US 12,447,670 B2
Method and apparatus for three-dimensional fabrication
Joseph M. DeSimone, Monte Sereno, CA (US); Alexander 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 Oct. 28, 2021, as Appl. No. 17/513,312.
Application 17/513,312 is a continuation of application No. 16/824,077, filed on Mar. 19, 2020, granted, now 11,235,516.
Application 16/824,077 is a continuation of application No. 16/105,378, filed on Aug. 20, 2018, granted, now 10,596,755, issued on Mar. 24, 2020.
Application 16/105,378 is a continuation of application No. 14/937,151, filed on Nov. 10, 2015, granted, now 10,093,064.
Application 14/937,151 is a continuation of application No. 14/572,128, filed on Dec. 16, 2014, granted, now 9,211,678, issued on Dec. 15, 2015.
Application 14/572,128 is a continuation of application No. PCT/US2014/015486, filed on Feb. 10, 2014.
Claims priority of provisional application 61/865,841, filed on Aug. 14, 2013.
Claims priority of provisional application 61/763,746, filed on Feb. 12, 2013.
Prior Publication US 2022/0048242 A1, Feb. 17, 2022
Prior Publication US 2023/0373156 A9, Nov. 23, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. B29C 33/52 (2006.01); A61F 2/82 (2013.01); A61M 37/00 (2006.01); B29C 35/08 (2006.01); B29C 64/124 (2017.01); B29C 64/129 (2017.01); B29C 64/135 (2017.01); B29C 64/393 (2017.01); B29C 64/40 (2017.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 50/02 (2015.01); B33Y 80/00 (2015.01); G03F 7/00 (2006.01); B29C 33/00 (2006.01); B29K 67/00 (2006.01); B29K 71/00 (2006.01); B29K 105/00 (2006.01); B29L 31/00 (2006.01)
CPC B29C 64/135 (2017.08) [A61F 2/82 (2013.01); A61M 37/0015 (2013.01); B29C 35/0888 (2013.01); B29C 64/124 (2017.08); B29C 64/129 (2017.08); B29C 64/393 (2017.08); B29C 64/40 (2017.08); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12); B33Y 80/00 (2014.12); G03F 7/0037 (2013.01); A61F 2240/001 (2013.01); B29C 2033/0005 (2013.01); B29C 2035/0827 (2013.01); B29K 2067/00 (2013.01); B29K 2071/02 (2013.01); B29K 2105/0005 (2013.01); B29K 2105/0058 (2013.01); B29K 2827/12 (2013.01); B29K 2883/005 (2013.01); B29K 2995/0026 (2013.01); B29K 2995/006 (2013.01); B29K 2995/0065 (2013.01); B29L 2031/753 (2013.01); B29L 2031/7534 (2013.01); G05B 2219/00 (2013.01); G05B 2219/49016 (2013.01)] 13 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 said build plate is substantially fixed or stationary.