Continuous Liquid Interphase Printing Gradient Polymerization
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Solution Overview
Problem
Existing three-dimensional fabrication techniques, particularly 'bottom up' methods, require mechanical separation steps that can complicate the process, slow it down, and potentially distort the final product.
Innovation Solution
The method involves continuous liquid interphase printing, where a three-dimensional object is produced from a liquid interface with a gradient of polymerization, allowing for continuous production without the need for mechanical separation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical separation steps are used in bottom up fabrication, then the solidified layer can be separated from the bottom plate, but the process becomes complicated, slower, and may distort the final product
Solution Approach 1:
The patent replaces mechanical separation methods with a chemical solution approach. A soluble adhesive is applied to the bottom plate, and a solvent is introduced to chemically dissolve the adhesive, enabling non-mechanical separation of the solidified layer from the bottom plate. This eliminates the need for mechanical scraping or peeling operations that cause distortion and complexity.
Solution Approach 2:
The patent changes the state of the adhesive from solid/attached to dissolved by introducing a solvent. The chemical parameter change (from bonded state to dissolved state) enables easy separation without mechanical force. The soluble adhesive transitions from a strong bond to a dissolved state, allowing the solidified layer to be easily removed without mechanical intervention.
2Ease of manufacture
If mechanical separation steps are used in bottom up fabrication, then the solidified layer can be separated from the bottom plate, but the fabrication speed decreases
Solution Approach 1:
The patent replaces time-consuming mechanical separation operations with a chemical dissolution process. The soluble adhesive, when exposed to the solvent, rapidly dissolves and releases the solidified layer without requiring mechanical scraping or peeling operations, significantly reducing the separation time and increasing overall fabrication speed.
Solution Approach 2:
The patent changes the separation mechanism from mechanical (requiring force and time) to chemical (rapid dissolution). By introducing the solvent, the adhesive rapidly transitions from a bonded state to a dissolved state, enabling quick separation without mechanical intervention and thereby increasing fabrication productivity.
3Ease of manufacture
If mechanical separation steps are used in bottom up fabrication, then the solidified layer can be separated from the bottom plate, but the final product may be distorted
Solution Approach 1:
The patent replaces mechanical separation operations that can apply force and cause distortion with a chemical dissolution approach. The soluble adhesive, when dissolved by the solvent, releases the solidified layer without mechanical contact, thereby preventing distortion and maintaining high manufacturing precision of the final product.
Solution Approach 2:
The patent changes the separation mechanism from mechanical (which can apply stress and cause distortion) to chemical dissolution (which occurs without physical contact). The adhesive transitions from a bonded state to a dissolved state through chemical action, enabling separation without the mechanical forces that would otherwise distort the delicate final product.
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 reduces or eliminates fault or cleavage lines in the final product, enables continuous production, and simplifies the fabrication process by avoiding mechanical separation complexities.
Implementation Method 1
layer formation is performed through solidification of photo curable resin under the action of visible or UV light irradiation
Implementation Method 2
the gradient of polymerization zone comprises the polymerizable liquid in partially cured form
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.