3D Printing Build Plate With Gas Permeable Sheet

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 layer and the build plate, lacking efficient methods for non-destructive separation.

Innovation Solution

The development of a continuous liquid interface production (CLIP) method using a build plate with a rigid, optically transparent, gas-impermeable base and a flexible, optically transparent, gas-permeable sheet with a gas flow enhancing feature, such as a channel layer, to facilitate the formation of three-dimensional objects without the need for mechanical separation, by maintaining a dead zone and polymerization gradient to inhibit polymerization and allow continuous advancement of the carrier.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If mechanical separation steps are used to separate solidified layers from the build plate, then the fabrication process can be completed, but the process becomes complicated, production speed decreases, and potential distortion occurs due to physical and chemical interactions

Engineering Contradiction:

Improveease of separationVSAvoidproduction speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces mechanical separation systems with an oxygen permeation-based release mechanism. The build plate allows oxygen to diffuse through it to form a liquid release layer at the interface, enabling non-mechanical separation of solidified layers. This eliminates complex mechanical elements while maintaining separation functionality, directly resolving the contradiction between ease of manufacture and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an oxygen permeation mechanism as an intermediary between the build plate and the solidified layer. Oxygen diffuses through the build plate to create a liquid release layer that acts as a mediator, allowing the solidified layer to separate without direct mechanical contact. This intermediary mechanism enables separation without the complications and speed losses associated with direct mechanical systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If mechanical separation steps are used to separate solidified layers from the build plate, then the fabrication process can be completed, but the process becomes complicated with additional mechanical elements

Engineering Contradiction:

Improveease of separationVSAvoidmechanical elements

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent replaces mechanical separation systems with an oxygen permeation-based release mechanism. The build plate allows oxygen to diffuse through it to form a liquid release layer at the interface, enabling non-mechanical separation of solidified layers. This eliminates complex mechanical elements while maintaining separation functionality, directly resolving the contradiction between ease of manufacture and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If mechanical separation steps are used to separate solidified layers from the build plate, then the fabrication process can be completed, but potential distortion occurs due to physical and chemical interactions

Engineering Contradiction:

Improveease of separationVSAvoidproduct distortion

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical separation systems with an oxygen permeation-based release mechanism. The build plate allows oxygen to diffuse through it to form a liquid release layer at the interface, enabling non-mechanical separation of solidified layers. This eliminates complex mechanical elements while maintaining separation functionality, directly resolving the contradiction between ease of manufacture and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the harmful effect of oxygen inhibition (which normally prevents complete polymerization at the liquid-resin interface) into a beneficial release mechanism. By allowing oxygen to permeate through the build plate and form a liquid release layer, the previously problematic oxygen interaction becomes the key to enabling separation without distortion, resolving the contradiction between ease of separation and manufacturing precision.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Ease of manufacture

If a deep pool of liquid resin is used to submerge the growing object, then new layers can be formed at the top surface, but the apparatus becomes more complex and the process slower

Engineering Contradiction:

Improvelayer formationVSAvoidfabrication speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent inverts the conventional layer formation approach by forming layers at the bottom surface of the growing object rather than at the top. The build plate with oxygen permeation capability enables new layers to form at the bottom interface, and the object is progressively released upward. This inversion eliminates the need for deep resin pools and mechanical separation, directly resolving the contradiction between ease of manufacture and fabrication speed.

Inventive Principle:

Principle #13The other way round (Inversion)

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 enables the production of three-dimensional objects without mechanical release steps, improving efficiency and reducing distortion, allowing for continuous and uninterrupted fabrication by maintaining a stable polymerization zone and inhibitor flow, thus enhancing the speed and quality of the manufacturing process.

Implementation Method 1

a flexible, optically transparent, gas-permeable sheet having an upper and lower surface, the sheet upper surface comprising a build surface for forming a three-dimensional object

Methodology Applied

Scientific EffectGas permeation: Permeation

Implementation Method 2

maintaining a dead zone and polymerization gradient to inhibit polymerization and allow continuous advancement of the carrier

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 3

layer formation is performed through solidification of photo curable resin under the action of visible or UV light irradiation

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 4

maintaining a dead zone and polymerization gradient to inhibit polymerization and allow continuous advancement of the carrier

Methodology Applied

Scientific EffectConcentration gradient: Density Gradient

Data Source

PatentUS11518096B2Three-dimensional printing with build plates having surface topologies for increasing permeability and related methods

Publication Date: 2022.12.06 CARBON INC

AI summary

A build plate for a three-dimensional printer includes: a rigid, optically transparent, gas-impermeable planar base having an upper surface and a lower surface; and a flexible, optically transparent, gas-permeable sheet having an upper and lower surface, the sheet upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface positioned on the base upper surface. The build plate includes a gas flow enhancing feature configured to increase gas flow to the build surface.