Carbon, Inc.

United States of America

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        Patent 374
        Trademark 8
Jurisdiction
        United States 233
        World 145
        Canada 3
        Europe 1
Date
2024 April 4
2024 March 3
2024 February 2
2024 (YTD) 12
2023 28
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IPC Class
B33Y 10/00 - Processes of additive manufacturing 232
B29C 64/124 - 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 171
B33Y 30/00 - 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 - Details thereof or accessories therefor 134
B33Y 70/00 - Materials specially adapted for additive manufacturing 122
B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask 85
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NICE Class
09 - Scientific and electric apparatus and instruments 4
01 - Chemical and biological materials for industrial, scientific and agricultural use 3
37 - Construction and mining; installation and repair services 3
40 - Treatment of materials; recycling, air and water treatment, 3
42 - Scientific, technological and industrial services, research and design 3
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Status
Pending 48
Registered / In Force 334
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1.

ONE PART, CATALYST CONTAINING, MOISTURE CURABLE DUAL CURE RESINS FOR ADDITIVE MANUFACTURING

      
Application Number 18530398
Status Pending
Filing Date 2023-12-06
First Publication Date 2024-04-25
Owner Carbon, Inc. (USA)
Inventor Wright, Andrew Gordon

Abstract

Provided is method of making a three-dimensional object comprising polyurea, which may include: (a) dispensing a one part (1K) dual cure resin into a stereolithography apparatus, the resin comprising or consisting essentially of a photoinitiator, a reactive blocked polyisocyanate, optionally a catalyst such as a polyurethane blowing catalyst, and optionally a polyepoxide; (b) additively manufacturing from said resin an intermediate object comprising the light polymerization product of said reactive blocked polyisocyanate; (c) optionally cleaning said intermediate object; and (d) reacting said polymerization product in said intermediate with water in the presence of a catalyst such as a polyurethane blowing catalyst (which may be included in the resin, the water, or both) to generate polyamine in situ that sequentially reacts with the remainder of the polymerization product to form urea linkages and thereby produce a three-dimensional object comprising polyurea. Dual cure resins useful for the method are also provided.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/35 - Cleaning
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • C08G 18/10 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
  • C08G 18/20 - Heterocyclic amines; Salts thereof
  • C08G 18/30 - Low-molecular-weight compounds
  • C08G 18/58 - Epoxy resins
  • C08G 18/78 - Nitrogen

2.

Miscellaneous Design

      
Serial Number 98504113
Status Pending
Filing Date 2024-04-17
Owner Carbon, Inc. ()
NICE Classes  ?
  • 25 - Clothing; footwear; headgear
  • 09 - Scientific and electric apparatus and instruments
  • 12 - Land, air and water vehicles; parts of land vehicles
  • 17 - Rubber and plastic; packing and insulating materials
  • 20 - Furniture and decorative products

Goods & Services

Footwear including insoles Helmets Bicycle and motorcycle saddles; wheelchair cushions; automobile cushions Compressible 3-D printed lattices having foam-like properties for use with helmets, footwear including insoles, bicycle and motorcycle saddles, seat cushions, and wheelchair cushions Seat cushions

3.

RESIN EXTRACTOR FOR ADDITIVE MANUFACTURING

      
Application Number 18390627
Status Pending
Filing Date 2023-12-20
First Publication Date 2024-04-11
Owner Carbon, Inc. (USA)
Inventor
  • Murillo, Michael
  • Dachs, Ii, Gregory W.
  • Feller, Bob E.

Abstract

A method of separating excess resin from at least one object, includes: (a) stereolithographically producing at least one object on at least one carrier platform, each carrier platform having a planar build surface to which at least one object is connected, each object carrying excess resin on a surface thereof; then (b) mounting each carrier platform to a rotor; (c) centrifugally separating excess resin from each object by spinning the rotor with each carrier platform connected thereto while each object remains connected to each carrier platform; and then (d) removing each carrier platform from the rotor with each object thereon, with excess resin separated therefrom.

IPC Classes  ?

  • B29C 64/35 - Cleaning
  • B29C 64/124 - 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
  • B29C 64/245 - Platforms or substrates
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing

4.

METHODS FOR PRODUCING THREE-DIMENSIONAL OBJECTS

      
Application Number 18504537
Status Pending
Filing Date 2023-11-08
First Publication Date 2024-04-11
Owner Carbon, Inc. (USA)
Inventor
  • Rolland, Jason P.
  • Chen, Kai
  • Poelma, Justin
  • Goodrich, James
  • Pinschmidt, Robert
  • Desimone, Joseph M.
  • Robeson, Lloyd M.

Abstract

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; (b) filling the build region with a polymerizable liquid, the polymerizable liquid comprising a mixture of: (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from the first component; (c) irradiating the build region with light through the optically transparent member to form a solid blocked polymer scaffold and advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, with the intermediate containing the second solidifiable component; and then (d) solidifying and/or curing the second solidifiable component to form from said three-dimensional intermediate the three-dimensional object.

IPC Classes  ?

  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/124 - 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
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B29C 64/135 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/286 - Optical filters, e.g. masks
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 71/00 - After-treatment of articles without altering their shape; Apparatus therefor
  • B29D 11/00 - Producing optical elements, e.g. lenses or prisms
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • C08F 220/34 - Esters containing nitrogen
  • C08F 283/00 - Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass
  • C08F 290/06 - Polymers provided for in subclass
  • C08G 18/10 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
  • C08G 18/24 - Catalysts containing metal compounds of tin
  • C08G 18/40 - High-molecular-weight compounds
  • C08G 18/42 - Polycondensates having carboxylic or carbonic ester groups in the main chain
  • C08G 18/48 - Polyethers
  • C08G 18/69 - Polymers of conjugated dienes
  • C08G 18/73 - Polyisocyanates or polyisothiocyanates acyclic
  • C08G 18/75 - Polyisocyanates or polyisothiocyanates cyclic cycloaliphatic
  • C08G 18/76 - Polyisocyanates or polyisothiocyanates cyclic aromatic
  • C08G 18/81 - Unsaturated isocyanates or isothiocyanates
  • C08J 5/00 - Manufacture of articles or shaped materials containing macromolecular substances
  • C08K 3/01 - Use of inorganic substances as compounding ingredients characterised by their specific function
  • C08K 3/013 - Fillers, pigments or reinforcing additives
  • C08K 5/00 - Use of organic ingredients
  • C08L 75/04 - Polyurethanes
  • C08L 75/14 - Polyurethanes having carbon-to-carbon unsaturated bonds
  • C09D 135/02 - Homopolymers or copolymers of esters
  • C09D 175/04 - Polyurethanes
  • C09D 175/08 - Polyurethanes from polyethers
  • G03F 7/00 - Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printed surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
  • G03F 7/027 - Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds
  • G03F 7/038 - Macromolecular compounds which are rendered insoluble or differentially wettable
  • G03F 7/075 - Silicon-containing compounds
  • G03F 7/38 - Treatment before imagewise removal, e.g. prebaking

5.

RESIN LEVEL DETECTION IN ADDITIVE MANUFACTURING

      
Application Number 18470731
Status Pending
Filing Date 2023-09-20
First Publication Date 2024-03-21
Owner Carbon, Inc. (USA)
Inventor
  • Truong, Ronald A.
  • Katzman, Steven R.

Abstract

In some embodiments, a method of determining the fill level of a resin pool in a bottom-up additive manufacturing apparatus includes the steps of: (a) providing an additive manufacturing apparatus including a build platform and a light transmissive window, the build platform and the window defining a build region there between, with the window carrying a resin pool, the pool having a resin top surface portion; (b) advancing the build platform and the window towards one another until the build platform contacts the resin top surface portion; (c) detecting the impact of the build platform with the resin top surface portion; and (d) determining the fill level of the resin pool from the detected impact.

IPC Classes  ?

  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/245 - Platforms or substrates
  • B29C 64/307 - Handling of material to be used in additive manufacturing

6.

LATTICE TRANSITIONING STRUCTURES IN ADDITIVELY MANUFACTURED PRODUCTS

      
Application Number 18521354
Status Pending
Filing Date 2023-11-28
First Publication Date 2024-03-21
Owner Carbon, Inc. (USA)
Inventor
  • Kabaria, Hardik
  • Kurtz, Aidan

Abstract

An additively manufactured lattice structure includes (a) a first three-dimensional lattice including a repeating interconnected array of a first lattice unit cell, (b) a second three-dimensional lattice including a repeating interconnected array of a second lattice unit cell, wherein the second lattice unit cell is different from the first lattice unit cell, and (c) a first transition segment interconnecting the first three-dimensional lattice and the second three-dimensional lattice. The first transition segment includes (i) a first three-dimensional transitional lattice including a repeating array of the first lattice unit cell and (ii) interleaved with and interconnected to the first three-dimensional transitional lattice, a second three-dimensional transitional lattice including a repeating array of the second lattice unit cell.

IPC Classes  ?

  • F16F 1/373 - Springs made of material having high internal friction characterised by having a particular shape
  • B29C 64/10 - Processes of additive manufacturing
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • F16H 51/00 - Levers of gearing mechanisms

7.

CONTINUOUS LIQUID INTERPHASE PRINTING

      
Application Number 18463383
Status Pending
Filing Date 2023-09-08
First Publication Date 2024-03-14
Owner Carbon, Inc. (USA)
Inventor
  • Desimone, Joseph M.
  • Ermoshkin, Alexander
  • Ermoshkin, Nikita
  • Samulski, Edward T.

Abstract

A method of forming a three-dimensional object is carried out by providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; filling the build region with a polymerizable liquid; irradiating the build region through the optically transparent member to form a solid polymer from the polymerizable liquid and advancing the carrier away from the build surface to form the three-dimensional object from the solid polymer, while also concurrently with the irradiating and/or advancing steps: (i) continuously maintaining a dead zone of polymerizable liquid in contact with the build surface, and (ii) continuously maintaining a gradient of polymerization zone between the dead zone and the solid polymer and in contact with each thereof. The gradient of polymerization zone comprises the polymerizable liquid in partially cured form (e.g., so that the formation of fault or cleavage lines between layers of solid polymer in the three-dimensional object is reduced). Apparatus for carrying out the method is also described.

