Bottom-Up CLIP Printing With Reciprocal Carrier Motion for Liquid Refill
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Solution Overview
Problem
Conventional three-dimensional fabrication techniques face challenges in mechanical separation steps, particularly in 'bottom-up' methods, which can distort the end product and complicate the apparatus, while 'top-down' methods require submerging the object in a deep resin pool.
Innovation Solution
A method and apparatus for continuous liquid interface production (CLIP) that involves filling a build region with polymerizable liquid, irradiating it through an optically transparent member, and continuously advancing the carrier away from the build surface to form a three-dimensional object, maintaining a dead zone and gradient of polymerization zone to avoid mechanical separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If new layers are formed at the bottom surface of the growing object, then the need for a deep resin pool is eliminated, but mechanical separation steps are required which complicate the apparatus and may distort the end product
Solution Approach 1:
The patent replaces the mechanical separation system with a chemical release mechanism. A release layer is applied to the build plate that prevents adhesion between the solidified material and the plate, allowing layers to separate without mechanical intervention. This substitution eliminates the complexity of mechanical separation mechanisms while maintaining the bottom-up fabrication approach.
Solution Approach 2:
The release layer acts as an intermediary between the build plate and the solidified material. This intermediate layer facilitates non-destructive separation by preventing direct adhesion between the material and the plate, solving the problem of mechanical separation requirements without adding complex mechanical systems.
2Device complexity
If new layers are formed at the top surface of the growing object, then mechanical separation is avoided, but the object must be submerged in a deep resin pool which increases apparatus complexity
Solution Approach 1:
The patent inverts the conventional top-down approach by implementing bottom-up fabrication. Instead of forming layers at the top surface and submerging the object in a deep resin pool, the build plate is lowered into a shallow resin pool, and layers are formed at the bottom surface. This inversion allows the object to grow upward without requiring a deep resin pool, while the release layer prevents the need for mechanical separation.
Solution Approach 2:
The patent changes the parameter of resin pool depth from deep to shallow by inverting the fabrication approach. By forming layers at the bottom surface and using a release layer for separation, the system requires only a shallow resin pool, significantly reducing the volume of stationary object while avoiding mechanical separation complexity.
3Productivity
If mechanical separation is used to remove solidified layers from the build plate, then continuous fabrication is interrupted, but the process can be completed with discrete steps
Solution Approach 1:
The patent replaces mechanical separation with chemical release through the release layer. This substitution enables continuous fabrication because the release layer allows layers to separate automatically without mechanical intervention that would interrupt the process. The chemical release mechanism maintains manufacturing precision by avoiding the distortion that can occur with mechanical separation forces.
Solution Approach 2:
The release layer enables continuous fabrication by allowing uninterrupted layer formation and automatic separation. The chemical release mechanism operates continuously without the need to stop the fabrication process for mechanical separation steps, maintaining both productivity and precision throughout the entire fabrication process.
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
Enables the production of three-dimensional objects without mechanical separation steps, allowing for continuous fabrication and minimizing distortion, while maintaining a stable polymerization gradient to ensure fault-free formation.
Implementation Method 1
irradiating it through an optically transparent member to form a three-dimensional object
Implementation Method 2
maintaining a dead zone and gradient of polymerization zone to avoid mechanical separation
Data Source
AI summary
Described herein are methods, systems and apparatus (including associated control methods, systems and apparatus), for the production of a three-dimensional object by “bottom up” additive manufacturing, in which a carrier is vertically reciprocated with respect to a build surface, to enhance or speed the refilling of the build region with a solidifiable liquid. In preferred (but not necessarily limiting) embodiments, the three-dimensional object is produced from a liquid interface by continuous liquid interface production (i.e., “CLIP”).