Permeable Window Additive Manufacturing Apparatus for Dual-Cure Resins
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Solution Overview
Problem
Conventional additive manufacturing techniques, such as stereolithography, are limited to prototyping due to poor tensile properties of produced parts, restricting their use in real-world applications, while recent developments like continuous liquid interface production (CLIP) have expanded capabilities but require further enhancements for improved structural and mechanical properties.
Innovation Solution
An apparatus and method utilizing a permeable window for delivering inhibitors and reactants during the additive manufacturing process, allowing for light polymerization and maintaining a liquid film release layer, which enables the formation of three-dimensional objects with enhanced properties through dual cure resins and thermoplastic particles, and optional further curing or vulcanization steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional stereolithography techniques are used to produce three-dimensional objects, then the manufacturing process can be performed in a step-wise layer-by-layer manner, but the tensile properties and structural integrity of the produced parts are poor
Solution Approach 1:
The patent changes the chemical parameters of the resin system by incorporating dual-cure chemistry (photo-curable and thermally-curable components) and controlling polymerization kinetics through inhibitor delivery, transforming the material properties to achieve both rapid fabrication and superior mechanical strength
Solution Approach 2:
The patent uses composite resin systems combining photo-curable monomers, thermally-curable monomers, and thermoplastic particles to create multi-phase materials that leverage the advantages of each component: rapid initial curing, enhanced structural development, and improved mechanical properties
2Productivity
If continuous liquid interface production (CLIP) is used to rapidly produce three-dimensional objects, then productivity is improved, but further enhancements are needed to maximize structural and mechanical properties
Solution Approach 1:
The patent maintains continuous polymerization action by delivering inhibitors and reactants dynamically during the CLIP process, ensuring uninterrupted chain growth and crosslinking while the object is being formed, which maximizes both production speed and material property development
Solution Approach 2:
The patent performs preliminary photo-curing to form an intermediate object structure, then follows with thermal curing to develop full structural properties, preparing the material in stages to achieve optimal mechanical characteristics
3Strength
If dual cure resins are used to improve tensile properties, then additional curing steps are required, but this increases process complexity
Solution Approach 1:
The patent merges two curing mechanisms (photo-curing and thermal curing) into a unified dual-cure resin system, where both curing actions occur within the same material matrix and can be sequentially activated, simplifying the overall process compared to using separate materials or processes
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 with improved tensile properties and structural integrity, suitable for functional parts beyond prototyping, by integrating inhibitors and reactants during the manufacturing process and incorporating dual cure resins and thermoplastic particles.
Implementation Method 1
a window permeable to an inhibitor of polymerization... configured to deliver an inhibitor of polymerization through the window to the build surface
Implementation Method 2
irradiating said build region with light... to thereby form said three-dimensional object from said polymerization liquid by light polymerization
Data Source
AI summary
Provided herein is an apparatus for producing three-dimensional objects by additive manufacturing, which may include: (a) optionally a window permeable to an inhibitor of polymerization; (b) a window mount to which the window is secured when the window is present; (c) optionally a carrier platform on which the three-dimensional object can be produced; (d) a carrier platform mount operatively associated with the window mount; (e) a drive assembly operatively associated with the window mount and the carrier platform mount; (f) a light source operatively associated with the window mount operatively associated with a patterning array; (g) an inhibitor of polymerization supply configured for operative association with the feed surface when present; and (h) at least one or two reactant supplies configured for operative association with the feed surface when present. Methods of making a three-dimensional object from a polymerization liquid that may use such apparatus are also provided.