxygen-carrying liquid 604 may include a fluorocarbon material such as perfluorodecalin or Krytox fluorine oil. The oxygen-carrying liquid 604 may have an oxygen solubility greater than 0.3 ml O2 / ml oxygen-carrying liquid. For example, the oxygen-carrying liquid 604 may have an oxygen solubility of 0.4 ml O2 / ml oxygen-carrying liquid, 0.5 ml O2 / ml oxygen-carrying liquid, or 0.6 ml O2 / ml oxygen-carrying liquid.

[0020] The build surface and platform 502 may define a build region 504 (e.g., a build window) therebetween. The system 500 may include a controller configured to advance the platform 502 away from the build surface. For example, the controller may lower or raise the platform 502. The controller may be configured to maintain an oxygen inhibition layer thickness of at least 20 μm. For example, the controller may maintain an oxygen inhibition layer thickness of 20 μm, 25 μm, 30 μm, 35 μm, 40 μm, 45 μm, or 50 μm.

[0021] The system 500 may include an illumination source 506 (e.g., a DLP projector, a projector, an illumination source, etc.) configured to illuminate the build region 504. The illumination source 506 may be configured to illuminate the build region 504 through an optically transparent member and the oxygen-containing solution 604 to form a solid polymer from a photosensitive liquid (e.g., a photopolymer, an ink, etc.). In some embodiments, the system 500 may include a peristaltic pump (e.g., a pump) for recirculating the oxygen-containing solution 604. The peristaltic pump may include a positive displacement pump used to pump the oxygen-containing solution 604.

[0022] 6 shows a detailed view of the XZ cross section of the platform 502 in FIG. 5. The platform 502 may include a transparent glass 602 (e.g., optically transparent glass, optically transparent member, etc.). For example, the transparent glass 602 may support an oxygen-soluble solution 604. The oxygen-soluble solution 604 may be disposed on the transparent glass 602. The thickness of the transparent glass 602 may be substantially smaller than the thickness of the oxygen-soluble solution 604.

[0023] The platform 502 may include a high-density oxygen-carrying liquid (e.g., a non-compressible oxygen-carrying liquid) on a transparent glass 602. The platform 502 may include an ink 608 (e.g., a photosensitive ink, a photosensitive liquid, etc.). The photosensitive liquid may be disposed in an oxygen-carrying liquid 604. The oxygen-carrying liquid 604 may be disposed below the ink 608. The density of the oxygen-carrying liquid 604 may be greater than the density of the photosensitive liquid. The platform 502 may include an interface 606 between the oxygen-carrying liquid and the photosensitive ink (e.g., an interface between the ink and the PFD). The thickness of the ink 608 may be greater than the thickness of the oxygen-carrying liquid 604. The thickness of the ink 608 may be substantially greater than the thickness of the transparent glass 602.

[0024] 7 shows a schematic diagram of an incompressible oxygen-carrying liquid. The incompressible oxygen-carrying liquid may be used to support an oxygen-permeable liquid. The platform 502 may include a transparent glass 602 (e.g., optically transparent glass, an optically transparent member, etc.). The platform 502 may include an incompressible oxygen-permeable liquid 604 (e.g., an oxygen-carrying liquid). The optically transparent member may support the oxygen-permeable liquid 604.

[0025] The platform 502 may include an oxygen permeable membrane 702. The oxygen permeable membrane 702 may include a polytetrafluoroethylene membrane. The oxygen permeable membrane 702 may have a thickness of 1600×10 -10 cm 3 (STP)cm / (cm 2 s cm Hg). The oxygen-permeable membrane 702 may have a build surface. The build surface and the platform 502 may define a build region 504 therebetween. The oxygen-permeable solution 604 may support the oxygen-permeable membrane 702. The density of the oxygen-permeable solution 604 may be greater than the density of the photosensitive solution. The thickness of the oxygen-permeable membrane 702 may be less than the thickness of the oxygen-permeable solution 604.

[0026] The platform 502 may include ink 608 (e.g., photosensitive ink). The photosensitive liquid may be disposed on an oxygen-permeable membrane 702. The platform may include an irradiation source 506. The irradiation source 506 may be configured to irradiate the build region 504 through the optically transparent member, the oxygen-permeable liquid 604, and the oxygen-permeable membrane 702 to form a solid polymer from the photosensitive liquid. The thickness of the oxygen-permeable liquid 604 may be less than the thickness of the ink 608.

