US 12,447,680 B2
Particle coating methods for additively manufactured products
Aayush A. Shah, San Francisco, CA (US); Kai Chen, Sunnyvale, CA (US); and Keith Michael Kirkwood, Lake Oswego, OR (US)
Assigned to Carbon, Inc., Redwood City, CA (US); and ADIDAS AG, Herzogenaurach (DE)
Appl. No. 17/753,999
Filed by Carbon, Inc., Redwood City, CA (US); and ADIDAS AG, Herzogenaurach (DE)
PCT Filed Sep. 25, 2020, PCT No. PCT/US2020/052615
§ 371(c)(1), (2) Date Mar. 21, 2022,
PCT Pub. No. WO2021/062079, PCT Pub. Date Apr. 1, 2021.
Claims priority of provisional application 62/905,718, filed on Sep. 25, 2019.
Prior Publication US 2022/0371277 A1, Nov. 24, 2022
Int. Cl. B29C 64/30 (2017.01); B29C 64/124 (2017.01); B29K 75/00 (2006.01); B29L 31/48 (2006.01); B29L 31/50 (2006.01); B33Y 10/00 (2015.01); B33Y 40/20 (2020.01)
CPC B29C 64/30 (2017.08) [B29C 64/124 (2017.08); B33Y 10/00 (2014.12); B33Y 40/20 (2020.01); B29K 2075/00 (2013.01); B29L 2031/4821 (2013.01); B29L 2031/504 (2013.01)] 20 Claims
 
1. A method of additively manufacturing an object having a particle surface coating thereon, comprising:
(a) providing an intermediate object produced in an additive manufacturing process by light polymerization of a dual cure resin, wherein said intermediate object is produced by bottom-up or top-down stereolithography, said resin comprising a mixture of (i) a light polymerizable first component, and (ii) a second solidifiable component that is different from said first component; said intermediate object having residual dual cure resin from which it was produced remaining on a surface portion thereof in unpolymerized liquid form; then
(b) partially removing said residual resin from said surface portion of the intermediate object under conditions in which a retained portion of said residual resin remains as a resin coating film on said surface portion; and then
(c) contacting said coating film with a dispersed composition comprising solid particles to form a solid particle coating adhered to said resin coating film; and then
(d) heating said intermediate object sufficiently to cure said object and said resin coating film to form a cured object having a solid particle surface coating thereon.