IPC Classes  ?

  • A61M 29/02 - Inflatable dilators; Dilators made of swellable materials
  • A61B 17/24 - Surgical instruments, devices or methods, e.g. tourniquets for use in the oral cavity, larynx, bronchial passages or nose; Tongue scrapers
  • A61B 17/34 - Trocars; Puncturing needles
  • A61M 25/10 - Balloon catheters

8.

THREE-DIMENSIONAL PRINTING WITH RECIPROCAL FEEDING OF POLYMERIZABLE LIQUID

      
Application Number 18239317
Status Pending
Filing Date 2023-08-29
First Publication Date 2024-02-15
Owner Carbon, Inc. (USA)
Inventor
  • Ermoshkin, Alexander
  • Shirvanyants, David
  • Phelps, Nordstrom Kirk
  • Ermoshkin, Nikita
  • Samulski, Edward T.
  • Desimone, Joseph M.

Abstract

Described herein are methods, systems and apparatus (including associated control methods, systems and apparatus), for the production of a three-dimensional object by “bottom up” additive manufacturing, in which a carrier is vertically reciprocated with respect to a build surface, to enhance or speed the refilling of the build region with a solidifiable liquid. In preferred (but not necessarily limiting) embodiments, the three-dimensional object is produced from a liquid interface by continuous liquid interface production (i.e., “CLIP”).

IPC Classes  ?

  • B29C 64/124 - 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/264 - Arrangements for irradiation
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

9.

METHODS FOR PRODUCING THREE-DIMENSIONAL OBJECTS

      
Application Number 18325343
Status Pending
Filing Date 2023-05-30
First Publication Date 2024-02-01
Owner Carbon, Inc. (USA)
Inventor
  • Rolland, Jason P.
  • Chen, Kai
  • Poelma, Justin
  • Goodrich, James
  • Pinschmidt, Jr., Robert K.
  • Desimone, Joseph M.
  • Robeson, Lloyd M.

Abstract

A method of forming a three-dimensional object is described. The method may use a polymerizable liquid, or resin, useful for the production by additive manufacturing of a three-dimensional object, comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from said first component.

IPC Classes  ?

  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • C08K 3/013 - Fillers, pigments or reinforcing additives
  • C08K 3/01 - Use of inorganic substances as compounding ingredients characterised by their specific function
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • G03F 7/00 - Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printed surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
  • G03F 7/027 - Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds
  • G03F 7/038 - Macromolecular compounds which are rendered insoluble or differentially wettable
  • G03F 7/075 - Silicon-containing compounds
  • G03F 7/38 - Treatment before imagewise removal, e.g. prebaking
  • B29C 64/124 - 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
  • B29C 64/135 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • C08G 18/81 - Unsaturated isocyanates or isothiocyanates
  • C08G 18/10 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
  • C08G 18/76 - Polyisocyanates or polyisothiocyanates cyclic aromatic
  • C08F 220/34 - Esters containing nitrogen
  • C08G 18/42 - Polycondensates having carboxylic or carbonic ester groups in the main chain
  • C08F 290/06 - Polymers provided for in subclass
  • C08G 18/73 - Polyisocyanates or polyisothiocyanates acyclic
  • C08G 18/48 - Polyethers
  • C08G 18/24 - Catalysts containing metal compounds of tin
  • C08G 18/69 - Polymers of conjugated dienes
  • C08G 18/75 - Polyisocyanates or polyisothiocyanates cyclic cycloaliphatic
  • C08F 283/00 - Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass
  • C08G 18/40 - High-molecular-weight compounds
  • B29C 71/00 - After-treatment of articles without altering their shape; Apparatus therefor
  • B29C 64/286 - Optical filters, e.g. masks
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29D 11/00 - Producing optical elements, e.g. lenses or prisms
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • C08K 5/00 - Use of organic ingredients
  • C08L 75/04 - Polyurethanes
  • B33Y 80/00 - Products made by additive manufacturing
  • C09D 135/02 - Homopolymers or copolymers of esters
  • C09D 175/04 - Polyurethanes
  • C09D 175/08 - Polyurethanes from polyethers
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • C08J 5/00 - Manufacture of articles or shaped materials containing macromolecular substances
  • C08L 75/14 - Polyurethanes having carbon-to-carbon unsaturated bonds
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

10.

FORCE-REGULATED ADDITIVE MANUFACTURING

      
Application Number 18256884
Status Pending
Filing Date 2021-12-10
First Publication Date 2024-01-18
Owner Carbon, Inc. (USA)
Inventor
  • Truong, Ronald
  • Yang, Daniel Jiaji

Abstract

A method of forming a three-dimensional object (31) includes the steps of: (a) providing an apparatus including a carrier (15), a light transmissive window (12) having a build surface, polymerizable liquid (21) on the build surface, and a growing object (31) on the carrier, the growing object produced by light polymerization of the polymerizable liquid; (b) vertically reciprocating the carrier (15) with respect to the build surface in an upstroke and a downstroke, the downstroke being shorter than the upstroke, to form a build region between the growing object and the build surface, and to fill the build region with the polymerizable liquid, while also: (i) sensing force exerted between the carrier and the build surface through the growing object (31) and the polymerizable liquid (21) during the upstroke; and (ii) modifying the speed, acceleration, or both speed and acceleration of the upstroke in response to the sensed force so that the sensed force approaches a predetermined target force; then (c) irradiating the build region with light through the light transmissive window to form a new portion of the object from the polymerizable liquid on the growing object; and then (d) repeating steps (b) through (c) to form additional portions on the growing object until the three-dimensional object is formed.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/124 - 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
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/245 - Platforms or substrates
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

11.

ADDITIVE MANUFACTURING WITH DUAL PRECUSOR RESINS

      
Application Number 18474433
Status Pending
Filing Date 2023-09-26
First Publication Date 2024-01-11
Owner Carbon, Inc. (USA)
Inventor Rolland, Jason P.

Abstract

Apparatus for, and associated method of, making a three-dimensional object from a light polymerizable resin by inkjet additive manufacturing are described. The methods and apparatus employ dual precursor resins, including but not limited to dual cure resins having a first component photopolymerizable and a second component polymerizable by a mechanism different from the first component.

IPC Classes  ?

  • B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
  • B29C 64/209 - Heads; Nozzles
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor

12.

PERFORMANCE OPTIMIZATION IN ADDITIVE MANUFACTURING

      
Application Number 18473715
Status Pending
Filing Date 2023-09-25
First Publication Date 2024-01-11
Owner Carbon, Inc. (USA)
Inventor
  • Tumbleston, John R.
  • Gutierrez, Clarissa
  • Truong, Ronald
  • Laaker, Kyle
  • Carlson, Craig B.
  • Goldman, Roy
  • Parmar, Abhishek

Abstract

A method of enhancing a performance characteristic of an additive manufacturing apparatus, the method including: (a) dispensing a batch of a light polymerizable resin into the additive manufacturing apparatus, the batch characterized by at least one physical characteristic; (b) determining the unique identity of the batch; (c) sending the unique identity of the batch to a database; then (d) either: (i) receiving on the controller from the database modified operating instructions for the resin batch, which modified operating instructions have been modified based on the at least one physical characteristic, or (ii) receiving on the controller from the database the at least one physical characteristic for the specific resin batch and modifying the operating instructions based on the at least one physical characteristic; and then (e) producing the object from the batch of light polymerizable resin on the additive manufacturing apparatus with the modified operating instructions.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/314 - Preparation
  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • G06Q 30/018 - Certifying business or products
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing

13.

METHOD AND APPARATUS FOR THREE-DIMENSIONAL FABRICATION

      
Application Number 17513312
Status Pending
Filing Date 2021-10-28
First Publication Date 2023-11-23
Owner Carbon, Inc. (USA)
Inventor
  • Desimone, Joseph M.
  • Ermoshkin, Alexander
  • Samulski, Edward T.

Abstract

A method of forming a three-dimensional object, is carried out by (a) providing a carrier and a build plate, the build plate comprising a semipermeable member, the semipermeable member comprising a build surface with the build surface and the carrier defining a build region therebetween, and with the build surface in fluid communication by way of the semipermeable member with a source of polymerization inhibitor; (b) filling the build region with a polymerizable liquid, the polymerizable liquid contacting the build surface, (c) irradiating the build region through the build plate to produce a solid polymerized region in the build region, while forming or maintaining a liquid film release layer comprised of the polymerizable liquid formed between the solid polymerized region and the build surface, wherein the polymerization of which liquid film is inhibited by the polymerization inhibitor; and (d) advancing the carrier with the polymerized region adhered thereto away from the build surface on the build plate to create a subsequent build region between the polymerized region and the build surface while concurrently filling the subsequent build region with polymerizable liquid as in step (b). Apparatus for carrying out the method is also described.

IPC Classes  ?

  • B29C 64/135 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • G03F 7/00 - Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printed surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • A61M 37/00 - Other apparatus for introducing media into the body; Percutany, i.e. introducing medicines into the body by diffusion through the skin
  • A61F 2/82 - Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
  • B33Y 80/00 - Products made by additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/124 - 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

14.

METHOD FOR DIRECT COLORATION OF RESINS FOR ADDITIVE MANUFACTURING

      
Application Number US2023066235
Publication Number 2023/220523
Status In Force
Filing Date 2023-04-26
Publication Date 2023-11-16
Owner CARBON, INC. (USA)
Inventor
  • Chen, Kai
  • Kirkwood, Keith M.

