IP Library › Granted Patent US 11,504,905
Granted Patent B2
US 11,504,905 · App. 16/970,455 · Granted Nov 22, 2022

Methods of reducing distortion of additively manufactured objects

Inventors: Kyle Laaker (Redwood City, CA); Leah Marie Heist (San Mateo, CA); Bob E. Feller (San Mateo, CA)
Assignee: Carbon, Inc.
B29C64/129B29C64/182B29C64/188B29C64/264B29C64/35B33Y10/00
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Quick Facts
Patent No.
US 11,504,905
App. No.
16/970,455
Granted
Nov 22, 2022
Kind
B2
Abstract

A method of making a three-dimensional object ( 11 ) from a light polymerizable dual cure resin ( 16 ), includes the steps of: (a) producing a green intermediate object by light polymerization of the resin in a stereolithography process (e.g., continuous liquid interface production); (i) the object comprising a body portion and a circumferential boundary portion ( 12 ) included in at least part of the body portion i (ii) the stereolithography process including overexposing the boundary portion (as compared to the exposure of the body portion) with light; (b) cleaning the intermediate object; and then (c) baking the object to produce the three-dimensional object.

Claims (35)

1. A method of making a three-dimensional object from a light polymerizable dual cure resin, comprising the steps of:

(a) producing a green intermediate object by light polymerization of said light polymerizable dual cure resin in a stereolithography process;

(i) said intermediate object comprising a body portion and a circumferential boundary portion included in at least part of said body portion;

(ii) said stereolithography process including overexposing said boundary portion, as compared to the exposure of said body portion, with light;

(b) cleaning said intermediate object; and then

(c) baking said intermediate object to produce said three-dimensional object,

wherein said circumferential boundary portion is configured to reduce distortion of said three-dimensional object during said baking step,

wherein said circumferential boundary portion is feathered in the Z dimension.

2. The method of claim 1 , wherein said circumferential boundary portion is interrupted or perforated.

3. The method of claim 1 , wherein said circumferential boundary portion is uninterrupted.

4. The method of claim 1 , wherein said circumferential boundary portion comprises a surface edge portion.

5. The method of claim 1 , wherein said circumferential boundary portion comprises an internal boundary portion.

6. The method of claim 1 , wherein said circumferential boundary portion comprises a combination of at least one surface edge portion and at least one internal boundary portion.

7. The method of claim 1 , wherein:

(i) that portion of said intermediate object that includes said boundary portion has an average thickness of from 0.4 or 0.5 millimeters to 5 or 10 millimeters; and/or

(ii) said boundary portion has an average thickness of from 10 or 50 micrometers to 100 or 200 micrometers.

8. The method of claim 1 , wherein said cleaning step is carried out by wiping including blowing, washing, or a combination thereof.

9. A method of making a plurality of dimensionally uniform three-dimensional objects from a light polymerizable dual cure resin, the method comprising the steps of:

(a) producing green intermediate objects by light polymerization of said light polymerizable dual cure resin in a stereolithography process;

(i) each said intermediate object comprising a body portion and a circumferential boundary portion included in at least part of said body portion;

(ii) said stereolithography process including overexposing said boundary portion, as compared to the exposure of said body portion, with light;

(b) cleaning said intermediate objects; and then

(c) baking said intermediate objects to produce said three-dimensional objects;

said circumferential boundary portion configured to enhance dimensional uniformity of said three-dimensional objects by reducing distortion of each said three-dimensional object during said baking step,

wherein said circumferential boundary portion is feathered in the Z dimension.

10. The method of claim 9 , wherein said circumferential boundary portion is interrupted or perforated.

11. The method of claim 9 , wherein said circumferential boundary portion is uninterrupted.

12. The method of claim 9 , wherein said circumferential boundary portion comprises a surface edge portion.

13. The method of claim 9 , wherein said circumferential boundary portion comprises an internal boundary portion.

14. The method of claim 9 , wherein said circumferential boundary portion comprises a combination of at least one surface edge portion and at least one internal boundary portion.

15. The method of claim 9 , wherein:

(i) that portion of said object that includes said boundary portion has an average thickness of from 0.4 or 0.5 millimeters to 5 or 10 millimeters; and/or

(ii) said boundary portion has an average thickness of from 10 or 50 micrometers to 100 or 200 micrometers.

16. The method of claim 9 , wherein said cleaning step is carried out by wiping (including blowing), washing, or a combination thereof.

17. The method of claim 9 , wherein said objects are produced simultaneously as a batch thereof on the same carrier platform.

Continuity (2)
Provisional Application 62633197 · Feb 21, 2018
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