Build Plate Assembly for Continuous Liquid Interphase Printing
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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, and lack continuous processes that are non-destructive to the object being produced.
Innovation Solution
The development of a continuous liquid interphase printing (CLIP) method and apparatus that uses a build plate assembly with a lighting panel, optically transparent gas-impermeable screen, and a gas-permeable sheet to form three-dimensional objects by continuously irradiating a polymerizable liquid and advancing the carrier away from the build surface, maintaining a dead zone and polymerization gradient to avoid mechanical separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mechanical separation steps are used in bottom-up fabrication, then the solidified layer can be separated from the build plate, but the process becomes complicated, slower, and potentially distorts the final product
Solution Approach 1:
The patent replaces mechanical separation systems with an oxygen permeation-based release mechanism. The build plate incorporates an oxygen-permeable membrane that allows oxygen to diffuse through it, creating an oxygen-rich environment at the build surface that prevents polymerization and forms a natural release layer. This eliminates the need for mechanical separation elements while achieving clean, distortion-free part release.
Solution Approach 2:
The patent introduces oxygen as an intermediary substance that mediates between the build plate and the polymerizable liquid. The oxygen-permeable membrane serves as an intermediary structure that transports oxygen from the environment through the build plate to the liquid interface, where it inhibits polymerization and enables non-destructive separation without direct mechanical contact.
2Productivity
If mechanical separation steps are used in bottom-up fabrication, then layers can be separated, but production speed decreases and distortion increases
Solution Approach 1:
The patent replaces mechanical separation operations with a continuous oxygen-permeation-based release process. The oxygen-rich environment maintained at the build surface through the permeable membrane continuously prevents adhesion between the solidified layer and the build plate, enabling parts to be removed without mechanical contact. This eliminates production interruptions and prevents distortion that would result from mechanical separation forces.
Solution Approach 2:
The patent maintains continuous oxygen permeation through the build plate throughout the fabrication process. This continuous supply of oxygen to the liquid interface ensures uninterrupted formation of the non-adhesive release layer, allowing for continuous or near-continuous production without the stop-start nature of mechanical separation cycles, thereby increasing productivity while maintaining precision.
3Device complexity
If oxygen permeation is used to prevent polymerization at the build surface, then mechanical separation is eliminated, but a controlled oxygen environment must be maintained
Solution Approach 1:
The patent employs a self-regulating oxygen permeation system where the build plate's oxygen-permeable membrane automatically maintains the oxygen-rich environment at the build surface. The membrane's inherent permeability properties self-regulate the oxygen flux based on the concentration gradient, eliminating the need for complex active control systems while ensuring consistent oxygen supply to prevent polymerization and enable part release.
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 allows for the continuous production of three-dimensional objects without the need for mechanical separation steps, enhancing speed and reducing distortion, while maintaining a stable polymerization process.
Implementation Method 1
irradiating the build region with light through the optically transparent member to form a solid polymer from the polymerizable liquid
Implementation Method 2
a flexible, optically transparent, gas-permeable sheet having upper and lower surfaces, the upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface positioned opposite the base, wherein the build plate is configured to permit gas flow to the build surface
Data Source
AI summary
A build plate assembly for a three-dimensional printer includes: a lighting panel having individually addressable pixels configured to selectively emit light and/or transmit light from illumination below the pixels to a top surface top surface of the lighting panel; a rigid, optically transparent, gas-impermeable planar screen or base having an upper surface having an uneven surface topology and a lower surface that is affixed to the top surface of the lighting panel; and a flexible, optically transparent, gas-permeable sheet having upper and lower surfaces, the upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface positioned opposite the base, wherein the build plate is configured to permit gas flow to the build surface.