Abstract

(a) (b) (i) (ii) (iii) (iv) (c) (c) mixing, in a second apparatus, the colored resin concentrate with a second portion of the bulk supply, to produce the pigmented additive manufacturing resin having the predefined color.

IPC Classes  ?

  • B29B 7/00 - Mixing; Kneading
  • B29B 7/74 - Mixing; Kneading using other mixers or combinations of dissimilar mixers
  • B29B 7/24 - Component parts, details or accessories; Auxiliary operations for feeding
  • B29B 7/60 - Component parts, details or accessories; Auxiliary operations for feeding, e.g. end guides for the incoming material
  • B29B 7/88 - Adding charges
  • B29B 7/08 - Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices shaking, oscillating or vibrating
  • B29B 7/10 - Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices rotary
  • B29B 7/32 - Mixing; Kneading continuous, with mechanical mixing or kneading devices with non-movable mixing or kneading devices
  • B29B 7/42 - Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with single shaft with screw or helix
  • B29B 7/48 - Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with more than one shaft with intermeshing devices, e.g. screws
  • B29C 64/00 - 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

15.

HOLLOW DENTAL MOLDS CONFIGURED FOR HIGH THROUGHPUT CLEANING

      
Application Number US2023065985
Publication Number 2023/205716
Status In Force
Filing Date 2023-04-20
Publication Date 2023-10-26
Owner CARBON, INC. (USA)
Inventor
  • Feller, Bob E.
  • Denmark, Alexander D.
  • Cristiani, Thomas R.

Abstract

Described herein is a mold in the shape of a dental arch produced by additive manufacturing from a polymerizable resin. The mold includes: an upper portion configured in the shape of a set of teeth; an intermediate portion having a hollow cavity formed therein; a planar base surface portion, the hollow cavity extending through the base surface portion; and a plurality of drain channels extending from the hollow cavity upward through the upper portion, the drain channels configured for draining of residual polymerizable resin from the hollow cavity.

IPC Classes  ?

  • A61C 7/08 - Mouthpiece-type retainers
  • A61C 13/00 - Dental prostheses; Making same
  • A61C 13/34 - Making or working of models, e.g. preliminary castings, trial dentures; Dowel pins
  • B29C 33/38 - 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 - Details thereof or accessories therefor characterised by the material or the manufacturing process
  • B29C 51/30 - Moulds
  • B33Y 80/00 - Products made by additive manufacturing

16.

CENTRIFUGAL CLEANING APPARATUS WITH PLATFORM-REVERSIBLE ROTOR FOR ADDITIVELY MANUFACTURED OBJECTS

      
Application Number 18303788
Status Pending
Filing Date 2023-04-20
First Publication Date 2023-10-26
Owner Carbon, Inc. (USA)
Inventor
  • Takahashi, Clara Lynne
  • Denmark, Alexander D.

Abstract

A centrifugal separator for separating residual resin from additively manufactured objects, the objects carried on a build surface of a build platform on which the objects were additively manufactured. The separator includes: an outer vessel; a rotor in the vessel, the rotor defining a center axis of rotation; a drive assembly operatively associated with the rotor; and a plurality of build platform mount assemblies operatively associated with the rotor, each mount assembly configured to receive one of the build platforms in (i) a first orientation in which the build surfaces face toward the axis of rotation, and (ii) a second orientation in which the build surfaces face away from the axis of rotation.

IPC Classes  ?

17.

Centrifugal Separator for Cleaning Additively Manufactured Objects with Adjustable Mount

      
Application Number 18298721
Status Pending
Filing Date 2023-04-11
First Publication Date 2023-10-19
Owner Carbon, Inc. (USA)
Inventor
  • Feller, Bob E.
  • Powell, W. Ryan
  • Kaufman, Mark O.

Abstract

A method of cleaning residual resin from an additively manufactured object, the method including: producing by additive manufacturing at least one object on at least one carrier platform, each object including a light polymerized resin with a surface coating of viscous, unpolymerized residual resin; operatively connecting each object to a rotor; separating the residual resin from each object; and removing the at least one object from the rotor with the residual resin separated therefrom. The separating step may include: centrifugally separating the residual resin from each object by spinning the rotor with the at least object operatively connected thereto; and rotating (or tilting) each object about at least one axis during the spinning to enhance the centrifugally separating the residual resin from each object.

IPC Classes  ?

  • B29C 64/35 - Cleaning
  • B29C 64/124 - 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
  • B29C 71/00 - After-treatment of articles without altering their shape; Apparatus therefor

18.

LIGHT SOURCE VARIABILITY CORRECTION IN ADDITIVE MANUFACTURING

      
Application Number 18302227
Status Pending
Filing Date 2023-04-18
First Publication Date 2023-10-19
Owner Carbon, Inc. (USA)
Inventor
  • Herrmann, Ariel M.
  • Tumbleston, John R.
  • Laaker, Kyle R.
  • Wheeler, Sean P.
  • Baker, Elliott Steele
  • Portnoy, Alexander
  • Denardo, Nicholas M.
  • Chimmalgi, Anant

Abstract

A method of reducing performance deviation in at least one additive manufacturing apparatus during production of parts is provided. Each apparatus has a light source configured for polymerizing a light polymerizable resin with sequential doses of patterned light to produce a 3D object. The light source has an assigned nominal emission data, such as an expected or preset standard emission data, and actual emission data. The method includes modifying at least some of said light doses in said at least one apparatus during production of parts therein to compensate for a deviation of said actual light source emission data from the assigned nominal emission data.

IPC Classes  ?

  • B29C 64/282 - Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] of the same type, e.g. using different energy levels
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask

19.

PROTECTIVE MOUTHGUARD

      
Application Number 18296489
Status Pending
Filing Date 2023-04-06
First Publication Date 2023-08-03
Owner CARBON, INC. (USA)
Inventor Truelove, Jeremy P.

Abstract

The present disclosure describes a polymer mouthguard for protecting the teeth of a wearer. The mouthguard includes a lingual portion, a facial portion, and an occlusal portion connected with one another in the shape of an arch and together defining a trough for receiving the upper (maxillary) or lower (mandibular) teeth of a wearer. At least one, or both, of the facial portion and the occlusal portion have a shock absorbing lattice formed therein. The mouthguard can be produced as a single object by the process of additive manufacturing (e.g., stereolithography).

IPC Classes  ?

  • A63B 71/08 - Body-protectors for players or sportsmen

20.

One part, catalyst containing, moisture curable dual cure resins for additive manufacturing

      
Application Number 17817673
Grant Number 11884000
Status In Force
Filing Date 2022-08-05
First Publication Date 2023-06-15
Grant Date 2024-01-30
Owner Carbon, Inc. (USA)
Inventor Wright, Andrew Gordon

Abstract

Provided is method of making a three-dimensional object comprising polyurea, which may include: (a) dispensing a one part (1K) dual cure resin into a stereolithography apparatus, the resin comprising or consisting essentially of a photoinitiator, a reactive blocked polyisocyanate, optionally a catalyst such as a polyurethane blowing catalyst, and optionally a polyepoxide; (b) additively manufacturing from said resin an intermediate object comprising the light polymerization product of said reactive blocked polyisocyanate; (c) optionally cleaning said intermediate object; and (d) reacting said polymerization product in said intermediate with water in the presence of a catalyst such as a polyurethane blowing catalyst (which may be included in the resin, the water, or both) to generate polyamine in situ that sequentially reacts with the remainder of the polymerization product to form urea linkages and thereby produce a three-dimensional object comprising polyurea. Dual cure resins useful for the method are also provided.

IPC Classes  ?

  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/35 - Cleaning
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • C08G 18/78 - Nitrogen
  • C08G 18/10 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
  • C08G 18/30 - Low-molecular-weight compounds
  • C08G 18/58 - Epoxy resins
  • B33Y 10/00 - Processes of additive manufacturing
  • C08G 18/20 - Heterocyclic amines; Salts thereof
  • B29K 75/00 - Use of polyureas or polyurethanes as moulding material

21.

METHOD FOR ADDITIVELY MANUFACTURING COMPOSITE OBJECTS FOR SECURING TO WEARABLE ARTICLES AND ARTICLES OBTAINED THEREBY

      
Application Number US2022049199
Publication Number 2023/091331
Status In Force
Filing Date 2022-11-08
Publication Date 2023-05-25
Owner CARBON, INC. (USA)
Inventor
  • Cristiani, Thomas R.
  • Fortner, Shawn
  • Jhaveri, Puneet Bhumipal

Abstract

The present disclosure describes a method of making a composite product (20) by additive manufacturing. The method includes providing an additive manufacturing apparatus having a build platform, the build platform having a planar face on which the product is formed; securing a fabric (22) sheet to the planar face (11) to provide a planar fabric surface thereon; additively manufacturing an intermediate object on the planar fabric surface in the apparatus (12) by light polymerizing a dual cure resin to produce an intermediate object on the build platform, the intermediate object including the fabric (22) sheet having the three-dimensional object (21) adhered thereto; and concurrently with or following the additively manufacturing step, further curing the intermediate object to produce a composite object including the fabric sheet having the three-dimensional object adhered thereto. Composite object and products are also described herein.

IPC Classes  ?

  • B33Y 80/00 - Products made by additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B29C 64/124 - 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
  • B29C 64/245 - Platforms or substrates
  • B29C 70/74 - Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding

22.

ADDITIVE MANUFACTURING FROM A VELOCITY INDUCED DEAD ZONE

      
Application Number 17754518
Status Pending
Filing Date 2020-10-28
First Publication Date 2023-05-18
Owner Carbon, Inc. (USA)
Inventor
  • Panzer, Matthew
  • Laaker, Kyle
  • Tumbleston, John R.
  • Feller, Bob E.
  • Rademacher, Soren
  • Land, Stephen Paul
  • Bibb, Iii, Henry Quarles
  • Shirvanyants, David
  • Ermoshkin, Alexander

Abstract

Methods of making a three-dimensional object from a light polymerizable resin are described. A method may include: (a) providing a window, a light polymerizable resin, a laterally translatable substrate between said window and said resin to which said resin is adhered, and a carrier platform above said window; (b) irradiating said resin with light through said window and said translatable substrate, and vertically advancing said carrier away from said window, to produce a growing object on said carrier platform and consume resin beneath said growing object; and (c) laterally advancing said translatable substrate with said resin adhered thereto across said window to drag fresh resin beneath said growing object, continue producing said growing object and continue consuming fresh resin, until said three-dimensional object is produced.

