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WO2020069060A1 - Cassette à fenêtre à régulation thermique pour appareil de fabrication additive - Google Patents

Cassette à fenêtre à régulation thermique pour appareil de fabrication additive Download PDF

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Publication number
WO2020069060A1
WO2020069060A1 PCT/US2019/053057 US2019053057W WO2020069060A1 WO 2020069060 A1 WO2020069060 A1 WO 2020069060A1 US 2019053057 W US2019053057 W US 2019053057W WO 2020069060 A1 WO2020069060 A1 WO 2020069060A1
Authority
WO
WIPO (PCT)
Prior art keywords
window
cassette
bottom portion
controller
top portion
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2019/053057
Other languages
English (en)
Inventor
Jordan Christopher FIDLER
Bob E. FELLER
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Carbon Inc
Original Assignee
Carbon Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Carbon Inc filed Critical Carbon Inc
Publication of WO2020069060A1 publication Critical patent/WO2020069060A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/295—Heating elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor

Definitions

  • the present invention concerns additive manufacturing in general, and particularly concerns streolithography-type additive manufacturing.
  • a group of additive manufacturing techniques sometimes referred to as "stereolithography” create a three-dimensional object by the sequential polymerization of a light polymerizable resin.
  • Such techniques include “bottom-up” techniques, where light is projected into the resin through a light-transmissive“window” onto the bottom of the growing object, which object is carried up and out of the resin pool on a“build platform.”
  • stereolithography resins both conventional and dual cure— can be viscous, that viscosity can limit the speeds of production otherwise attainable by CLIP, and that resins may be heated when necessary to reduce their viscosity.
  • the resins may need to be cooled under certain operating conditions if higher speeds of production are to be maintained (see, e.g., US Patent Nos, 9,211,678; 9,205,601; and 9,216,546 to DeSimone et al.).
  • a first aspect of the invention is a removable window cassette for a bottom-up stereolithography apparatus, including: (a) a light-transmissive window having a rigid bottom portion and a semipermeable top portion, with the rigid bottom portion comprised of a thermally conductive material; (b) a circumferential frame surrounding the window and into which the window is recessed, the frame having a top portion, a bottom portion, and an internal wall portion, the frame internal wall portion defining with the window semipermeable top portion a well into which a polymerizable liquid may be received; and (c) at least one thermoelectric device in the circumferential frame and in thermal contact with the rigid bottom portion.
  • the at least one thermoelectric device comprises a plurality of thermoelectric devices.
  • the at least one thermoelectric device comprises (i) at least one resistive heater, (ii) at least one Peltier device, or ( Hi ) both at least one resistive heater and at least one Peltier device.
  • the rigid bottom portion is comprised of glass, sapphire, or transparent aluminum (ALON).
  • the window semipermeable top portion is comprised of a fluoropolymer.
  • the cassette further includes a fluid channel bed formed in said window between said bottom portion and said top portion, said channel bed having a first header, a second header, and a channel array therebetween, with said channel array configured to supply an inhibitor of polymerization through said semipermeable top portion; a first fluid inlet in said circumferential frame bottom portion, said first fluid inlet connected to said first channel bed header; and a second fluid inlet in said circumferential frame bottom portion, said second fluid inlet connected to said second channel bed header.
  • the window top portion and the window bottom portion have opposing internal surfaces directly or indirectly adhered to one another, and in thermal contact with one another (e.g., through the entire surface area of the faces, except as interrupted by the channels of said fluid channel bed).
  • the circumferential frame is rectangular.
  • the window is generally flat and planar.
  • a second aspect of the invention is a bottom-up stereolithography apparatus, including: a removable window cassette as described above, and in further detail below; a carrier platform positioned above the window and configured for defining a build region between the semipermeable top portion and the carrier platform; a drive operatively associated with the carrier platform and the window and configured for advancing the window and the carrier platform away from one another; a light source positioned beneath the window; at least one temperature sensor operatively associated with the build region and configured to sense the temperature of a polymerizable resin in the build region; and a temperature controller operatively associated with the temperature sensor and the at least one thermoelectric device, the controller configured to activate the at least one thermoelectric device to maintain the temperature of a polymerizable resin in the build region above a predetermined minimum temperature and/or below a predetermined maximum temperature.
  • the controller comprises a proportional-integral-derivative (PID) controller, a proportional integral (PI) controller, or a dynamic matrix controller (DMC).
  • PID proportional-integral-derivative
  • PI proportional integral
  • DMC dynamic matrix controller
  • the at least one thermoelectric device and the controller are configured for both heating and cooling said resin.
  • the temperature sensor includes a contact or non-contact temperature sensor operatively associated with the window.
  • the apparatus further includes a fluid (e.g., an oxygen-enriched gas) supply system operatively associated with the first fluid inlet and the second fluid inlet (e.g., a fluid source operatively associated with said first inlet, and a vacuum source operatively associated with the second inlet).
  • a fluid e.g., an oxygen-enriched gas
  • the apparatus further includes a break-away electrical connector (e.g., a magnetic break-away connector) on the frame and electrically interconnecting the at least one thermoelectric device to the temperature controller.
  • FIG. 1 is a schematic diagram of a first embodiment of a window cassette and stereolithography apparatus of the present invention, employing a plurality of heaters.
  • FIG. 2 is a top plan view of a window cassette of FIG. 1.
