Permeable Build Plates for Continuous CLIP Without Mechanical Separation
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Solution Overview
Problem
Conventional three-dimensional fabrication techniques, particularly 'bottom-up' methods, require mechanical separation steps that can distort the end product and complicate the process, while 'top-down' methods necessitate submersion in deep resin pools.
Innovation Solution
A continuous liquid interface printing (CLIP) method using a build plate with a rigid, optically transparent, gas-permeable base and adhesive layer, allowing for the production of three-dimensional objects without mechanical separation by maintaining a dead zone and polymerization gradient, enabling continuous fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If bottom-up fabrication techniques are used to eliminate deep resin pool submersion, then the need for deep well submersion is reduced, but mechanical separation steps are required that complicate the apparatus and may distort the end product
Solution Approach 1:
The patent replaces mechanical separation mechanisms with a chemical solution: an oxygen-permeable build plate that maintains a dead zone through oxygen diffusion. This eliminates the need for elastic separation layers, sliding build plates, or other mechanical separation devices, directly resolving the contradiction between reduced resin pool volume and avoidance of mechanical separation complexity
Solution Approach 2:
The build plate is made oxygen-permeable (porous) to allow oxygen diffusion into the resin, creating and maintaining a dead zone at the build surface. This porous material approach enables continuous fabrication without mechanical separation, solving both the resin pool volume reduction and eliminating mechanical separation requirements
2Productivity
If bottom-up fabrication techniques are used to lift object out of shallow well, then deep well submersion is eliminated, but extreme care and additional mechanical elements are needed for separation
Solution Approach 1:
The patent substitutes mechanical separation operations with a chemically maintained dead zone through oxygen-permeable build plate diffusion. This eliminates the need for careful mechanical separation operations, enabling continuous fabrication and directly improving productivity while simplifying ease of operation
Solution Approach 2:
The oxygen-permeable build plate automatically maintains the dead zone through continuous oxygen diffusion into the resin. This self-maintaining mechanism eliminates the need for operator intervention in separation operations, enabling continuous fabrication without extreme care or additional mechanical elements
3Manufacturing precision
If mechanical separation steps are employed to separate solidified layer from bottom plate, then layer separation is achieved, but the process is slowed and the end product may be distorted
Solution Approach 1:
The patent replaces mechanical separation steps with a chemically maintained dead zone through oxygen diffusion from the build plate. This eliminates mechanical separation operations that cause product distortion and slow fabrication, directly improving manufacturing precision while enabling continuous fabrication for higher productivity
Solution Approach 2:
The oxygen-permeable build plate enables continuous fabrication by maintaining a persistent dead zone through continuous oxygen diffusion. This eliminates interrupting mechanical separation steps, allowing uninterrupted fabrication that improves both productivity and prevents product distortion from repeated separation operations
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
Facilitates non-destructive, continuous production of three-dimensional objects by avoiding mechanical separation, maintaining a polymerization gradient, and ensuring precise formation without distortion.
Implementation Method 1
a rigid, optically transparent, gas-permeable planar base
Implementation Method 2
a gas permeable adhesive layer on the base upper surface
Implementation Method 3
layer formation is performed through solidification of photo curable resin under the action of visible or UV light irradiation
Data Source
AI summary
A build plate for a three-dimensional printer includes a rigid, optically transparent, gas-permeable planar base having an upper surface and an opposing lower surface; a gas permeable adhesive layer on the base upper surface; 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 on the adhesive layer opposite the base.