Continuous Liquid Interphase Printing for Bottom-Up 3D Fabrication
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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 methods for non-destructive production in 'bottom-up' systems.
Innovation Solution
The development of continuous liquid interphase printing methods where a three-dimensional object is produced from a liquid interface with a gradient of polymerization between two zones, one with an inhibitor and the other without, allowing for continuous production without mechanical separation, using a semipermeable build plate to maintain a 'dead zone' and a gradient of polymerization zone, facilitating the formation of a three-dimensional object without fault lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mechanical separation steps are used in bottom-up fabrication, then layers can be separated from the build plate, but the process becomes complicated, slower, and may distort the final product
Solution Approach 1:
The patent replaces mechanical separation systems with a chemical solution. An elastic separation layer made of polymeric material is used that allows layers to be separated through controlled deformation and release mechanisms rather than complex mechanical tools. The separation is achieved through the elastic properties of the polymeric layer rather than mechanical force application tools
Solution Approach 2:
The elastic separation layer acts as an intermediary between the build plate and the solidified layers. This polymeric intermediate layer facilitates separation by providing a compliant interface that can deform to release adhesion forces, eliminating the need for direct mechanical separation tools that contact the object being fabricated
2Ease of operation
If mechanical separation steps are used in bottom-up fabrication, then layers can be removed from the build plate, but production speed decreases and fault lines may form
Solution Approach 1:
The patent replaces slow mechanical separation processes with a faster elastic release mechanism. The polymeric separation layer enables rapid layer removal through controlled elastic deformation, significantly reducing the time required for each layer separation event and increasing overall fabrication throughput
Solution Approach 2:
The elastic separation layer is prepared in advance on the build plate before fabrication begins. This preliminary preparation of the separation interface allows for rapid layer removal during fabrication without requiring time-consuming setup or complex mechanical operations, thereby increasing productivity
3Ease of operation
If mechanical separation elements are used, then layer separation is achieved, but the apparatus becomes more complex and the final product may be distorted
Solution Approach 1:
The patent replaces mechanical separation tools that may contact and distort the object with an elastic polymeric separation layer. This layer provides separation through controlled deformation and release, eliminating direct mechanical contact with the fabricated object and preventing distortion of fine features
Solution Approach 2:
The elastic separation layer is implemented as a flexible polymeric film or shell on the build plate. This thin, compliant layer can deform to release adhesion forces without applying concentrated mechanical stresses that would distort the object, providing separation while maintaining manufacturing precision
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 continuous production of three-dimensional objects without mechanical separation steps, reducing fault lines and allowing for the creation of complex structures with reduced mechanical complexity and increased efficiency.
Implementation Method 1
using a semipermeable build plate to maintain a 'dead zone' and a gradient of polymerization zone
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 providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; filling the build region with a polymerizable liquid; irradiating the build region through the optically transparent member to form a solid polymer from the polymerizable liquid and advancing the carrier away from the build surface to form the three-dimensional object from the solid polymer, while also concurrently with the irradiating and/or advancing steps: (i) continuously maintaining a dead zone of polymerizable liquid in contact with the build surface, and (ii) continuously maintaining a gradient of polymerization zone between the dead zone and the solid polymer and in contact with each thereof. The gradient of polymerization zone comprises the polymerizable liquid in partially cured form (e.g., so that the formation of fault or cleavage lines between layers of solid polymer in the three-dimensional object is reduced). Apparatus for carrying out the method is also described.