Semipermeable Build Plate for 3D Printing Without Mechanical Separation

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Solution Overview

Problem

Conventional three-dimensional fabrication techniques face challenges in layer formation, particularly with 'top down' methods requiring deep resin pools and 'bottom up' methods needing mechanical separation, which complicates the process and can distort the end product.

Innovation Solution

A method and apparatus using a rigid semipermeable build plate with a separate feed surface for a polymerization inhibitor, allowing for continuous layer formation without mechanical separation by inhibiting polymerization of a liquid film between the build surface and the object, enabling the object to be advanced away from the build plate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of stationary object

If new layers are formed at the bottom of the growing object, then the need for a deep resin pool is eliminated, but mechanical separation steps are required to separate the solidified layer from the bottom plate

Engineering Contradiction:

Improvedepth of resin poolVSAvoidmechanical separation mechanism

Core Design Contradiction:

Length of stationary objectVSDevice complexity

Solution Approach 1:

A Teflon AF film is introduced as an intermediary layer between the build plate and the polymerizable liquid. This film acts as a mediator that prevents polymerization at the build plate interface while allowing easy separation of solidified layers without complex mechanical mechanisms. The film is replenished periodically to maintain the release function.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The Teflon AF film is treated as a consumable component that is periodically replenished rather than maintained indefinitely. This disposable approach simplifies the overall system by replacing a complex mechanical separation mechanism with a simple, replaceable film that performs the release function until it becomes saturated or degraded.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Ease of operation

If an elastic separation layer is used to facilitate separation of solidified material, then separation is enabled, but the apparatus is complicated and the method is slowed

Engineering Contradiction:

Improveseparation of solidified layerVSAvoidapparatus complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The Teflon AF film serves as a permanent intermediary layer that remains on the build plate throughout the fabrication process. It provides continuous separation functionality without requiring complex mechanical elements or dynamic adjustments, thereby simplifying the apparatus while maintaining ease of operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If a sliding build plate is employed, then separation of layers is achieved, but the process is slowed and the end product may be distorted

Engineering Contradiction:

Improveseparation of layersVSAvoidfabrication speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The Teflon AF film provides a passive separation mechanism that requires no movement or mechanical action. Layers are separated simply by peeling them away from the film, eliminating the time-consuming sliding operations and potential distortions associated with mechanical build plate movement.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If the build plate is moved to replenish oxygen, then polymerization inhibition is maintained, but the process becomes more complex

Engineering Contradiction:

Improvepolymerization inhibitionVSAvoidbuild plate movement mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The Teflon AF film continuously supplies oxygen to the interface between the build plate and polymerizable liquid through its inherent permeability. This self-service mechanism maintains polymerization inhibition without requiring external intervention or mechanical movement of the build plate to replenish oxygen.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The mechanical system of moving the build plate to replenish oxygen is replaced with a chemical/physical system where the Teflon AF film passively provides oxygen through permeation. This substitution eliminates complex mechanical movement while maintaining reliable polymerization inhibition.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 eliminates the need for mechanical separation steps, allowing for continuous and efficient three-dimensional object formation without distortion, improving the fabrication process by maintaining a non-polymerized film and preventing damage to the build surface.

Implementation Method 1

a rigid stationary build plate, the build plate comprising a fixed semipermeable member, said semipermeable member comprising a build surface and a feed surface separate from said build surface... with the feed surface in fluid contact with a (liquid or gas) polymerization inhibitor

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

a liquid film release layer comprised of the polymerizable liquid formed between the solid polymerized region and the build surface, the polymerization of which liquid film is inhibited by said polymerization inhibitor

Methodology Applied

Scientific EffectPermeation: Permeation