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)] | 23 Claims |
1. A method of forming a three-dimensional object, 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 the first component;
(c) irradiating said build region with light through said optically transparent member to form a solid polymer scaffold from the first component and advancing said carrier away from said build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, said three-dimensional object, with said intermediate containing said second solidifiable component carried in the scaffold in unsolidified or uncured form;
(d) concurrently with 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 the irradiating step, solidifying and/or curing the second solidifiable component to form from said three-dimensional intermediate said three-dimensional object,
wherein said build surface comprises a fluoropolymer film, and
wherein said solidifying and/or curing step (e) is carried out by:
(i) heating or microwave irradiating said second solidifiable component;
(ii) irradiating said second solidifiable component with light at a wavelength different from that of the light in said irradiating step (c);
(iii) contacting said second solidifiable component to water; or
(iv) contacting said second solidifiable component to a catalyst.
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