3D Fabrication with a Semipermeable Build Plate Release Layer
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Solution Overview
Problem
Conventional three-dimensional fabrication techniques, particularly 'bottom-up' methods, require mechanical separation steps that can complicate the process, slow down production, and potentially distort the final product due to physical and chemical interactions between the solidified layers and the build plate.
Innovation Solution
The method involves continuous liquid interphase printing, where a three-dimensional object is produced from a liquid interface with a gradient of polymerization between two zones, allowing for continuous production without the need for mechanical separation steps, using a semipermeable build plate that maintains a 'dead zone' of inhibitor to prevent polymerization and facilitate smooth layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If bottom-up fabrication techniques are used to eliminate the need for submerging the object in liquid resin, then the need for deep wells is reduced, but mechanical separation steps are required that complicate the apparatus and slow production
Solution Approach 1:
The patent extracts the separation function from mechanical means and transfers it to a chemical mechanism. The build plate is treated with a release agent that creates a release layer, allowing the solidified material to be released chemically rather than through mechanical separation. This eliminates complex mechanical separation elements while maintaining continuous production capability.
Solution Approach 2:
The release agent acts as an intermediary substance between the build plate and the polymerizable material. This intermediary creates a release layer that prevents adhesion during the build process, enabling easy separation without mechanical complexity. The release agent mediates the interaction between the solidified material and build plate, solving the contradiction between simplicity and productivity.
2Manufacturing precision
If mechanical separation steps are used to separate solidified layers from the build plate, then layer separation is achieved, but the process is slowed and potential distortion occurs
Solution Approach 1:
The patent replaces the mechanical separation system with a chemical release system. Instead of using mechanical elements to separate layers, the build plate is treated with a release agent that prevents adhesion through chemical means. This substitution eliminates mechanical separation steps that cause distortion and slow production, achieving both precision and productivity.
Solution Approach 2:
The release agent is applied to the build plate in advance before the fabrication process begins. This preliminary action creates a release layer that prevents adhesion issues during the build process. By preparing the build plate beforehand with the release agent, the patent avoids the need for mechanical separation steps that would slow production and cause distortion.
3Manufacturing precision
If elastic separation layers are used to achieve non-destructive separation, then material integrity is maintained, but the apparatus becomes more complex
Solution Approach 1:
The patent uses a release agent that creates a disposable release layer on the build plate. This release layer is consumed during the build process and can be replenished by applying more release agent. Instead of using complex elastic separation layers, the patent employs a simple, replenishable chemical layer that maintains material integrity without adding apparatus complexity.
4Manufacturing precision
If sliding build plates are used to separate layers, then mechanical separation is achieved, but the process is complicated and potential distortion occurs
Solution Approach 1:
The patent replaces the sliding build plate mechanical system with a stationary build plate treated with a release agent. Instead of mechanically moving the build plate to separate layers, the patent uses the chemical release layer to prevent adhesion. This substitution eliminates the complexity of sliding mechanisms while maintaining the ability to separate layers without distortion.
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 approach reduces or eliminates fault lines in the final product, enables continuous production, and avoids the mechanical complexities of traditional layer-by-layer methods, allowing for more precise and efficient fabrication of three-dimensional objects.
Implementation Method 1
using a semipermeable build plate that maintains a 'dead zone' of inhibitor to prevent 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.