Continuous 3D Printing via Chemical Dissolution of Supports
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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 efficient continuous processes for non-destructive object creation.
Innovation Solution
The method involves continuous or intermittent irradiation of a polymerizable liquid through an optically transparent member to form a solid polymer, while simultaneously advancing a carrier away from the build surface, maintaining a dead zone and gradient of polymerization to avoid mechanical separation and enhance production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If bottom-up fabrication techniques are used to eliminate the need for submerging the object in a deep resin pool, 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 replaces the mechanical separation system with a chemical solution system. Instead of using elastic separation layers or sliding build plates that require mechanical intervention, the invention uses a liquid chemical solution to dissolve and remove the support structure holding the object at the bottom of the well. This substitution eliminates complex mechanical separation mechanisms while maintaining the ability to retrieve fabricated objects from the resin pool.
Solution Approach 2:
The patent introduces a chemical intermediary (liquid solution) that facilitates the separation of the fabricated object from the support structure. This intermediary substance acts as a mediator between the object and the retrieval process, allowing non-destructive separation without direct mechanical contact. The chemical solution penetrates and dissolves the support material, enabling easy object recovery without complex mechanical separation apparatus.
2Ease of manufacture
If mechanical separation steps are employed to separate solidified layers from the bottom plate, then layer separation is achieved, but production time increases and potential distortions occur
Solution Approach 1:
The patent replaces time-consuming mechanical separation operations with a chemical dissolution process. Instead of manually or mechanically separating solidified layers from the bottom plate, the invention uses a liquid chemical solution that automatically dissolves the support structure. This chemical approach eliminates the need for prolonged mechanical separation steps, significantly reducing production time while maintaining ease of layer separation.
Solution Approach 2:
The patent enables the support structure to self-dissolve when exposed to the liquid chemical solution. The support material is designed to be chemically responsive, automatically breaking down and releasing the fabricated object without requiring external mechanical intervention. This self-service mechanism eliminates the need for operator involvement in separation steps, accelerating production while maintaining ease of manufacture.
3Manufacturing precision
If mechanical separation elements are used to achieve non-destructive separation, then object integrity is maintained, but apparatus complexity and potential distortions increase
Solution Approach 1:
The patent replaces mechanical separation elements that could potentially distort objects with a gentle chemical dissolution process. The liquid solution chemically breaks down the support structure without applying mechanical forces to the fabricated object, thereby maintaining object integrity while eliminating complex mechanical separation mechanisms. This substitution achieves non-destructive separation with simpler apparatus.
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, reducing production time and minimizing distortions, and enables the creation of complex structures with improved precision and speed.
Implementation Method 1
irradiating the build region with light through the optically transparent member to form a solid polymer from the polymerizable liquid
Data Source
AI summary
A method of forming a three-dimensional object is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween, with the carrier positioned adjacent and spaced apart from the build surface at a start position; then (b) forming an adhesion segment of the three-dimensional object (c) optionally but preferably forming a transition segment of the three dimensional object; and then (d) forming a body segment of the three dimensional object. In each case, the segment can be formed by: (i) filling the build region with a polymerizable liquid, (ii) continuously or intermittently irradiating the build region with light through the optically transparent, and (iii) continuously or intermittently advancing the carrier away from the build surface, to thereby form that segment from the polymerizable liquid.