US 11,707,893 B2
Methods for producing three-dimensional objects with apparatus having feed channels
Jason P. Rolland, San Carlos, CA (US); Kai Chen, Sunnyvale, CA (US); Justin Poelma, Sunnyvale, CA (US); James Goodrich, Downington, PA (US); Robert K. Pinschmidt, Jr., Carrboro, NC (US); Joseph M. DeSimone, Monte Sereno, CA (US); and Lloyd M. Robeson, Macungie, PA (US)
Assigned to Carbon, Inc., Redwood City, CA (US)
Filed by Carbon, Inc., Redwood City, CA (US)
Filed on Mar. 17, 2022, as Appl. No. 17/655,282.
Application 17/655,282 is a continuation of application No. 17/068,962, filed on Oct. 13, 2020, granted, now 11,312,084.
Application 17/068,962 is a continuation of application No. 16/803,047, filed on Feb. 27, 2020, granted, now 10,899,868, issued on Jan. 26, 2021.
Application 16/803,047 is a continuation of application No. 15/963,550, filed on Apr. 26, 2018, granted, now 10,647,879, issued on May 21, 2020.
Application 15/963,550 is a continuation of application No. 15/240,157, filed on Aug. 18, 2016, granted, now 9,982,164, issued on May 12, 2020.
Application 15/240,157 is a continuation of application No. 14/977,974, filed on Dec. 22, 2015, granted, now 9,453,142, issued on May 29, 2018.
Application 14/977,974 is a continuation in part of application No. PCT/US2015/036946, filed on Jun. 22, 2015.
Claims priority of provisional application 62/133,642, filed on Mar. 16, 2015.
Claims priority of provisional application 62/129,187, filed on Mar. 6, 2015.
Claims priority of provisional application 62/111,961, filed on Feb. 4, 2015.
Claims priority of provisional application 62/101,671, filed on Jan. 9, 2015.
Claims priority of provisional application 62/036,161, filed on Aug. 12, 2014.
Claims priority of provisional application 62/015,780, filed on Jun. 23, 2014.
Prior Publication US 2022/0402214 A1, Dec. 22, 2022
Int. Cl. C08F 2/46 (2006.01); C08F 2/50 (2006.01); C08G 61/04 (2006.01); B29C 64/40 (2017.01); C08K 3/013 (2018.01); C08K 3/01 (2018.01); B29C 64/129 (2017.01); G03F 7/00 (2006.01); G03F 7/027 (2006.01); G03F 7/038 (2006.01); G03F 7/075 (2006.01); G03F 7/38 (2006.01); B29C 64/124 (2017.01); B29C 64/135 (2017.01); B29C 64/386 (2017.01); C08G 18/81 (2006.01); C08G 18/10 (2006.01); C08G 18/76 (2006.01); C08F 220/34 (2006.01); C08G 18/42 (2006.01); C08F 290/06 (2006.01); C08G 18/73 (2006.01); C08G 18/48 (2006.01); C08G 18/24 (2006.01); C08G 18/69 (2006.01); C08G 18/75 (2006.01); C08F 283/00 (2006.01); C08G 18/40 (2006.01); B29C 71/00 (2006.01); B29C 64/286 (2017.01); B33Y 10/00 (2015.01); B33Y 70/00 (2020.01); B29D 11/00 (2006.01); B29C 35/08 (2006.01); C08K 5/00 (2006.01); C08L 75/04 (2006.01); B33Y 80/00 (2015.01); C09D 135/02 (2006.01); C09D 175/04 (2006.01); C09D 175/08 (2006.01); B29C 64/255 (2017.01); B29C 64/106 (2017.01); B29C 64/165 (2017.01); B33Y 30/00 (2015.01); C08J 5/00 (2006.01); C08L 75/14 (2006.01); B33Y 50/02 (2015.01); B29C 33/00 (2006.01); B29K 105/00 (2006.01); B29K 75/00 (2006.01); B29K 105/04 (2006.01); B29L 11/00 (2006.01); B29L 31/10 (2006.01); B29K 105/16 (2006.01); B29K 509/00 (2006.01); B29L 31/00 (2006.01)
