US 12,214,546 B2
Rapid, large volume, dead layer-free 3D printing
David A. Walker, Evanston, IL (US); James L. Hedrick, III, Evanston, IL (US); and Chad A. Mirkin, Wilmette, IL (US)
Assigned to NORTHWESTERN UNIVERSITY, Evanston, IL (US)
Appl. No. 17/436,754
Filed by NORTHWESTERN UNIVERSITY, Evanston, IL (US)
PCT Filed Mar. 9, 2020, PCT No. PCT/US2020/021729
§ 371(c)(1), (2) Date Sep. 7, 2021,
PCT Pub. No. WO2020/185692, PCT Pub. Date Sep. 17, 2020.
Claims priority of provisional application 62/948,577, filed on Dec. 16, 2019.
Claims priority of provisional application 62/913,712, filed on Oct. 10, 2019.
Claims priority of provisional application 62/815,175, filed on Mar. 7, 2019.
Prior Publication US 2022/0193988 A1, Jun. 23, 2022
Int. Cl. B29C 64/129 (2017.01); B29C 64/307 (2017.01); B29C 64/357 (2017.01); B29C 64/364 (2017.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 40/00 (2020.01)
CPC B29C 64/129 (2017.08) [B29C 64/307 (2017.08); B29C 64/357 (2017.08); B29C 64/364 (2017.08); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 40/00 (2014.12)] 18 Claims
OG exemplary drawing
 
1. A method of forming a three-dimensional object using an apparatus having a movable adhesion stage separate from a member, the method comprising:
flowing a dewetting material across the member, the dewetting material having a build surface;
providing a polymerization liquid on the dewetting material, wherein the polymerization liquid is immiscible with the dewetting material such that an interface is defined between the polymerization liquid and the dewetting material and a build region is defined between the interface and the adhesion stage; and
exposing the polymerization liquid in the build region to a pattern of energy through at least a portion of the member and the dewetting material to polymerize the polymerization liquid and form a green polymer;
and advancing the adhesion stage away from the build surface to form the three-dimensional object comprised of the green polymer,
wherein
the dewetting material is flowed across the member and is recirculated under conditions sufficient to dissipate heat and maintain a slip boundary between the green polymer and the dewetting material.