IPC Classes  ?

  • B29C 64/124 - 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/223 - Foils or films, e.g. for transferring layers of building material from one working station to another
  • B29C 64/245 - Platforms or substrates

23.

PRODUCTION OF ADDITIVELY MANUFACTURED PARTS IN BATCHES ADAPTED FOR EFFICIENT METROLOGY

      
Application Number 18055538
Status Pending
Filing Date 2022-11-15
First Publication Date 2023-05-18
Owner Carbon, Inc. (USA)
Inventor Troise, James Patrick

Abstract

A method of additively manufacturing a plurality of parts in a manner that facilitates efficient collection of metrology data on the parts is described herein. The method includes the steps of: additively manufacturing a construct, the construct comprising: (i) a backing, and (ii) a plurality of parts connected to the backing; inserting the backing into an imaging apparatus in an orientation in which the plurality of parts are positioned for imaging; then imaging the plurality parts in the imaging apparatus to collect image data from each part, and then removing the construct from the imaging apparatus and separating the parts from the backing.

IPC Classes  ?

  • G01N 23/046 - Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups , or by transmitting the radiation through the material and forming images of the material using tomography, e.g. computed tomography [CT]
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • G01N 23/083 - Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups , or by transmitting the radiation through the material and measuring the absorption the radiation being X-rays

24.

DUAL CURE STEREOLITHOGRAPHY RESINS CONTAINING DIELS-ALDER ADDUCTS

      
Application Number 17524093
Status Pending
Filing Date 2021-11-11
First Publication Date 2023-05-11
Owner Carbon, Inc. (USA)
Inventor
  • Menyo, Matthew S.
  • Robeson, Lloyd M.

Abstract

Provided herein according to some embodiments is a dual cure stereolithography resin that includes a Diels-Alder adduct, which adduct is light polymerizable in the first, light, cure to produce an intermediate object, and on heating the intermediate object yields a bis-maleimide that can further react and/or polymerize during the second, heat, cure.

IPC Classes  ?

  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • C08F 2/50 - Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light with sensitising agents
  • C08L 69/00 - Compositions of polycarbonates; Compositions of derivatives of polycarbonates
  • C08L 79/08 - Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

25.

Partially reversible thermosets useful for recycling

      
Application Number 17905779
Grant Number 11859057
Status In Force
Filing Date 2021-03-11
First Publication Date 2023-04-27
Grant Date 2024-01-02
Owner Carbon, Inc. (USA)
Inventor
  • Poelma, Justin
  • Curvers, Rick Hubertus Nicolas

Abstract

Provided herein is a method of recycling reactive prepolymers from additively manufactured articles or recovered coating material that comprises a crosslinked polymer formed from a single-cure resin comprising a reactive blocked prepolymer and a crosslinker, by forming and recovering a regenerated reactive prepolymer. Light-polymerizable resins, methods of making recyclable objects from such resins, and methods for sustainable manufacturing are also provided.

IPC Classes  ?

  • C08J 11/08 - Recovery or working-up of waste materials of polymers without chemical reactions using selective solvents for polymer components
  • C08J 11/18 - Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation by treatment with organic material

26.

SYSTEMS AND METHODS FOR ADDITIVELY MANUFACTURING SEMI-CUSTOM OBJECTS

      
Application Number 18047413
Status Pending
Filing Date 2022-10-18
First Publication Date 2023-04-20
Owner Carbon, Inc. (USA)
Inventor
  • Sauerbaum, Jr., James J.
  • Iczkowski, Matthew S.
  • Mak, Kieran

Abstract

A computer-implemented method of making a semi-custom product for a user, includes the steps of: (a) providing a set of data files, each data file representing a distinct variant of the product; (b) providing personal data from the user, the personal data including at least first and second distinct user attributes; (c) providing product preference data from the user, the product preference data including at least first and second distinct product attributes; and then (d) ranking the set of data files with (i) the personal data and (ii) the product preference data to identify a best fit data file, the best fit data file representing a variant of the product that most closely meets the product preference data based on the personal data.

IPC Classes  ?

  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing

27.

ONE PART MOISTURE CURABLE RESINS FOR ADDITIVE MANUFACTURING

      
Application Number 17904668
Status Pending
Filing Date 2021-02-25
First Publication Date 2023-03-30
Owner CARBON, INC. (USA)
Inventor
  • Wright, Andrew Gordon
  • Chen, Kai
  • Rolland, Jason P.

Abstract

Provided herein is an additive manufacturing method of making a three-dimensional object comprising polyurea, comprising: (a) dispensing a one part (1K) dual cure resin into a stereolithography apparatus, the resin comprising or consisting essentially of a photoinitiator, a reactive blocked polyisocyanate, and optionally a polyepoxide, the reactive blocked polyisocyanate comprising the reaction product of a polyisocyanate and an amine or hydroxyl (meth)acrylate or (meth)acrylamide monomer blocking agent; (b) additively manufacturing from said resin an intermediate object comprising the light polymerization product of said reactive blocked polyisocyanate; (c) optionally cleaning said intermediate object; and (d) reacting said polymerization product in said intermediate with water to generate polyamine in situ that sequentially reacts with the remainder of the polymerization product to form urea linkages and hereby produce a three-dimensional object comprising polyurea. One part (1K) dual cure resins useful for the method are also provided.

IPC Classes  ?

  • B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • C08G 18/10 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
  • C08G 18/30 - Low-molecular-weight compounds
  • C08G 18/48 - Polyethers

28.

TOUGH, HIGH TEMPERATURE POLYMERS PRODUCED BY STEREOLITHOGRAPHY

      
Application Number 18059687
Status Pending
Filing Date 2022-11-29
First Publication Date 2023-03-30
Owner Carbon, Inc. (USA)
Inventor Menyo, Matthew S.

Abstract

The present invention concerns methods of forming a three-dimensional object, and polymerizable liquids such as dual cure resins useful for making a three-dimensional object by sterolithography, such as by continuous liquid interface production (CLIP).

IPC Classes  ?

  • C08F 2/48 - Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 64/124 - 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
  • B29C 64/35 - Cleaning
  • C08L 63/00 - Compositions of epoxy resins; Compositions of derivatives of epoxy resins

29.

METHODS OF MAKING A THREE-DIMENSIONAL OBJECT

      
Application Number 17904425
Status Pending
Filing Date 2021-02-22
First Publication Date 2023-03-16
Owner CARBON, INC. (USA)
Inventor
  • Poelma, Justin
  • Feller, Bob E.

Abstract

Provided herein is a method of making a three-dimensional object (31) by bottom-up additive manufacturing, which method may include: providing a carrier platform (14), a light source (13), and a light transmissive window (11) therebetween, the light transmissive window comprising a gas permeable member having a top surface and a bottom surface; depositing a liquid resin (21) on the window, the resin comprising a cyclic olefin monomer and a ring-opening metathesis polymerization (ROMP) photocatalyst; contacting a gas to said gas permeable member bottom surface; and exposing said resin to light from said light source while advancing aid carrier platform away from said window to form said three-dimensional object on said carrier platform. An apparatus useful for carrying out the method and a method useful for recycling the object are also provided.

IPC Classes  ?

  • B29C 64/124 - 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
  • B29C 64/205 - Means for applying layers
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 80/00 - Products made by additive manufacturing
  • B01J 35/00 - Catalysts, in general, characterised by their form or physical properties

30.

Low viscosity dual cure additive manufacturing resins

      
Application Number 18047318
Grant Number 11845200
Status In Force
Filing Date 2022-10-18
First Publication Date 2023-03-16
Grant Date 2023-12-19
Owner Carbon, Inc. (USA)
Inventor
  • Wright, Andrew Gordon
  • Chen, Kai
  • Feller, Bob E.

Abstract

Provided herein according to some embodiments is a dual cure additive manufacturing resin, comprising: (i) a light polymerizable component, (ii) a photoinitiator, (iii) a heat polymerizable component, and (iv) a non-reactive diluent, which resin is useful for the production of three-dimensional objects by additive manufacturing. Methods of using the same are also provided.

IPC Classes  ?

  • B29C 35/02 - Heating or curing, e.g. crosslinking or vulcanising
  • C08F 2/50 - Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light with sensitising agents
  • C08G 61/04 - Macromolecular compounds containing only carbon atoms in the main chain of the macromolecule, e.g. polyxylylenes only aliphatic carbon atoms
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • C08F 222/10 - Esters
  • C08F 2/48 - Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light
  • C08F 220/34 - Esters containing nitrogen
  • C08G 18/48 - Polyethers
  • C08G 18/67 - Unsaturated compounds having active hydrogen
  • C08G 18/75 - Polyisocyanates or polyisothiocyanates cyclic cycloaliphatic
  • C08G 65/08 - Saturated oxiranes
  • C08J 3/24 - Crosslinking, e.g. vulcanising, of macromolecules
  • C08J 3/28 - Treatment by wave energy or particle radiation
  • C08K 3/22 - Oxides; Hydroxides of metals
  • C08K 5/06 - Ethers; Acetals; Ketals; Ortho-esters
  • C08K 5/10 - Esters; Ether-esters
  • C08K 5/17 - Amines; Quaternary ammonium compounds
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing

31.

