US 11,786,711 B2
Continuous liquid interphase printing
Joseph M. DeSimone, Monte Sereno, CA (US); Alexander Ermoshkin, Pittsboro, NC (US); Nikita Ermoshkin, Pittsboro, NC (US); and Edward T. Samulski, Chapel Hill, NC (US)
Assigned to Carbon, Inc., Redwood City, CA (US)
Filed by Carbon, Inc., Redwood City, CA (US)
Filed on Jan. 22, 2021, as Appl. No. 17/155,349.
Application 17/155,349 is a continuation of application No. 16/003,178, filed on Jun. 8, 2018, granted, now 11,260,208.
Application 16/003,178 is a continuation of application No. 15/143,986, filed on May 2, 2016, granted, now 10,016,938, issued on Jul. 10, 2018.
Application 15/143,986 is a continuation of application No. 14/456,270, filed on Aug. 11, 2014, granted, now 9,360,757, issued on Jun. 7, 2016.
Claims priority of provisional application 61/980,430, filed on Apr. 16, 2014.
Claims priority of provisional application 61/919,903, filed on Dec. 23, 2013.
Claims priority of provisional application 61/865,841, filed on Aug. 14, 2013.
Prior Publication US 2021/0283383 A1, Sep. 16, 2021
Int. Cl. B29C 33/58 (2006.01); B29C 33/62 (2006.01); A61M 25/00 (2006.01); A61M 29/02 (2006.01); A61B 17/24 (2006.01); A61B 17/34 (2006.01); A61M 25/10 (2013.01); A61B 90/00 (2016.01)
CPC A61M 29/02 (2013.01) [A61B 17/24 (2013.01); A61B 17/3415 (2013.01); A61M 25/1002 (2013.01); A61M 25/1025 (2013.01); A61B 2090/062 (2016.02); A61M 2025/1054 (2013.01); A61M 2025/1061 (2013.01); A61M 2029/025 (2013.01); A61M 2210/0675 (2013.01); A61M 2210/0681 (2013.01)] 10 Claims
OG exemplary drawing
 
1. A method of forming a three-dimensional object, comprising the steps of:
(a) providing a carrier and a build plate, said build plate comprising a semipermeable member, said semipermeable member comprising a build surface with said build surface and said carrier defining a build region therebetween, and with said build surface in fluid communication by way of the semipermeable member with a source of polymerization inhibitor;
(b) filling said build region with a polymerizable liquid, said polymerizable liquid contacting said build surface,
(c) irradiating said build region through said build plate to produce a solid polymerized region in said build region, while forming or maintaining a liquid film release layer comprised of said polymerizable liquid formed between said solid polymerized region and said build surface, wherein the polymerization of which liquid film is inhibited by said polymerization inhibitor; and
(d) advancing said carrier with said polymerized region adhered thereto away from said build surface on said build plate to create a subsequent build region between said polymerized region and said build surface while concurrently filling said subsequent build region with polymerizable liquid as in step (b);
wherein a gradient of polymerizable liquid is continuously maintained as an interphase between said liquid film release layer and said solid polymerized region and in contact with each thereof, said gradient of polymerizable liquid comprising said polymerizable liquid in partially cured form, and
wherein said liquid film release layer is continuously maintained by feeding said polymerization inhibitor through said semipermeable member, thereby creating a gradient of inhibitor in said liquid film release layer and optionally in at least a portion of said gradient of polymerizable liquid; and
(e) continuing and/or repeating steps (b), (c), and (d) to produce a subsequent polymerized region adhered to a previous polymerized region until the continued or repeated deposition of polymerized regions adhered to one another forms said three-dimensional object.