Method and apparatus for three-dimensional fabrication

Abstract

A method of making a three-dimensional object includes: (a) providing an apparatus comprising a radiation source, a carrier, and a movable belt positioned therebetween, with the belt comprised of an optically transparent material, and with the belt permeable to a polymerization inhibitor; (b) applying a polymerizable liquid to a first surface of the belt, and contacting a second surface of the belt to the polymerization inhibitor, (c) contacting a portion of the first surface to the carrier or the three dimensional object so that the belt adheres thereto with the polymerizable liquid positioned therebetween; (d) irradiating the polymerizable liquid with actinic radiation through the belt from the radiation source to polymerize the polymerizable liquid positioned therebetween; then (e) optionally separating the belt from the carrier or the three dimensional object; and then (f) repeating steps (b) through (e) until the three dimensional object is completed.

That which is claimed is: 
     
         1 . A method of making a three-dimensional object, comprising:
 (a) providing an apparatus comprising a radiation source, a carrier on which said three dimensional object is made, and a movable belt positioned therebetween, said belt having a first surface and an opposite second surface, with said belt comprised of an optically transparent material, and with said belt permeable to a polymerization inhibitor;   (b) applying a polymerizable liquid to said first surface of said belt, and contacting said second surface of said belt to said polymerization inhibitor,   (c) contacting a portion of said belt first surface having said polymerizable liquid thereon to said carrier or said three dimensional object so that said belt adheres thereto with said polymerizable liquid positioned therebetween;   (d) irradiating said polymerizable liquid with actinic radiation through said belt from said radiation source to polymerize the polymerizable liquid positioned therebetween, and/or while:
 (i) moving said radiation source lengthwise across said substrate or said three-dimensional object; 
 (ii) continuously adhering a leading edge portion of said belt to said carrier or said object; 
 (iii) continuously peeling a trailing edge portion of said belt from said carrier or said object, with 
 (iv) said polymerization inhibitor passing through said belt to form an active surface on said object, and optionally, a dead zone of unpolymerized liquid between said active surface and said polymerizable liquid; then 
   (e) optionally separating said belt from said carrier or said three dimensional object; and then   (f) repeating steps (b) through (e) until said three dimensional object is completed.   
     
     
         2 . The method of  claim 1 , wherein:
 said moving belt is configured to pass through a contact region which contact region is in fixed contact with said carrier or said object, and   said contact region has a length dimension less than that of said carrier or said object.   
     
     
         3 . The method of  claim 1 , wherein said irradiating step is carried out with patterned actinic radiation. 
     
     
         4 . The method of  claim 1 , wherein said applying step is carried out by patterned coating of said belt with said polymerizable liquid. 
     
     
         5 . The method of  claim 1 , wherein said apparatus further comprises a frame, with said belt and said radiation source connected to said frame, and with said contact region defined by said frame. 
     
     
         6 . The method of  claim 1 , wherein said belt is continuous. 
     
     
         7 . The method of  claim 1 , wherein said belt is reversible in direction of travel. 
     
     
         8 . The method of  claim 1 , wherein said separating step (e) is carried out by (i) advancing said belt contact region lengthwise beyond said carrier or said three dimensional object, and then (ii) advancing said belt contact region and said carrier or said three dimensional object in the height dimension. 
     
     
         9 . The method of  claim 1 , wherein said repeating step (f) is carried out by repeatedly reversing the direction of travel of said belt and radiation source. 
     
     
         10 . The method of  claim 1 , wherein said repeating step (f) is carried out by (i) spacing said belt above said three dimensional object; (ii) moving said belt and radiation source lengthwise across said three dimensional object without contacting the same to return said belt and radiation source to a start position; and (iii) repeating steps (b) through (e) in the same direction of travel as in the previous repetition of steps (b) through (e) 
     
     
         11 . The method of  claim 1 , wherein said repeating step (f) further comprises laterally shifting said belt and radiation source with respect to said direction of travel prior to repeating steps (b) through (e). 
     
     
         12 . The method of  claim 1 , wherein said belt is electrostatically charged, and/or said applying step is carried out by electrospray. 
     
     
         13 . The method of  claim 1 , further comprising pressing said belt against said carrier or said object to promote uniform coating of the object with the polymerizable liquid. 
     
     
         14 . The method of  claim 1 , wherein said polymerizable liquid has a viscosity at said contacting step of at least 1,000 centipoise. 
     
     
         15 . The method of  claim 1 , further comprising co-fabricating a sacrificial leading bumper and/or sacrificial trailing bumper with said object. 
     
     
         16 . The method of  claim 1 , wherein said belt is comprised of a fluoropolymer. 
     
     
         17 . The method of  claim 1 , wherein said radiation source comprises a light source. 
     
     
         18 . The method of  claim 1 , wherein:
 said polymerizable liquid comprises a free radical polymerizable liquid and said inhibitor comprises oxygen; or   said first polymerizable liquid comprises an acid-catalyzed or cationically polymerizable liquid, and said inhibitor comprises a base.   
     
     
         19 . The method of  claim 1 , wherein said irradiating step is carried out as a series of separate successive exposures that occur prior to each repeating step repeating step (f). 
     
     
         20 . The method of  claim 19 , wherein a subsequent series of successive exposures is offset from an immediately prior series of successive exposures after at least one, or a plurality of, said repeating steps (f). 
     
     
         21 . An apparatus useful for making a three-dimensional object, comprising:
 (a) a radiation source;   (b) a carrier on which said three dimensional object is made;   (c) a movable belt positioned between said carrier and said radiation source, said belt having a first surface and an opposite second surface, with said belt comprised of an optically transparent material, and with said belt permeable to a polymerization inhibitor;   (d) an applicator assembly operably associated with said belt and configured to apply a polymerizable liquid thereto; and   (e) a frame, with said belt and said radiation source connected to said frame, and with said frame defining a contact region in which said belt contacts said carrier or object;   (f) a first drive assembly interconnecting said movable belt and said frame; and   (g) a second drive assembly interconnecting said frame and said carrier.   
     
     
         22 . The apparatus of  claim 21 , wherein said applicator assembly comprises a roller, sprayer, blade, bath, or combination thereof. 
     
     
         23 . The apparatus of  claim 21 , wherein said applicator assembly comprises a plurality of independently controllable spray orifices. 
     
     
         24 . The apparatus of  claim 21 , wherein said radiation source comprises a light source. 
     
     
         25 . The apparatus of  claim 21 , wherein said belt comprises a fluoropolymer.