VERSATILE LATTICE CELL TRANSITIONING FOR ADDITIVELY MANUFACTURED PRODUCTS

      
Application Number US2022075372
Publication Number 2023/028502
Status In Force
Filing Date 2022-08-24
Publication Date 2023-03-02
Owner CARBON, INC. (USA)
Inventor
  • Chen, Ruiqi
  • Kloster, Kyle
  • Kurtz, Aidan
  • Sage, Robert G.
  • Zheng, Weixiong
  • Kabaria, Hardik

Abstract

Three-dimensional (3D) lattice objects with multiple zones of different lattice unit cells may be formed by additive manufacturing. Sets of primary unit cells are provided such that each primary unit cell is configured to smoothly transition to other primary unit cells through a series of intermediate unit cells. A universal unit cell may define the primary and intermediate unit cells.

IPC Classes  ?

32.

Resin level detection in additive manufacturing

      
Application Number 17428786
Grant Number 11801642
Status In Force
Filing Date 2020-02-25
First Publication Date 2023-02-23
Grant Date 2023-10-31
Owner Carbon, Inc. (USA)
Inventor
  • Truong, Ronald A.
  • Katzman, Steven R.

Abstract

In some embodiments, a method of determining the fill level of a resin pool in a bottom-up additive manufacturing apparatus includes the steps of: (a) providing an additive manufacturing apparatus including a build platform and a light transmissive window (12), the build platform (15) and the window (12) defining a build region therebetween, with the window (12) carrying a resin pool, the pool having a resin top surface portion; (b) advancing the build platform (15) and the window (12) towards one another until the build platform (15) contacts the resin top surface portion; (c) detecting the impact of the build platform (15) with the resin top surface portion; and (d) determining the fill level of the resin pool from the detected impact.

IPC Classes  ?

  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 64/245 - Platforms or substrates
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing

33.

WINDOW THERMAL PROFILE CALIBRATION IN ADDITIVE MANUFACTURING

      
Application Number 17967969
Status Pending
Filing Date 2022-10-18
First Publication Date 2023-02-09
Owner Carbon, Inc. (USA)
Inventor
  • Mohsenizadeh, Daniel N.
  • Laaker, Kyle
  • Truong, Ronald A.

Abstract

Methods, systems, and/or apparatuses for making an object on a bottom-up stereolithography apparatus that includes a light source, a drive assembly, optionally a heater and/or cooler, and a controller. The light source, optional heater and/or cooler, and/or the drive assembly have at least one adjustable parameter that is adjustable by said controller. An example method comprises (a) installing a removable window cassette on said apparatus in a configuration through which said light source projects, said window cassette comprising an optically transparent member having a build surface on which an object can be produced, and with said optically transparent member having at least one thermal profile associated therewith; and then (b) modifying said at least one adjustable parameter by said controller based on said at least one thermal profile of said optically transparent member; and then (c) producing the object on said build surface from a light-polymerizable liquid by bottom-up stereolithography.

IPC Classes  ?

  • B29C 64/245 - Platforms or substrates
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/295 - Heating elements
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/124 - 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
  • B33Y 10/00 - Processes of additive manufacturing

34.

Chemical recycling of additively manufactured objects

      
Application Number 17791073
Grant Number 11981778
Status In Force
Filing Date 2021-01-13
First Publication Date 2023-01-26
Grant Date 2024-05-14
Owner Carbon, Inc. (USA)
Inventor
  • Chen, Kai
  • Yang, Benjamin Huan

Abstract

Provided is a method of recycling an additively manufactured object into a reusable thermoplastic polymer, which method in some embodiments may include: (a) providing at least one additively manufactured object produced by stereolithography from a dual cure resin, the object comprising (i) a light polymerized polymer, and (ii) a heat polymerized polymer intermixed with said light polymerized polymer; (b) comminuting the object to produce a particulate material therefrom; (c) contacting the particulate material to a polar, aprotic solvent for a time and at a temperature sufficient to extract the heat polymerized polymer from the particulate material into said solvent, leaving residual particulate material comprising said light polymerized polymer in solid form; (d) separating the residual particulate material from said solvent; and then (e) separating the heat polymerized polymer from said solvent to provide a reusable thermoplastic polymer material in solid form.

IPC Classes  ?

  • C08J 11/08 - Recovery or working-up of waste materials of polymers without chemical reactions using selective solvents for polymer components

35.

VAPOR SPIN CLEANING OF ADDITIVELY MANUFACTURED PARTS

      
Application Number 17937544
Status Pending
Filing Date 2022-10-03
First Publication Date 2023-01-26
Owner Carbon, Inc. (USA)
Inventor
  • Feller, Bob E.
  • Powell, W. Ryan
  • Kaufman, Mark O.

Abstract

A method of cleaning residual resin from an additively manufactured object, includes: (a) enclosing an additively manufactured object in an inner chamber of a centrifugal separator, the additively manufactured object including a light polymerized resin with a surface coating of viscous, unpolymerized, residual resin; (b) flooding the chamber with a volatile organic solvent vapor without contacting liquid organic solvent to the object, the vapor present in an amount sufficient to reduce the viscosity of the residual resin; and (c) spinning the additively manufactured object in the chamber to centrifugally separate at least a first portion of the residual resin from the object.

IPC Classes  ?

  • B29C 64/35 - Cleaning
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B08B 3/08 - Cleaning involving contact with liquid the liquid having chemical or dissolving effect
  • B08B 5/00 - Cleaning by methods involving the use of air flow or gas flow
  • B08B 7/02 - Cleaning by methods not provided for in a single other subclass or a single group in this subclass by distortion, beating, or vibration of the surface to be cleaned
  • B08B 7/04 - Cleaning by methods not provided for in a single other subclass or a single group in this subclass by a combination of operations

36.

INTEGRATED ADDITIVE MANUFACTURING SYSTEMS

      
Application Number 17815736
Status Pending
Filing Date 2022-07-28
First Publication Date 2023-01-19
Owner Carbon, Inc. (USA)
Inventor
  • Desimone, Joseph M.
  • Goldman, Roy
  • Pollack, Steven Kenneth

Abstract

An integrated additive manufacturing system includes: (a) at least one resin supply; (b) a plurality of additive manufacturing machines on which parts may be produced, each of the additive manufacturing machines operatively associated with the at least one resin supply; and (c) at least one peripheral machine operatively associated with each of the additive manufacturing machines and the at least one resin supply.

IPC Classes  ?

  • B29C 64/35 - Cleaning
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/124 - 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
  • B29C 64/245 - Platforms or substrates
  • B29C 64/295 - Heating elements
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/321 - Feeding
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/371 - Conditioning of environment using an environment other than air, e.g. inert gas
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing

37.

Bioabsorbable resin for additive manufacturing

      
Application Number 17930174
Grant Number 11884774
Status In Force
Filing Date 2022-09-07
First Publication Date 2023-01-19
Grant Date 2024-01-30
Owner Carbon, Inc. (USA)
Inventor
  • Gu, Xinyu
  • Chen, Sharon
  • Policastro, Gina Michelle
  • Hopson, Peyton
  • Donners, Jackie
  • Vendely, Michael
  • Harris, Jason L.

Abstract

Provided herein according to aspects of the present invention are resins that: (a) are suitable for use in additive manufacturing techniques such as bottom-up and top-down stereolithography, (b) produce objects that are bioresorbable, and (c) produce objects that are flexible or elastic (preferably at at least typical room temperatures of 25° C., and in some embodiments at typical human body temperatures of 37° C.). Such resins may include: (a) a bioresorbable polyester oligomer having reactive end groups; (b) non-reactive diluent; (c) optionally reactive diluent; and (d) a photoinitiator.

IPC Classes  ?

  • C08F 2/46 - Polymerisation initiated by wave energy or particle radiation
  • C08F 2/50 - Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light with sensitising agents
  • C08G 61/04 - Macromolecular compounds containing only carbon atoms in the main chain of the macromolecule, e.g. polyxylylenes only aliphatic carbon atoms
  • C08G 63/08 - Lactones or lactides
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 64/124 - 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
  • B29C 64/35 - Cleaning
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • C08F 290/06 - Polymers provided for in subclass
  • C08G 63/91 - Polymers modified by chemical after-treatment
  • C08K 11/00 - Use of ingredients of unknown constitution, e.g. undefined reaction products
  • B29C 71/00 - After-treatment of articles without altering their shape; Apparatus therefor

38.

Inhibition of crystallization in polyurethane resins

      
Application Number 17757255
Grant Number 11713367
Status In Force
Filing Date 2020-12-15
First Publication Date 2023-01-12
Grant Date 2023-08-01
Owner Carbon, Inc. (USA)
Inventor
  • Lu, Jie
  • Chen, Kai

Abstract

A resin composition useful for additive manufacturing is provided, which resin composition may exhibit improved shelf life through inhibition of crystallization. Such resin composition may include a crystallization inhibitor as taught herein, and/or a prepolymer produced by reaction of an isocyanate with multiple isomers and comprising a lower percentage of the structurally symmetric isomer. Methods of forming a three-dimensional object using such resin composition are also provided.

IPC Classes  ?

  • C08F 290/06 - Polymers provided for in subclass
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 64/124 - 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
  • B29C 64/35 - Cleaning
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • C08G 18/10 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
  • C08G 18/32 - Polyhydroxy compounds; Polyamines; Hydroxy amines
  • C08G 18/67 - Unsaturated compounds having active hydrogen
  • C08G 18/73 - Polyisocyanates or polyisothiocyanates acyclic
  • C08G 18/75 - Polyisocyanates or polyisothiocyanates cyclic cycloaliphatic
  • C08G 18/76 - Polyisocyanates or polyisothiocyanates cyclic aromatic
  • C08G 18/81 - Unsaturated isocyanates or isothiocyanates
  • C08K 5/098 - Metal salts of carboxylic acids
  • C08K 5/17 - Amines; Quaternary ammonium compounds
  • C08K 5/21 - Urea; Derivatives thereof, e.g. biuret
  • B29K 75/00 - Use of polyureas or polyurethanes as moulding material
  • B29K 105/00 - Condition, form or state of moulded material

39.

