METHOD OF ADDITIVE MANUFACTURING BY FABRICATION THROUGH MULTIPLE ZONES

摘要

A method of forming a three-dimensional object is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween, with the carrier positioned adjacent and spaced apart from the build surface at a start position; then (b) forming an adhesion segment of the three-dimensional object (c) optionally but preferably forming a transition segment of the three dimensional object; and then (d) forming a body segment of the three dimensional object. In each case, the segment can be formed by: (i) filling the build region with a polymerizable liquid, (ii) continuously or intermittently irradiating the build region with light through the optically transparent, and (iii) continuously or intermittently advancing the carrier away from the build surface, to thereby form that segment from the polymerizable liquid.

主权项

1. A method of forming a three-dimensional object, comprising:
(a) providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween, with said carrier positioned adjacent and spaced apart from said build surface at a start position; then (b) forming an adhesion segment of said three-dimensional object by:
(i) filling said build region with a polymerizable liquid,(ii) irradiating said build region with light through said optically transparent member (e.g., by a single exposure), while(iii) maintaining said carrier stationary or advancing said carrier away from said build surface at a first cumulative rate of advance, to thereby form from said polymerizable liquid a solid polymer adhesion segment of said object adhered to said carrier; then (c) optionally but preferably forming a transition segment of said three dimensional object by
(i) filling said build region with a polymerizable liquid,(ii) continuously or intermittently irradiating said build region with light through said optically transparent member, and(iii) continuously or intermittently advancing said carrier away from said build surface at a second cumulative rate of advance to thereby form from said polymerizable liquid a transition segment of said object between said adhesion segment and said build surface;wherein said second cumulative rate of advance is greater than said first cumulative rate of advance; and then (d) forming a body segment of said three dimensional object by:
(i) filling said build region with a polymerizable liquid,(ii) continuously or intermittently irradiating said build region with light through said optically transparent, and(iii) continuously or intermittently advancing said carrier away from said build surface at a third cumulative rate of advance, to thereby form from said polymerizable liquid a body segment of said object between said transition segment and said build surface;wherein said third cumulative rate of advance is greater than said first and/or said second cumulative rate of advance.