[0027] Highly oxygen-permeable membranes, such as AF2400, can be very thin to allow sufficient oxygen transport to maintain an ideal dead zone thickness. When a large amount of ink is loaded, thin membranes can undergo significant deformation. This problem can become more severe when printing large cross-sectional areas. Figure 8 shows a schematic diagram of membrane deformation under hydrostatic pressure. In some cases, the amount of deformation can be so great that the projected image deviates from the projector's focal plane. The deformation problem can be described by two nonlinear differential equations:

[0028]

number

[0029]

number

[0030] where u(r) and w(r) are the radial and axial displacements, i.e., r and z, respectively, d is the membrane thickness, p is the uniform hydrostatic pressure, and F is a function of elasticity, Young's modulus, and Poisson's ratio. The boundary conditions can be defined as follows:

[0031]

number

[0032]

number

[0033] Figure 9 shows the deformation of an AF2400 membrane. Using COMSOL Multiphysics 5.4, the maximum deformation (cm) across the membrane can be calculated. Figure 10 shows the membrane deformation across the dotted line shown in Figure 9 for different hydrostatic pressures applied to the membrane. The hydrostatic pressure can be varied by loading different amounts of ink into the vat to evaluate the membrane deformation across the center line. The normalized deformation at the center of the membrane can be up to 60% compared to the height of the membrane platform. To avoid this problem, the membrane may include a rigid and strong support from below. An oxygen-carrying liquid with high density and strong wetting ability for AF2400 may be used as the oxygen source in conjunction with an oxygen-permeable membrane. Figure 11 shows a plot of normalized deformation (%) versus hydrostatic pressure (Pa). As the hydrostatic pressure increases, the normalized maximum deformation increases.

[0034] A method for forming a three-dimensional object (e.g., an article) may include providing a platform and an oxygen-acceptable solution having a build surface. The build surface and platform may define a build region therebetween. The method may include disposing a photosensitive liquid in the oxygen-acceptable solution. The density of the oxygen-acceptable solution may be greater than the density of the photosensitive liquid. The method may include supporting the oxygen-acceptable solution on an optically transparent member. The method may include irradiating the build region through the optically transparent member and the oxygen-acceptable solution to form a solid polymer from the photosensitive liquid. The method may include advancing the platform in a direction away from the build surface.

[0035] In some embodiments, the method may include providing an oxygen-permeable membrane disposed between the photosensitive solution and the oxygen-acceptable solution. In some embodiments, the method may include maintaining an oxygen-inhibiting layer thickness of at least 20 μm. In some embodiments, the method may include recirculating the oxygen-acceptable solution using a peristaltic pump. In some embodiments, the oxygen-acceptable solution is a fluorocarbon material such as perfluorodecalin or Krytox fluorine oil. In some embodiments, the three-dimensional object is an artificial organ (e.g., an artificial lung, an artificial heart, an artificial kidney, an artificial liver, etc.).

[0036] Any reference to implementations or elements or acts of systems and methods herein that are referred to in the singular may include implementations that include a plurality of such elements, and any reference to any implementations or elements or acts herein that are referred to in the plural may include implementations that include only a single element. References in the singular or plural are not intended to limit the systems or methods, components, acts, or elements of the present disclosure to single or multiple configurations. References to any act or element that is based on any information, act, or element may include implementations in which the act or element is based at least in part on any information, act, or element.

[0037] As used herein, the terms "approximately," "about," "substantially," and similar terms are intended to have broad meanings consistent with common and established usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of ordinary skill in the art reviewing this disclosure that these terms are intended to permit description of the particular features described and claimed without limiting the scope of such features to the precise numerical ranges presented. Accordingly, these terms should be interpreted as indicating that substantial or insignificant modifications or variations of the subject matter described and claimed are considered to be within the scope of the present disclosure as set forth in the appended claims.

[0038] It should be noted that the use of the term "exemplary" and variations thereof herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to imply that such embodiments are necessarily particular or extreme examples).