Bioabsorbable resin for additive manufacturing with non-cytotoxic photoinitiator

      
Application Number 17853180
Grant Number 11952457
Status In Force
Filing Date 2022-06-29
First Publication Date 2023-01-05
Grant Date 2024-04-09
Owner Carbon, Inc. (USA)
Inventor Policastro, Gina Michelle

Abstract

A resin useful for producing objects is provided, which resin contains a photoinitiator of low cytotoxicity. The resins may be suitable for use in additive manufacturing techniques such as bottom-up and top-down stereolithography, produce objects that are bioresorbable and non-cytotoxic, and/or produce objects that are flexible or elastic. Methods of use of the resin and objects produced therefrom are also provided.

IPC Classes  ?

  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • C08G 63/08 - Lactones or lactides
  • C08G 63/78 - Preparation processes
  • C08K 5/00 - Use of organic ingredients
  • C08K 5/11 - Esters; Ether-esters of acyclic polycarboxylic acids

40.

METHODS OF PRODUCING THREE-DIMENSIONAL OBJECTS WITH APPARATUS HAVING FEED CHANNELS

      
Application Number 17662706
Status Pending
Filing Date 2022-05-10
First Publication Date 2023-01-05
Owner Carbon, Inc. (USA)
Inventor
  • Rolland, Jason P.
  • Chen, Kai
  • Poelma, Justin
  • Goodrich, James
  • Pinschmidt, Robert
  • Desimone, Joseph M.
  • Robeson, Lloyd M.

Abstract

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; (b) filling the build region with a polymerizable liquid, the polymerizable liquid including a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from the first component; (c) irradiating the build region with light through the optically transparent member to form a solid polymer scaffold from the first component and also advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, and containing the second solidifiable component carried in the scaffold in unsolidified and/or uncured form; and (d) concurrently with or subsequent to the irradiating step, solidifying and/or curing the second solidifiable component in the three-dimensional intermediate to form the three-dimensional object.

IPC Classes  ?

  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/286 - Optical filters, e.g. masks
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing

41.

Shelf stable, low tin concentration, dual cure additive manufacturing resins

      
Application Number 17930194
Grant Number 11649312
Status In Force
Filing Date 2022-09-07
First Publication Date 2022-12-29
Grant Date 2023-05-16
Owner Carbon, Inc. (USA)
Inventor Wright, Andrew Gordon

Abstract

Provided herein are methods of making (meth)acrylate blocked polyurethanes with zirconium catalysts, dual cure resins containing (meth)acrylate blocked polyurethanes and zirconium catalysts, methods of using the same in additive manufacturing, and products made therefrom.

IPC Classes  ?

  • C08F 290/06 - Polymers provided for in subclass
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 64/124 - 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
  • B29C 64/245 - Platforms or substrates
  • B29C 64/35 - Cleaning
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • C08F 299/06 - Macromolecular compounds obtained by interreacting polymers involving only carbon-to-carbon unsaturated bond reactions, in the absence of non-macromolecular monomers from unsaturated polycondensates from polyurethanes
  • C08G 18/10 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
  • C08G 18/22 - Catalysts containing metal compounds
  • C08G 18/73 - Polyisocyanates or polyisothiocyanates acyclic
  • B29K 75/00 - Use of polyureas or polyurethanes as moulding material

42.

Methods and apparatus for washing objects produced by stereolithography

      
Application Number 17929357
Grant Number 11987003
Status In Force
Filing Date 2022-09-02
First Publication Date 2022-12-29
Grant Date 2024-05-21
Owner Carbon, Inc. (USA)
Inventor
  • Converse, Courtney F.
  • Powell, W. Ryan
  • Forlee, Sherwood
  • Scheinman, David Eliot
  • Heines, Scott
  • Sabathia, Jr., Edwin James

Abstract

A method of making a three-dimensional object, including the steps of: (a) providing a carrier platform; (b) producing the three-dimensional object adhered to the carrier platform; (c) immersing the object in a wash liquid with the object remaining adhered to the carrier platform; (d) agitating the object in the wash liquid and/or the wash liquid with the object immersed therein to at least partially remove residual resin from the object; (e) separating the object from the wash liquid, with the object remaining adhered to the carrier platform; (f) agitating the object at least partially remove residual wash liquid; and (g) repeating steps (c) through (f) at least once to remove additional polymerizable resin, steps (c) through (f) are carried out in the same vessel, the immersing step (c) includes filling the vessel with the wash liquid, and the separating step (e) includes draining the wash liquid from the vessel.

IPC Classes  ?

  • B29C 64/35 - Cleaning
  • B08B 3/04 - Cleaning involving contact with liquid
  • B08B 3/10 - Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
  • B08B 3/12 - Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration by sonic or ultrasonic vibrations
  • B29C 64/20 - 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 - Details thereof or accessories therefor
  • B08B 3/08 - Cleaning involving contact with liquid the liquid having chemical or dissolving effect
  • B08B 3/14 - Removing waste, e.g. labels, from cleaning liquid

43.

Methods for producing three-dimensional objects with apparatus having feed channels

      
Application Number 17655282
Grant Number 11707893
Status In Force
Filing Date 2022-03-17
First Publication Date 2022-12-22
Grant Date 2023-07-25
Owner Carbon, Inc. (USA)
Inventor
  • Rolland, Jason P.
  • Chen, Kai
  • Poelma, Justin
  • Goodrich, James
  • Pinschmidt, Jr., Robert K.
  • Desimone, Joseph M.
  • Robeson, Lloyd M.

Abstract

A method of forming a three-dimensional object, wherein said three-dimensional object is an insert for use between a helmet and a human body, is described. The method may use a polymerizable liquid, or resin, useful for the production by additive manufacturing of a three-dimensional object, comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from said first component.

IPC Classes  ?

  • C08F 2/46 - Polymerisation initiated by wave energy or particle radiation
  • C08F 2/50 - Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light with sensitising agents
  • C08G 61/04 - Macromolecular compounds containing only carbon atoms in the main chain of the macromolecule, e.g. polyxylylenes only aliphatic carbon atoms
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • C08K 3/013 - Fillers, pigments or reinforcing additives
  • C08K 3/01 - Use of inorganic substances as compounding ingredients characterised by their specific function
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • G03F 7/00 - Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printed surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
  • G03F 7/027 - Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds
  • G03F 7/038 - Macromolecular compounds which are rendered insoluble or differentially wettable
  • G03F 7/075 - Silicon-containing compounds
  • G03F 7/38 - Treatment before imagewise removal, e.g. prebaking
  • B29C 64/124 - 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
  • B29C 64/135 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • C08G 18/81 - Unsaturated isocyanates or isothiocyanates
  • C08G 18/10 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
  • C08G 18/76 - Polyisocyanates or polyisothiocyanates cyclic aromatic
  • C08F 220/34 - Esters containing nitrogen
  • C08G 18/42 - Polycondensates having carboxylic or carbonic ester groups in the main chain
  • C08F 290/06 - Polymers provided for in subclass
  • C08G 18/73 - Polyisocyanates or polyisothiocyanates acyclic
  • C08G 18/48 - Polyethers
  • C08G 18/24 - Catalysts containing metal compounds of tin
  • C08G 18/69 - Polymers of conjugated dienes
  • C08G 18/75 - Polyisocyanates or polyisothiocyanates cyclic cycloaliphatic
  • C08F 283/00 - Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass
  • C08G 18/40 - High-molecular-weight compounds
  • B29C 71/00 - After-treatment of articles without altering their shape; Apparatus therefor
  • B29C 64/286 - Optical filters, e.g. masks
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29D 11/00 - Producing optical elements, e.g. lenses or prisms
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • C08K 5/00 - Use of organic ingredients
  • C08L 75/04 - Polyurethanes
  • B33Y 80/00 - Products made by additive manufacturing
  • C09D 135/02 - Homopolymers or copolymers of esters
  • C09D 175/04 - Polyurethanes
  • C09D 175/08 - Polyurethanes from polyethers
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • C08J 5/00 - Manufacture of articles or shaped materials containing macromolecular substances
  • C08L 75/14 - Polyurethanes having carbon-to-carbon unsaturated bonds
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 33/00 - 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 - Details thereof or accessories therefor
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 75/00 - Use of polyureas or polyurethanes as moulding material
  • B29K 105/04 - Condition, form or state of moulded material cellular or porous
  • B29L 11/00 - Optical elements, e.g. lenses, prisms
  • B29L 31/10 - Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
  • B29K 105/16 - Fillers
  • B29K 509/00 - Use of inorganic materials not provided for in groups , as filler
  • B29L 31/00 - Other particular articles

44.

MECHANICALLY ANISOTROPIC 3D PRINTED FLEXIBLE POLYMERIC SHEATH

      
Application Number 17762208
Status Pending
Filing Date 2020-10-20
First Publication Date 2022-12-22
Owner Carbon, Inc. (USA)
Inventor
  • Kabaria, Hardik
  • Meyer, Eleanor R.
  • Pollock, Steven Kenneth

Abstract

A connective or supportive sheath comprising, consisting of, or consisting essentially of a hollow tube having a circumferential or perimeter wall, the wall having an inner surface and an outer surface, the wall comprising interconnected, radially projecting, partitions, the partitions forming radially extending pores, the pores extending from said inner surface through said outer surface, and wherein the tube is comprised of, consists of, or consists essentially of a flexible or elastic polymer.

IPC Classes  ?

  • C08G 63/08 - Lactones or lactides
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask

45.