  • FIG. 3 is a schematic diagram of a second embodiment of a window cassette of the present invention, employing a plurality of Peltier coolers.
  • FIG. 4 is a top plan view of the window cassette of FIG. 3.
  • FIG. 5 is a schematic diagram of a third embodiment of a window cassette, and a portion of a stereolithography apparatus, of the present invention, again employing a plurality of Peltier coolers.
  • FIG. 6 is a top plan view of the window cassette of FIG. 5.
  • FIG. 7 is a schematic diagram of a fourth embodiment of a window cassette, and a portion of a stereolithography apparatus, of the present invention, again employing a plurality of Peltier coolers.
  • spatially relative terms such as“under,”“below,”“lower,”“over,”“upper” and the like, may be used herein for ease of description to describe an element’s or feature’s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is inverted, elements described as“under” or“beneath” other elements or features would then be oriented“over” the other elements or features. Thus the exemplary term“under” can encompass both an orientation of over and under.
  • the device may otherwise be oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
  • the terms“upwardly,” “downwardly,”“vertical,”“horizontal” and the like are used herein for the purpose of explanation only, unless specifically indicated otherwise.
  • the object is formed by continuous liquid interface production (CLIP).
  • CLIP is known and described in, for example, US Patent No. 9,211,678, US Patent No. 9,205,601, US Patent No 9,216,546, and in J. Tumbleston, D, Shirvanyants, N. Ermoshkin et al., Continuous liquid interface production of 3D Objects, Science 347, 1349- 1352 (published online 16 March 2015). See also R. Janusziewcz et al., Layerless fabrication with continuous liquid interface production, Proc. Natl. Acad. Sci. USA 113, 11703-11708 (October 18, 2016).
  • the additive manufacturing apparatus is a bottom-up stereolithography apparatus (including but not limited to apparatus carrying out CLIP), employing a window cassette, such as described in B. Feller et al., Three-dimensional printing with build plates having reduced pressure and/or channels for increased fluid flow, PCT Patent Application Pub. No. WO 2018/006029, or B. Feller et al., Three-dimensional printing method and apparatus for reducing bubbles by de-gassing through build plate, PCT Patent Application Pub. No. WO 2018/006018 (where the“build plate” therein refers to the “window cassette” as described herein).
  • a window cassette such as described in B. Feller et al., Three-dimensional printing with build plates having reduced pressure and/or channels for increased fluid flow, PCT Patent Application Pub. No. WO 2018/006029, or B. Feller et al., Three-dimensional printing method and apparatus for reducing bubbles by de-gassing through build plate, PCT Patent Application Pub. No. WO 2018/00
  • FIGS. 1-2 illustrate first non-limiting examples of embodiments of the present invention.
  • the stereolithography apparatus includes a window cassette (discussed further below) removably connected to the apparatus top deck (21); a carrier platform (23) positioned above the window and configured for defining a build region between the semipermeable top portion of the window and the carrier platform (23); a drive (24) operatively associated with the carrier platform and the window and configured for advancing the window and the carrier platform away from one another; a light source (22) (e.g., a UV light and associated micromirror array) positioned beneath the window; at least one temperature sensor (28) operatively associated with the build region and configured to sense (directly or indirectly) the temperature of a polymerizable resin in the build region; and a controller (27), including a temperature controller, operatively associated with the temperature sensor and the at least one thermoelectric device, the controller configured to activate the at least one thermoelectric device to maintain the temperature of a polymerizable resin in the build region above a
  • the removable window cassette includes a a light-transmissive window having a rigid bottom portion (31) and a semipermeable top portion (32), with the rigid bottom portion comprised of a thermally conductive material; a circumferential frame (33) surrounding the window and into which the window is recessed, the frame having a top portion, a bottom portion, and an internal wall portion, the frame internal wall portion defining with the window semipermeable top portion a well into which a polymerizable liquid may be received; and at least one thermoelectric device (34) in the circumferential frame and in thermal contact with the rigid bottom portion.
  • the frame is optionally, but preferably, rectangular, and the window is preferably generally flat and planar.
  • the bottom portion (31) may be comprised of any suitable light-transmissive, thermally conductive, material, such as of glass, sapphire, transparent aluminum (ALON).
  • the semipermeable top portion is preferably comprised of a fluoropolymer.
  • the window top portion (32) and the window bottom portion (31) have opposing internal surfaces that are preferably directly or indirectly adhered to one another, and preferably in thermal contact with one another (e.g., through the entire surface area of the faces, except as interrupted by the channels of a fluid channel bed as discussed further below).
  • the window cassette includes a fluid channel bed formed in the window between the bottom portion and the top portion.
  • a channel bed will typically have a first header, a second header, and a channel array therebetween, with said channel array configured to supply an inhibitor of polymerization through the semipermeable top portion.
  • a first fluid inlet can be included in the said circumferential frame bottom portion and connected to the first channel bed header; and a second fluid inlet can be included in the circumferential frame bottom portion and connected to the second channel bed header.
  • the stereolithography apparatus can further comprise a fluid (e.g., an oxygen-enriched gas) supply system operatively associated with the first fluid inlet and the second fluid inlet (e.g., a fluid source operatively associated with the first inlet, and a vacuum source operatively associated with the second inlet, optionally switchable therebetween).
  • a fluid e.g., an oxygen-enriched gas
  • the second fluid inlet e.g., a fluid source operatively associated with the first inlet, and a vacuum source operatively associated with the second inlet, optionally switchable therebetween.
  • the at least one thermoelectric device (34) preferably comprises a plurality (e.g., 2, 3, 4 or more) thermoelectric devices, which may be of the same type, or different from one another.
