3D Fabrication with a Semipermeable Build Plate Dead Zone
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Solution Overview
Problem
Conventional three-dimensional fabrication techniques face challenges in 'bottom-up' methods due to the need for mechanical separation steps, which can distort the end product and complicate the process, while 'top-down' methods require submersion in a deep resin pool.
Innovation Solution
A continuous liquid interphase printing method where a gradient of polymerization is maintained between a 'dead zone' and a polymerization zone, allowing for the formation of a three-dimensional object without mechanical separation, using a semipermeable build plate to inhibit polymerization and advance the object continuously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If bottom-up fabrication techniques are used to eliminate the need for deep resin pool submersion, then the need for submersion is reduced, but mechanical separation steps are required which complicate the process and may distort the end product
Solution Approach 1:
The patent replaces mechanical separation systems with a chemical solution. A semipermeable membrane is used to create a concentration gradient of polymerization inhibitor, allowing continuous chemical inhibition of polymerization at the build surface without mechanical intervention. This substitutes mechanical separation elements with a chemically-based continuous process.
Solution Approach 2:
The semipermeable membrane acts as an intermediary that allows selective passage of polymerization inhibitor while blocking polymerizable liquid. This intermediary creates the dead zone and maintains the concentration gradient, enabling continuous inhibition without direct mechanical contact or separation steps.
2Productivity
If continuous polymerization is maintained to enable efficient production, then productivity increases, but fault lines and distortion may occur in the end product
Solution Approach 1:
The patent applies local quality by creating a spatially varying concentration of polymerization inhibitor. The dead zone immediately adjacent to the build surface has high inhibitor concentration that prevents polymerization, while the concentration gradient allows controlled polymerization in regions further away. This localized chemical environment enables continuous fabrication while preventing fault lines through controlled stress distribution.
3Reliability
If a semipermeable membrane is used to maintain inhibitor gradient, then continuous inhibition is achieved, but the device complexity increases due to additional components
Solution Approach 1:
The semipermeable membrane performs multiple functions simultaneously: it acts as a physical barrier, enables selective mass transport of inhibitor, maintains the concentration gradient, and defines the dead zone boundary. This multi-functionality reduces the need for additional separate components, offsetting the initial complexity increase.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces fault lines and eliminates the need for mechanical separation, enabling efficient and distortion-free production of three-dimensional objects.
Implementation Method 1
using a semipermeable build plate to inhibit polymerization
Implementation Method 2
layer formation is performed through solidification of photo curable resin under the action of visible or UV light irradiation
Data Source
AI summary
A method of forming a three-dimensional object, is carried out by (a) providing a carrier and a build plate, the build plate comprising a semipermeable member, the semipermeable member comprising a build surface with the build surface and the carrier defining a build region therebetween, and with the build surface in fluid communication by way of the semipermeable member with a source of polymerization inhibitor; (b) filling the build region with a polymerizable liquid, the polymerizable liquid contacting the build surface, (c) irradiating the build region through the build plate to produce a solid polymerized region in the build region, while forming or maintaining a liquid film release layer comprised of the polymerizable liquid formed between the solid polymerized region and the build surface, wherein the polymerization of which liquid film is inhibited by the polymerization inhibitor; and (d) advancing the carrier with the polymerized region adhered thereto away from the build surface on the build plate to create a subsequent build region between the polymerized region and the build surface while concurrently filling the subsequent build region with polymerizable liquid as in step (b). Apparatus for carrying out the method is also described.