[0039] As used herein, the term "coupled" and variations thereof refer to the direct or indirect joining of two members to one another. Such joining may be static (e.g., permanent or fixed) or movable (e.g., removable or releasable). Such joining may be achieved by directly joining two members to one another, by joining two members to one another using a separate intervening member and some additional intermediate member to one another, or by joining two members to one another using an intervening member that is integrally formed with one of the two members as a single unit. When "coupled" or variations thereof are modified by an additional term (e.g., directly coupled), the general definition of "coupled" provided above is modified by the ordinary meaning of that additional term (e.g., "directly coupled" means joining two members without any separate intervening member), resulting in a definition narrower than the general definition of "coupled" provided above. Such joining may be mechanical, electrical, or fluid.

[0040] Any implementation disclosed herein may be combined with any other implementation, and references to "one implementation," "some implementations," "alternative implementations," "various implementations," "one implementation," etc. are not necessarily mutually exclusive and are intended to indicate that a particular feature, structure, or characteristic described with respect to that implementation may be included in at least one implementation. Such terms as used herein do not necessarily all refer to the same implementation. Any implementation may be combined with any other implementation, inclusively or exclusively, in any manner consistent with the aspects and implementations disclosed herein.

[0041] References to "or" may be construed as inclusive, such that any term described with "or" may refer to either one, more than one, or all of the described terms. Reference to at least one of a conjunctive list of terms may be construed as an inclusive or indicating either one, more than one, or all of the described terms. For example, a reference to "at least one of 'A' and 'B'" may include 'A' alone, 'B' alone, and both 'A' and 'B'. Elements other than 'A' and 'B' may be included.

[0042] References herein to the location of elements (e.g., "top," "bottom," "upper," "lower") are used merely to describe the orientation of the various elements in the drawings. It should be noted that the orientation of the various elements may be different in other exemplary embodiments, and such variations are intended to be encompassed by the present disclosure.

[0043] While the figures and description may indicate a particular order of method steps, the order of such steps may differ from that shown and described unless otherwise indicated above. Also, two or more steps may be performed concurrently or with partial concurrence unless otherwise indicated above. Such variations may depend, for example, on the software and hardware systems selected and designer choices. All such variations are within the scope of this disclosure. Similarly, software implementations of the described methods may be implemented using standard programming techniques with rule-based logic and other logic to implement the various connecting, processing, comparing, and deciding steps.

[0044] The systems and methods described herein may be embodied in other specific forms without departing from their characteristics. The foregoing implementations are illustrative rather than limiting of the described systems and methods.

[0045] Where reference signs follow technical features in the drawings, detailed description, or any claims, those reference signs are included to enhance the clarity of the drawings, detailed description, and claims, and therefore the presence or absence of a reference sign does not have any limiting effect on the scope of any claim element.

