Continuous liquid interphase printing

1. A method of forming a three-dimensional object, comprising:

providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween;

filling said build region with a polymerizable liquid;

irradiating said build region through said optically transparent member to form a solid polymer from said polymerizable liquid while concurrently advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer, while also concurrently:

(i) continuously maintaining a dead zone of polymerizable liquid in contact with said build surface, and

(ii) continuously maintaining a gradient of polymerization zone between said dead zone and said solid polymer and in contact with each thereof, said gradient of polymerization zone comprising said polymerizable liquid in partially cured form,

wherein said optically transparent member comprises a semipermeable member, and said continuously maintaining a dead zone is carried out by feeding an inhibitor of polymerization through said optically transparent member, thereby creating a gradient of inhibitor in said dead zone and optionally in at least a portion of said gradient of polymerization zone, and

wherein said polymerizable liquid comprises a free radical polymerizable liquid, said inhibitor comprises oxygen, and said step of irradiating is carried out by irradiating said build region with light.

2. A method of forming a three-dimensional object, comprising:

providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween;

filling said build region with a polymerizable liquid;

irradiating said build region through said optically transparent member to form a solid polymer from said polymerizable liquid while concurrently advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer, while also concurrently:

(i) continuously maintaining a dead zone of polymerizable liquid in contact with said build surface, and

(ii) continuously maintaining a gradient of polymerization zone between said dead zone and said solid polymer and in contact with each thereof, said gradient of polymerization zone comprising said polymerizable liquid in partially cured form,

wherein said optically transparent member comprises a semipermeable member, and said continuously maintaining a dead zone is carried out by feeding an inhibitor of polymerization through said optically transparent member, thereby creating a gradient of inhibitor in said dead zone and optionally in at least a portion of said gradient of polymerization zone,

wherein said optically transparent member is comprised of a semipermeable fluoropolymer, a rigid gas-permeable polymer, porous glass, or a combination thereof, and

wherein said polymerizable liquid comprises a free radical polymerizable liquid, said inhibitor comprises oxygen, and said irradiating step is carried out by irradiating said build region with light.

3. The method of claim 1 , wherein said irradiating step is carried out by maskless photolithography.

4. The method claim 1 , wherein said gradient of polymerization zone and said dead zone together have a thickness of from 1 to 1000 microns.

5. The method of claim 1 , wherein said gradient of polymerization zone is maintained for a time of at least 5 seconds.

6. The method of claim 1 , further comprising the step of disrupting said gradient of polymerization zone for a time sufficient to form a cleavage line in said three-dimensional object.

7. The method of claim 1 , further comprising the step of heating said polymerizable liquid to reduce the viscosity thereof in said build region.

8. The method of claim 1 , wherein said carrier has at least one channel formed therein, and said filling step is carried out by passing or forcing said polymerizable liquid into said build region through said at least one channel.

9. The method of claim 1 , wherein said irradiating step is carried out with UV light radiation.

10. The method of claim 1 , wherein said concurrently advancing is carried out at a cumulative rate of at least 10 microns per second.

11. The method of claim 1 , wherein:

the total surface area of the build region occupies at least seventy percent of the total surface area of the build surface; and/or

wherein lateral movement of the carrier and object in any direction is not more than thirty percent of the width of said build region in the corresponding direction.

12. A method of forming a three-dimensional object, comprising:

providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween;

filling said build region with a polymerizable liquid;

irradiating said build region with actinic radiation through said optically transparent member to form a solid polymer from said polymerizable liquid while concurrently advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer, while also concurrently:

(i) continuously maintaining a dead zone of polymerizable liquid in contact with said build surface, and

(ii) continuously maintaining a gradient of polymerization zone between said dead zone and said solid polymer and in contact with each thereof, said gradient of polymerization zone comprising said polymerizable liquid in partially cured form;

wherein said gradient of polymerization zone and said dead zone together have a thickness of from 1 to 1000 microns;

wherein said gradient of polymerization zone is maintained for a time of at least 5 seconds;

and wherein said optically transparent member comprises a semipermeable member, and said continuously maintaining a dead zone is carried out by feeding an inhibitor of polymerization through said optically transparent member, thereby creating a gradient of inhibitor in said dead zone and optionally in at least a portion of said gradient of polymerization zone

wherein said polymerizable liquid comprises a free radical polymerizable liquid, said inhibitor comprises oxygen, and irradiating step is carried out by irradiating said build region with light.

13. The method of claim 12 , wherein:

said optically transparent member is comprised of a semipermeable fluoropolymer, a rigid gas-permeable polymer, porous glass, or a combination thereof.

14. The method of claim 2 , further comprising the step of heating said polymerizable liquid to reduce the viscosity thereof in said build region.

15. The method of claim 12 , further comprising the step of heating said polymerizable liquid to reduce the viscosity thereof in said build region.