Resin dispenser for additive manufacturing

      
Application Number 17821555
Grant Number 11724445
Status In Force
Filing Date 2022-08-23
First Publication Date 2022-12-22
Grant Date 2023-08-15
Owner Carbon, Inc. (USA)
Inventor
  • Rolland, Jason P.
  • Converse, Courtney F.
  • Nazarian, Oshin
  • Panzer, Matthew

Abstract

A method of making a three-dimensional object by additive manufacturing from a blended resin including (i) at least one light polymerizable first component and, (ii) at least one, or a plurality of, second solidifiable components that are different from said first component, the method including: providing a first resin and a second resin, where the resins produce three-dimensional objects having different mechanical properties from one another when all are produced under the same process conditions; mixing the first and second resins with one another to produce the blended resin, the blended resin producing a three-dimensional object having mechanical properties intermediate between that of objects produced by the first and second resins when all are produced under the same process conditions; and dispensing the blended resin to the build region of an additive manufacturing apparatus; and then optionally but preferably producing a three-dimensional object from the blended resin in the apparatus.

IPC Classes  ?

  • B29C 64/124 - 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
  • B29C 64/314 - Preparation
  • B29C 64/321 - Feeding
  • B29C 64/364 - Conditioning of environment
  • B29C 64/245 - Platforms or substrates
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/35 - Cleaning
  • B29C 64/205 - Means for applying layers
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B29K 63/00 - Use of epoxy resins as moulding material
  • B29K 75/00 - Use of polyureas or polyurethanes as moulding material
  • B29K 83/00 - Use of polymers having silicon, with or without sulfur, nitrogen, oxygen or carbon only, in the main chain, as moulding material

46.

METHODS FOR SURFACE COATING ADDITIVELY MANUFACTURED OBJECTS

      
Application Number US2022033806
Publication Number 2022/266331
Status In Force
Filing Date 2022-06-16
Publication Date 2022-12-22
Owner CARBON, INC. (USA)
Inventor
  • Wright, Andrew, Gordon
  • Denmark, Alexander
  • Feller, Bob, E.
  • Rolland, Jason, P.

Abstract

Provided are methods of making an additively manufactured object having an outer surface coating thereon. Also provided are additively manufactured objects having an outer surface coating thereon.

IPC Classes  ?

  • B29C 64/124 - 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
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/241 - Driving means for rotary motion
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B05D 1/18 - Processes for applying liquids or other fluent materials performed by dipping
  • B05D 7/02 - Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber
  • B29C 64/35 - Cleaning

47.

SYSTEMS AND METHODS FOR MAKING POLYMER DENTAL APPLIANCES

      
Application Number US2022031907
Publication Number 2022/260921
Status In Force
Filing Date 2022-06-02
Publication Date 2022-12-15
Owner CARBON, INC. (USA)
Inventor
  • Swarup, Keshav
  • Robbins, Gregory Robert
  • Feller, Bob E.
  • Denmark, Alexander D.
  • Lu, Owen

Abstract

A method of making a plurality of polymer dental appliances, including the steps of: (a) additively manufacturing a plurality of hollow molds from a polymerizable resin, each mold having an external surface portion configured in the shape of a dental arch and a bottom portion having a hollow cavity therein, and with the additively manufacturing step carried out with the plurality of hollow molds formed on a build platform; (b) centrifugally separating residual resin from both the external surface portion and the bottom portion (including the hollow cavity) of each mold; (c) further curing, concurrently or sequentially, the external surface portion and the bottom portion of each mold with ultraviolet light; then (d) thermoforming a thermoplastic polymer sheet on each hollow mold external surface portion to produce the plurality of polymer dental appliances; and (e) separating the plurality of polymer dental appliances from the plurality of hollow molds.

IPC Classes  ?

  • B29C 37/02 - Deburring or deflashing
  • A61C 7/00 - Orthodontics, i.e. obtaining or maintaining the desired position of teeth, e.g. by straightening, evening, regulating, separating, or by correcting malocclusions
  • A61C 13/00 - Dental prostheses; Making same
  • B29C 64/245 - Platforms or substrates
  • B29C 64/35 - Cleaning
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 33/38 - 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 - Details thereof or accessories therefor characterised by the material or the manufacturing process
  • B29C 51/30 - Moulds
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing

48.

Methods for producing three-dimensional objects with apparatus having feed channels

      
Application Number 17655275
Grant Number 11850803
Status In Force
Filing Date 2022-03-17
First Publication Date 2022-12-08
Grant Date 2023-12-26
Owner Carbon, Inc. (USA)
Inventor
  • Rolland, Jason P.
  • Chen, Kai
  • Poelma, Justin
  • Goodrich, James
  • Pinschmidt, Robert
  • Desimone, Joseph M.
  • Robeson, Lloyd M.

Abstract

A method of forming a three-dimensional object (e.g. comprised of polyurethane, polyurea, or copolymer thereof) 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; (b) filling the build region with a polymerizable liquid, the polymerizable liquid comprising a mixture of: (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from the first component; (c) irradiating the build region with light through the optically transparent member to form a solid blocked polymer scaffold and advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, with the intermediate containing the second solidifiable component; and then (d) contacting the three-dimensional intermediate to water to form the three-dimensional object.

IPC Classes  ?

  • B29C 71/02 - Thermal after-treatment
  • B29C 71/04 - After-treatment of articles without altering their shape; Apparatus therefor by wave energy or particle radiation
  • B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
  • C08K 3/013 - Fillers, pigments or reinforcing additives
  • C08K 3/01 - Use of inorganic substances as compounding ingredients characterised by their specific function
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • G03F 7/00 - Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printed surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
  • G03F 7/027 - Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds
  • G03F 7/038 - Macromolecular compounds which are rendered insoluble or differentially wettable
  • G03F 7/075 - Silicon-containing compounds
  • G03F 7/38 - Treatment before imagewise removal, e.g. prebaking
  • B29C 64/124 - 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
  • B29C 64/135 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • C08G 18/81 - Unsaturated isocyanates or isothiocyanates
  • C08G 18/10 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
  • C08G 18/76 - Polyisocyanates or polyisothiocyanates cyclic aromatic
  • C08F 220/34 - Esters containing nitrogen
  • C08G 18/42 - Polycondensates having carboxylic or carbonic ester groups in the main chain
  • C08F 290/06 - Polymers provided for in subclass
  • C08G 18/73 - Polyisocyanates or polyisothiocyanates acyclic
  • C08G 18/48 - Polyethers
  • C08G 18/24 - Catalysts containing metal compounds of tin
  • C08G 18/69 - Polymers of conjugated dienes
  • C08G 18/75 - Polyisocyanates or polyisothiocyanates cyclic cycloaliphatic
  • C08F 283/00 - Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass
  • C08G 18/40 - High-molecular-weight compounds
  • B29C 71/00 - After-treatment of articles without altering their shape; Apparatus therefor
  • B29C 64/286 - Optical filters, e.g. masks
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29D 11/00 - Producing optical elements, e.g. lenses or prisms
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • C08K 5/00 - Use of organic ingredients
  • C08L 75/04 - Polyurethanes
  • B33Y 80/00 - Products made by additive manufacturing
  • C09D 135/02 - Homopolymers or copolymers of esters
  • C09D 175/04 - Polyurethanes
  • C09D 175/08 - Polyurethanes from polyethers
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • C08J 5/00 - Manufacture of articles or shaped materials containing macromolecular substances
  • C08L 75/14 - Polyurethanes having carbon-to-carbon unsaturated bonds
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 33/00 - 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 - Details thereof or accessories therefor
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 75/00 - Use of polyureas or polyurethanes as moulding material
  • B29K 105/04 - Condition, form or state of moulded material cellular or porous
  • B29L 11/00 - Optical elements, e.g. lenses, prisms
  • B29L 31/10 - Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
  • B29K 105/16 - Fillers
  • B29K 509/00 - Use of inorganic materials not provided for in groups , as filler
  • B29L 31/00 - Other particular articles

49.

LOFTED LATTICE STRUCTURES AND METHODS OF MAKING THE SAME

      
Application Number 17830719
Status Pending
Filing Date 2022-06-02
First Publication Date 2022-12-08
Owner Carbon, Inc. (USA)
Inventor Merlo, Austin M.

Abstract

An additively manufactured lattice includes a plurality of symmetrically oriented repeating unit cells. Each of the unit cells is comprised of a vertically oriented tubular structure having a top edge and bottom edge, said tubular structure defined by a circumferential side wall extending from said top edge to said bottom edge. The side wall has a lower portion, an intermediate portion, and an upper portion, with the lower portion terminating at the bottom edge, the upper portion terminating at the top edge, and the intermediate portion positioned between the lower portion and the upper portion. A plurality of spaced legs is included with each unit cell, with each leg formed as an outfolding of the side wall, each outfolding beginning at the side wall intermediate portion and extending progressively further outward through the side wall lower portion to the bottom edge.

IPC Classes  ?

  • A42B 3/12 - Cushioning devices
  • A41D 13/015 - Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches with shock-absorbing means
  • B33Y 80/00 - Products made by additive manufacturing

50.

METHODS FOR THE RAPID PRODUCTION OF BLOCKED PREPOLYMERS

      
Application Number US2022032135
Publication Number 2022/256635
Status In Force
Filing Date 2022-06-03
Publication Date 2022-12-08
Owner CARBON, INC. (USA)
Inventor Wright, Andrew Gordon

Abstract

Provided according to embodiments of the invention are methods for the rapid production of a composition that includes a reactive blocked prepolymer. Such methods may include continuously mixing a first precursor composition and a second precursor composition, the first precursor composition including a polyisocyanate oligomer and the second precursor composition including an amine (meth)acrylate to produce the composition that includes a reactive blocked prepolymer.

IPC Classes  ?

  • C08G 18/10 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
  • B29C 64/00 - 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
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • C08F 220/34 - Esters containing nitrogen
  • C08F 283/00 - Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass
  • C08F 290/06 - Polymers provided for in subclass
  • C08G 18/24 - Catalysts containing metal compounds of tin
  • C08G 18/48 - Polyethers
  • C08G 18/72 - Polyisocyanates or polyisothiocyanates
  • C08G 18/75 - Polyisocyanates or polyisothiocyanates cyclic cycloaliphatic
  • C08G 18/80 - Masked polyisocyanates
  • C08G 18/81 - Unsaturated isocyanates or isothiocyanates
  • G03F 7/00 - Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printed surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor

51.