  • Any suitable thermoelectric device can be used to carry out the present invention, including resistive heaters (e.g., metal, polymer, and composite resistive heaters), ultrasonic or piezoelectric heaters, thermoelectric devices relying on the thermoelectric or Peltier effect (e.g., “Peltier devices” for heating and/or cooling), etc., including combinations thereof. Examples include but are not limited to those set forth in US Patents No. 6,300,150 and U.S. Patent Publication Nos. 2007/0028956 and 2006/0086118.
  • Heat sinks may optionally be thermally coupled to the thermoelectric device (e.g ., by direct contact or through a thermally conductive coupling), as discussed further below.
  • Peltier devices are preferred, as they can be used to both heat and cool resin by reversing polarity (though Peltier coolers can be used in combination with dedicated heaters, such as resistive heaters, as well).
  • the controller is configured to both heat the resin with the thermoelectric device(s), when the temperature of the resin is below a predetermined minimum (e.g., at the beginning, or early stages, of production of a particular object or group of objects), and, cool the resin when the temperature of the resin approaches a predetermined maximum).
  • a predetermined minimum e.g., at the beginning, or early stages, of production of a particular object or group of objects
  • Such cooling as temperature of the resin increases during production may be advantageous where the other option to avoiding excessively high temperatures is to slow down the speed of production.
  • the predetermined minimum temperature may, for example, be at least 30 or 35 °C.
  • the method may further comprise the step of warming the resin to an actual temperature greater than the predetermined minimum temperature prior to the initial production steps.
  • the activating can be discontinued (or in the case of a Peltier device, function changed and cooling initiated initiated) prior to the resin actual temperature exceeding a predetermined maximum temperature (e.g., not more than 40, 50, 60, 80, or 100 °C).
  • one or more temperature sensors (28) are operatively associated with the build region, and are configured to sense, directly or indirectly, the temperature of a polymerizable resin in the build region.
  • Any suitable temperature sensor(s) can be used, including contact or non-contact temperature sensors such as infrared sensors, pyrometers, microbolometers, thermal cameras, thermistors, etc.).
  • an IR sensor can be positioned beneath the window, and directed to the bottom of the window.
  • Such an IR sensor can be tuned to a wavelength such that it primarily senses the temperature of the window itself as a surrogate for the temperature of the resin (with the controller 27 adjusted or configured accordingly), or can be a sensor which is tuned to a wavelength that looks through the window and more directly sense the temperature of the resin.
  • Controller 27 may comprise at least one temperature controller is operatively associated with the temperature sensor and the infrared heat source, the controller configured to intermittently activate the heat source.
  • Suitable controllers include proportional-integral- derivative (PID) controllers, proportional integral (PI) controllers, dynamic matrix controllers (DMCs), etc. (See, e.g., US Patent Nos. 9,841,186 9,795,528; 9,766,287; 9,220,362).
  • the controllers may perform pulse-width modulation to each the infrared heat source.
  • the controllers may be configured to maintain the resin within a predetermined temperature range of from 30 or 35 °C to 60, 80, or 100 °C, or more.
  • the heat sources may be independently controlled by the temperature controller(s), such as where different regions of the window are subject to different heat input (e.g., from heat of polymerization) or heat drain (e.g., from contact with an adjacent supporting structure, contact to a carrier plate, etcl).
  • different heat input e.g., from heat of polymerization
  • heat drain e.g., from contact with an adjacent supporting structure, contact to a carrier plate, etcl
  • multiple, separately focused or directed, temperature sensor may be used, or one or more infrared camera (providing a thermal map) can be used to provide independent data for independent control of the the multiple heat sources.
  • the heater (34) and/or coolers (35) are preferably electrically connected to the controller (37) by a connector, such as a latching connector or a break-away electrical connector.
  • a connector such as a latching connector or a break-away electrical connector.
  • break-away connectors typically comprised two mating members, one of which is connected to the frame (33), and the other of which is connected to a flexible line which is in turn connected to controller (27).
  • Such connectors are known and described in, for example, US Patent Nos. 2,933,711; 3,363,214; 7,517,222; and 7,874,844, the disclosures of which are incorporated herein by reference in their entirety.
  • FIGS. 3-4 illustrate second non-limiting examples of the present invention, where the thermoelectric devices 36 comprise Peltier devices configured to operate in a cooling mode.
  • the thermoelectric devices 36 comprise Peltier devices configured to operate in a cooling mode.
  • heat sinks 36 are connected to the frame 33, and are in thermal contact to the Peltier devices 35, to dissipate heat when the Peltier device is cooling the resin. Conversely, if the Peltier devices are operated in a mode of heating the resin, the heat sinks will be cooled (or, will withdraw heat from the ambient atmosphere). Additional components of a cassette or apparatus of FIGS. 3-4 may be as described above.
  • FIGS. 5-6 illustrate third non-limiting examples of the present invention.
  • the heat sinks 36’ are connected to the apparatus upper deck 21, and access ports, slots, or openings are provided in the window cassette frame 33 so that the Peltier devices can contact the heat sinks 36’ when the window cassette is mounted on the stereolithography apparatus upper deck 21. Additional components of a cassette or apparatus of FIGS. 5-6 may be as described above.
  • FIG. 7 illustrates a fourth non-limiting embodiment of the present invention. In this embodiment no separate heat sink is provided for the Peltier device 35, as the frame 33’ and/or the upper deck 21’ of the apparatus are formed from a thermally conductive material and configured in contact with the Peltier device so that they serve as the heat sink. Additional components of a cassette or apparatus of FIG. 7 may be as described above.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)