CPC B29C 64/40 (2017.08) [B29C 35/0805 (2013.01); B29C 64/106 (2017.08); B29C 64/124 (2017.08); B29C 64/129 (2017.08); B29C 64/135 (2017.08); B29C 64/165 (2017.08); B29C 64/255 (2017.08); B29C 64/286 (2017.08); B29C 64/386 (2017.08); B29C 71/0009 (2013.01); B29D 11/00009 (2013.01); B29D 11/00663 (2013.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12); B33Y 70/00 (2014.12); B33Y 80/00 (2014.12); C08F 220/34 (2013.01); C08F 283/006 (2013.01); C08F 290/067 (2013.01); C08G 18/10 (2013.01); C08G 18/244 (2013.01); C08G 18/40 (2013.01); C08G 18/42 (2013.01); C08G 18/4825 (2013.01); C08G 18/4854 (2013.01); C08G 18/69 (2013.01); C08G 18/73 (2013.01); C08G 18/755 (2013.01); C08G 18/758 (2013.01); C08G 18/7671 (2013.01); C08G 18/81 (2013.01); C08G 18/8175 (2013.01); C08J 5/00 (2013.01); C08K 3/01 (2018.01); C08K 3/013 (2018.01); C08K 5/0008 (2013.01); C08K 5/0041 (2013.01); C08L 75/04 (2013.01); C08L 75/14 (2013.01); C09D 135/02 (2013.01); C09D 175/04 (2013.01); C09D 175/08 (2013.01); G03F 7/00 (2013.01); G03F 7/0037 (2013.01); G03F 7/027 (2013.01); G03F 7/038 (2013.01); G03F 7/0757 (2013.01); G03F 7/38 (2013.01); B29C 2033/0005 (2013.01); B29C 2035/0827 (2013.01); B29C 2035/0855 (2013.01); B29K 2075/00 (2013.01); B29K 2075/02 (2013.01); B29K 2105/0002 (2013.01); B29K 2105/0058 (2013.01); B29K 2105/0073 (2013.01); B29K 2105/0091 (2013.01); B29K 2105/043 (2013.01); B29K 2105/16 (2013.01); B29K 2105/251 (2013.01); B29K 2509/00 (2013.01); B29K 2995/0026 (2013.01); B29L 2011/00 (2013.01); B29L 2011/0016 (2013.01); B29L 2011/0075 (2013.01); B29L 2031/001 (2013.01); B29L 2031/10 (2013.01); C08J 2375/14 (2013.01)] 19 Claims
 
1. A method of forming a three-dimensional object, wherein said three-dimensional object is a cushion, a dental mold, a dental implant, a dental aligner, a footwear sole, a footwear heel, a footwear innersole, a footwear midsole, or an insert for use between a helmet and a human body, comprising:
(a) providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween, said optically transparent member comprising a plurality of channels;
(b) filling said build region with a polymerizable liquid, said polymerizable liquid comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from said first component;
(c) irradiating said build region with light through said optically transparent member to form a solid polymer scaffold from said first component and also advancing said carrier away from said build surface to form a three-dimensional intermediate having a shape of said three-dimensional object, said three-dimensional intermediate containing said second solidifiable component carried in said scaffold in unsolidified and/or uncured form;
(d) concurrently or subsequent to said irradiating step, feeding a polymerization inhibitor through said plurality of channels to said build surface to facilitate formation of a release layer on said build surface; and
(e) subsequent to said irradiating step, heating, microwave irradiating, or both heating and microwave irradiating, said second solidifiable component in said three-dimensional intermediate to form said three-dimensional object,
wherein said build surface comprises a fluoropolymer film.