[0046] The systems and methods described herein may be embodied in other specific forms without departing from their characteristics. The foregoing implementation examples are illustrative rather than limiting of the described systems and methods. Accordingly, the scope of the systems and methods described herein is indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalents of the claims are embraced therein. It should be noted that the present specification discloses the following aspects. [Aspect 1] 1. An apparatus for forming a three-dimensional object, comprising: a platform on which the three-dimensional object is formed; and an oxygen-soluble solution having a build surface, said build surface and said platform defining a build region therebetween; a photosensitive solution disposed in the oxygen-containing solution, the density of the oxygen-containing solution being greater than the density of the photosensitive solution; a light-transmitting member configured to support the oxygen-soluble material; an irradiation source configured to irradiate the build area through the optically transparent member and the oxygen-soluble solution to form a solid polymer from the photosensitive solution; a controller configured to advance the platform away from the build surface; An apparatus comprising: [Aspect 2] a peristaltic pump for recirculating the oxygen-soluble solution; 10. The apparatus of embodiment 1, further comprising: [Aspect 3] 10. The apparatus of claim 1, wherein the oxygen-soluble material is a fluorocarbon material. [Aspect 4] The oxygen-soluble solution is 0.3 ml O 2 10. The device of embodiment 1, having an oxygen solubility greater than 1 / ml oxygen soluble. [Aspect 5] 2. The apparatus of claim 1, wherein the three-dimensional object is an artificial organ. [Aspect 6] 1. An apparatus for forming a three-dimensional object, comprising: a platform on which the three-dimensional object is formed; and an oxygen permeable membrane having a build surface, said build surface and said platform defining a build region therebetween; a photosensitive solution disposed on the oxygen permeable membrane; an oxygen-permeable solution for supporting the oxygen-permeable membrane, the density of the oxygen-permeable solution being greater than the density of the photosensitive solution; a light-transmitting member for supporting the oxygen-soluble material; an irradiation source configured to irradiate the build area through the optically transparent member, the oxygen-permeable solution, and the oxygen-permeable membrane to form a solid polymer from the photosensitive solution; a controller configured to advance the platform away from the build surface; An apparatus comprising: [Aspect 7] a peristaltic pump for recirculating the oxygen-soluble solution; 7. The apparatus of embodiment 6, further comprising: [Aspect 8] 7. The device of embodiment 6, wherein the oxygen-soluble solvent is at least one of perfluorodecalin, Krytox fluorinated oil, or Solvay Fomblin Y. [Aspect 9] The oxygen-soluble solution is 0.3 ml O 2 7. The device of embodiment 6, having an oxygen solubility greater than 1 / ml oxygen soluble. [Aspect 10] 7. The apparatus of embodiment 6, wherein the three-dimensional object is an artificial organ. [Aspect 11] 7. The device of embodiment 6, wherein the oxygen permeable membrane is a polytetrafluoroethylene membrane. [Aspect 12] The oxygen permeable membrane is 1600×10 -10 cm 3 (STP)cm / (cm 2 7. The device of embodiment 6, having an oxygen permeability of greater than 100 s cm Hg. [Aspect 13] 7. The apparatus of embodiment 6, wherein the controller is configured to maintain an oxygen inhibition layer thickness of at least 20 μm. [Aspect 14] 1. A method for forming a three-dimensional object, comprising: providing an oxysoluble solution having a platform and a build surface, the build surface and the platform defining a build region therebetween; disposing a photosensitive solution in the oxygen-permeable solution, the density of the oxygen-permeable solution being greater than the density of the photosensitive solution; supporting the oxygen-containing solution on a light-transmitting member; irradiating the build area through the optically transparent member and the oxygen-sensitive solution to form a solid polymer from the photosensitive solution; advancing the platform away from the build surface; A method comprising: [Aspect 15] providing an oxygen-permeable membrane disposed between the photosensitive solution and the oxygen-soluble solution; 15. The method of embodiment 14, further comprising: [Aspect 16] Maintain an oxygen inhibition layer thickness of at least 20 μm 15. The method of embodiment 14, further comprising: [Aspect 17] Recirculating the oxygen-soluble solution using a peristaltic pump. 15. The method of embodiment 14, further comprising: [Aspect 18] 15. The method of claim 14, wherein the oxygen-soluble material is a fluorocarbon material. [Aspect 19] 15. The method of embodiment 14, wherein the three-dimensional object is an artificial organ. [Aspect 20] 15. An article comprising the three-dimensional object produced by the method of claim 14. [Explanation of symbols]

[0047] 500 Systems 502 Platform 504 Modeling area 506 Irradiation source 602 Clear glass 604 Oxygen-soluble 606 Interface 608 Ink 702 Oxygen permeable membrane

Claims

1. 1. An apparatus for forming a three-dimensional object, comprising: a platform on which the three-dimensional object is formed; and an oxygen permeable membrane having a build surface, said build surface and said platform defining a build region therebetween; a photosensitive solution containing bioink disposed on the oxygen-permeable membrane; An oxygen-permeable solution comprising perfluorodecalin, the oxygen-permeable membrane being disposed on the oxygen-permeable solution, (1) the density of the oxygen-permeable solution is greater than the density of the photosensitive solution, and (2) the oxygen-permeable solution is 0.3 ml O ２ / ml oxygen soluble solution, (3) the thickness of the oxygen permeable membrane is less than the thickness of the oxygen permeable membrane, and (4) the oxygen permeable membrane is configured to support the oxygen permeable membrane; an optically transparent member, wherein the oxygen-permeable solution is disposed on a flat surface of the optically transparent member, the flat surface extending across the dimensions of the build surface, (1) the perfluorodecalin is in physical contact with the oxygen-permeable membrane and the optically transparent member, (2) the dimensions of the build surface define a support region between the oxygen-permeable membrane and the optically transparent member, and (3) the support region is comprised of the oxygen-permeable solution; a peristaltic pump configured to maintain a constant concentration of oxygen in the oxygen-containing solution in the build zone by recirculating the oxygen-containing solution through the peristaltic pump; an illumination source including a projector configured to illuminate the build region through the optically transparent member, the oxygen-permeable solution, and the oxygen-permeable membrane to form a solid polymer from the photosensitive solution, wherein a polymerization surface is positioned in alignment with a focal plane of the projector during formation of the three-dimensional object; a controller configured to advance the platform away from the build surface; An apparatus comprising:

2. The device of claim 1 , wherein the three-dimensional object is an artificial organ.

3. 10. The device of claim 1, wherein the oxygen permeable membrane is a polytetrafluoroethylene membrane.

4. The apparatus of claim 1 , wherein the controller is configured to maintain an oxygen inhibition layer thickness of at least 20 μm.

5. 1. A method for forming a three-dimensional object, comprising: providing an oxygen permeable membrane having a platform and a building surface, the building surface and the platform defining a building region therebetween; disposing a photosensitive solution containing a bio-ink on the oxygen permeable membrane; The oxygen-permeable membrane is placed on an oxygen-permeable solution comprising perfluorodecalin, wherein (1) the density of the oxygen-permeable solution is greater than the density of the photosensitive solution, and (2) the oxygen-permeable solution has a density of 0.3 ml O ２ / ml oxygen solubility greater than 10 ... supporting the photosensitive solution on the oxygen permeable membrane; disposing the oxyacid-soluble solution on a flat surface of an optically transparent member, the flat surface extending across the dimensions of the build surface, (1) the perfluorodecalin being in physical contact with the oxygen permeable membrane and the optically transparent member, (2) the dimensions of the build surface defining a support region between the oxygen permeable membrane and the optically transparent member, and (3) the support region consisting of the oxyacid-soluble solution; maintaining a constant concentration of oxygen in the oxygen-containing solution in the build zone by recirculating the oxygen-containing solution through the peristaltic pump using a peristaltic pump; irradiating the build area through the optically transparent member, the oxygen-soluble material, and the oxygen-permeable membrane with a projector to form a solid polymer from the photosensitive solution, wherein a polymerization surface is aligned with a focal plane of the projector during formation of the three-dimensional object; advancing the platform away from the build surface; A method comprising:

6. Maintaining an oxygen inhibition layer thickness of at least 20 μm The method of claim 5 further comprising:

7. 6. The method of claim 5, wherein the oxygen-soluble material is a fluorocarbon material.

8. The method of claim 5 , wherein the three-dimensional object is an artificial organ.

9. The method of claim 5 , wherein the oxygen permeable membrane is a polytetrafluoroethylene membrane.

10. The method of claim 5 , wherein the thickness of the photosensitive solution is greater than the thickness of the oxygen-containing solution.

11. The method of claim 5 , wherein the thickness of the optically transparent member is less than the thickness of the oxygen-soluble solution.

12. The oxygen permeable membrane is 1600 x 10 －１０ cm ３ (STP)cm / (cm ２ 6. The method of claim 5, wherein the membrane has an oxygen permeability of greater than 1000 s cm Hg.

13. The oxygen-soluble solution contains 0.5 ml of ２ 6. The method of claim 5, wherein the oxygen solubility is 0.01 / ml oxygen soluble.

14. The oxygen-soluble solution was 0.6 ml O ２ 6. The method of claim 5, wherein the oxygen solubility is 0.01 / ml oxygen soluble.

15. The method of claim 5 , further comprising projecting an image onto a focal plane of the projector.

16. 16. The method of claim 15, further comprising modifying the image based on a difference in refractive index between air and the oxygen-soluble solution.

17. The method of claim 5 , wherein the thickness of the photosensitive liquid is greater than the thickness of the optically transparent member.

18. The method of claim 5 wherein the photosensitive solution is water-soluble.

19. 6. The method of claim 5, wherein the oxygen-soluble solution is incompressible.

20. The method of claim 5 , wherein the oxygen-permeable solution is configured to prevent deformation of the oxygen-permeable membrane.

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