Abstract

L'invention concerne une cassette amovible à fenêtre, pour un appareil de stéréolithographie ascendante, qui comprend (a) une fenêtre transmettant la lumière, ayant une partie inférieure rigide et une partie supérieure semi-perméable, la partie inférieure rigide étant constituée d'un matériau thermiquement conducteur ; (b) un cadre périphérique entourant la fenêtre, et dans lequel la fenêtre est encastrée, le cadre ayant une partie supérieure, une partie inférieure et une partie paroi interne, la partie paroi interne du cadre délimitant avec la partie supérieure semi-perméable de la fenêtre un puits dans lequel peut être placé un liquide polymérisable ; (c) au moins un dispositif thermoélectrique dans le cadre périphérique et en contact thermique avec la partie inférieure rigide.
PCT/US2019/053057 2018-09-28 2019-09-26 Cassette à fenêtre à régulation thermique pour appareil de fabrication additive Ceased WO2020069060A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201862738061P 2018-09-28 2018-09-28
US62/738,061 2018-09-28

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WO2020069060A1 true WO2020069060A1 (fr) 2020-04-02

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Cited By (6)

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US10843411B2 (en) 2019-04-17 2020-11-24 Origin Laboratories, Inc. Method for regulating temperature at a resin interface in an additive manufacturing process
US11104075B2 (en) 2018-11-01 2021-08-31 Stratasys, Inc. System for window separation in an additive manufacturing process
US11123918B2 (en) 2018-11-01 2021-09-21 Stratasys, Inc. Method for build separation from a curing interface in an additive manufacturing process
US11590712B2 (en) 2019-08-02 2023-02-28 Stratasys, Inc. Method and system for interlayer feedback control and failure detection in an additive manufacturing process
EP3984721B1 (fr) * 2020-10-15 2024-12-04 Ivoclar Vivadent AG Procédé de commande de processus d'un processus de stereolithographie-3d
WO2025173049A1 (fr) * 2024-02-14 2025-08-21 Stronglayer Srl Dispositif de suspension de particules dans un polymère fluide et appareil et procédé associés

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