PARTICLE COATING METHODS FOR ADDITIVELY MANUFACTURED PRODUCTS

      
Application Number 17753999
Status Pending
Filing Date 2020-09-25
First Publication Date 2022-11-24
Owner
  • Carbon, Inc. (USA)
  • ADIDAS AG (Germany)
Inventor
  • Shah, Aayush A.
  • Chen, Kai
  • Kirkwood, Keith Michael

Abstract

Provided herein according to aspects of the present invention is a method of additively manufacturing an object having a particle surface coating thereon, using an intermediate object produced in an additive manufacturing process by light polymerization of a dual cure resin, said intermediate object having residual dual cure resin from which it was produced remaining on a surface portion thereof in unpolymerized form; forming a solid particle coating adhered to the resin coating film; and then further curing the intermediate object.

IPC Classes  ?

  • B29C 64/30 - Auxiliary operations or equipment
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B29C 64/124 - 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

52.

Reduction of polymerization inhibitor irregularity on additive manufacturing windows

      
Application Number 17872227
Grant Number 11685110
Status In Force
Filing Date 2022-07-25
First Publication Date 2022-11-10
Grant Date 2023-06-27
Owner Carbon, Inc. (USA)
Inventor
  • Feller, Bob E.
  • Price, R. Griffin

Abstract

An apparatus for producing a three-dimensional object by additive manufacturing includes a drive assembly operatively associated with a carrier and a window mount and configured to advance the carrier and the window mount away from one another. A first fluid switch is connected to a first fluid orifice when a window is present, or connected to the window mount and configured for connection to the window when the window is absent. A second fluid switch is connected to a second fluid orifice when the window is present, or connected to the window mount and configured for connection to the window when the window is absent. A fluid supply is connected to both the first and second fluid switch, and the fluid includes a polymerization inhibitor.

IPC Classes  ?

  • B29C 64/124 - 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/321 - Feeding
  • B29C 64/364 - Conditioning of environment
  • B29C 64/245 - Platforms or substrates

53.

THREE-DIMENSIONAL PRINTING WITH SUPPORTED BUILD PLATES

      
Application Number 17860466
Status Pending
Filing Date 2022-07-08
First Publication Date 2022-11-03
Owner Carbon, Inc. (USA)
Inventor
  • Desimone, Joseph M.
  • Ermoshkin, Alexander
  • Samulski, Edward T.
  • Rolland, Jason P.

Abstract

A method of forming a three-dimensional object includes: providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; filling the build region with a polymerizable liquid, irradiating the build region with light through the optically transparent member to form a solid polymer from the polymerizable liquid, and advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer. The irradiating step includes projecting focused light at the build region, and the advancing step is carried out at a rate that is dependent on an average light intensity of the focused light.

IPC Classes  ?

  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/112 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
  • B29C 64/124 - 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
  • B29C 64/245 - Platforms or substrates
  • B33Y 80/00 - Products made by additive manufacturing

54.

Rapid wash system for additive manufacturing

      
Application Number 17857371
Grant Number 11897200
Status In Force
Filing Date 2022-07-05
First Publication Date 2022-10-20
Grant Date 2024-02-13
Owner Carbon, Inc. (USA)
Inventor
  • Graham, Ian Alastair
  • Laaker, Kyle
  • Barth, Florian Markus

Abstract

A dental model, includes (a) an upper segment, the upper segment having a shape corresponding to at least a portion of a dental arch of a human patient; (b) a base segment having an external surface and a bottom surface; (c) at least one internal cavity formed in the base segment, and optionally the upper segment, the at least one internal cavity extending through the bottom surface; and (d) at least one wash channel extending from the external surface of the base segment through the base segment and into the at least one internal cavity.

IPC Classes  ?

  • A61C 13/34 - Making or working of models, e.g. preliminary castings, trial dentures; Dowel pins
  • B29C 64/35 - Cleaning
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/135 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • A61C 5/77 - Methods or devices for making crowns
  • B29L 31/00 - Other particular articles

55.

Dual cure additive manufacturing resins for production of flame retardant objects

      
Application Number 17808209
Grant Number 11834574
Status In Force
Filing Date 2022-06-22
First Publication Date 2022-10-13
Grant Date 2023-12-05
Owner Carbon, Inc. (USA)
Inventor
  • Grover, Ikpreet Singh
  • Menyo, Matthew S.

Abstract

The present invention concerns methods of forming a three-dimensional object, and polymerizable liquids such as dual cure resins useful for making a three-dimensional object by sterolithography, such as by continuous liquid interface production (CLIP), wherein the three-dimensional object is flame retardant.

IPC Classes  ?

  • B29C 64/00 - 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
  • C08L 51/00 - Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 64/124 - 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
  • B29C 64/35 - Cleaning
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B29K 63/00 - Use of epoxy resins as moulding material
  • B29K 105/00 - Condition, form or state of moulded material

56.

SYSTEMS AND METHODS FOR CONSTRUCTING LATTICE OBJECTS FOR ADDITIVE MANUFACTURING

      
Application Number US2022022503
Publication Number 2022/212472
Status In Force
Filing Date 2022-03-30
Publication Date 2022-10-06
Owner CARBON, INC. (USA)
Inventor
  • Chen, Ruiqi
  • Kabaria, Hardik

Abstract

Tdd symmetry); and then (c) filling said tetrahedral mesh with the tetrahedral unit cell to thereby construct a 3D object comprising repeating interconnected unit cells of the selected primary lattice. In some embodiments the method further includes the step of (d) additively manufacturing the 3D object.

IPC Classes  ?

  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • G06F 30/00 - Computer-aided design [CAD]
  • G06T 17/10 - Volume description, e.g. cylinders, cubes or using CSG [Constructive Solid Geometry]
  • G06T 17/20 - Wire-frame description, e.g. polygonalisation or tessellation
  • G06T 17/30 - Surface description, e.g. polynomial surface description

57.

HYBRID SURFACE LATTICES FOR ADDITIVELY MANUFACTURED PRODUCTS

      
Application Number US2022022509
Publication Number 2022/212475
Status In Force
Filing Date 2022-03-30
Publication Date 2022-10-06
Owner CARBON, INC. (USA)
Inventor
  • Kloster, Kyle
  • Kurtz, Aidan
  • Chen, Ruiqi
  • Kabaria, Hardik
  • Zheng, Weixiong

Abstract

e.g.,e.g., stiffness, energy absorption, energy return, resilience, toughness) along a predefined axis therein not achieved by either said first or second surface lattice unit cell when formed from the same material as said hybrid surface lattice unit cell.

IPC Classes  ?

  • G06F 30/23 - Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
  • B22F 10/80 - Data acquisition or data processing
  • B29C 64/00 - 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
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • G06F 111/06 - Multi-objective optimisation, e.g. Pareto optimisation using simulated annealing [SA], ant colony algorithms or genetic algorithms [GA]
  • G06F 113/10 - Additive manufacturing, e.g. 3D printing
  • G06F 119/14 - Force analysis or force optimisation, e.g. static or dynamic forces

58.

SYSTEMS AND METHODS FOR SURFACE TEXTURING OBJECTS DURING ADDITIVE MANUFACTURING

      
Application Number 17655865
Status Pending
Filing Date 2022-03-22
First Publication Date 2022-09-29
Owner Carbon, Inc. (USA)
Inventor Denmark, Alexander D.

Abstract

Surface texturing of objects during additive manufacturing, including systems and methods thereof. For example, a method of surface texturing a three-dimensional (3D) object during additive manufacturing of the object: (a) irradiating a resin segment with patterned light at a build plane to polymerize said resin and grow said 3D object, then (b) advancing said object away from said build plane to bring a new segment of said resin in contact with said growing 3D object and establish a new build plane, and then repeating steps (a) through (b) until said 3D object is formed. For resin segments that correspond to portions of said 3D object to which surface texture is applied, said irradiating step is carried out by sequentially irradiating each resin segment with: (i) a first sub-exposure pattern and (ii) a second sub-exposure pattern, one of which is modified to include a texture pattern on a surface thereof.

IPC Classes  ?

  • B29C 64/282 - Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] of the same type, e.g. using different energy levels
  • B29C 64/35 - Cleaning
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

59.

PREEMPTIVE APPARATUS FAILURE DETECTION IN ADDITIVE MANUFACTURING

      
Application Number 17596754
Status Pending
Filing Date 2020-05-27
First Publication Date 2022-09-22
Owner Carbon, Inc. (USA)
Inventor
  • Gupta, Akruti M.
  • Stewart, Devlin David
  • Navarro, Gabriel Alfonso
  • Van Adelsberg, Hunter Alex

Abstract

Systems, methods, and devices may be configured to detect and remediate component failures in three-dimensional object printers (10, 10a-f) preemptively. For example, systems may include: (a) a plurality of printers (10, 10a-f) each configured to produce three-dimensional objects (13), each printer including: (i) a plurality of subsystems; and (ii) at least one sensor; and (b) processor(s) (41, 42) and memory resource(s) (21) storing an inventory of available replacement components for at least some of said subsystems. The one or more memory resources may (21) store instructions that may cause the one or more processors to: (i) identify a predetermined pattern in data sensed during a process of producing a three-dimensional object by a sensor of a printer as an indicator of likely failure of a subsystem or component thereof; and (ii) assign a component in inventory to said printer based on a unique identifier of the printer and the indicator of likely failure identified in the signal.

IPC Classes  ?

  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/124 - 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
  • B29C 64/364 - Conditioning of environment
  • B29C 64/264 - Arrangements for irradiation
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - 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 - Details thereof or accessories therefor

60.

CUSHIONS CONTAINING SHOCK ABSORBING TRIPLY PERIODIC LATTICE AND RELATED METHODS

      
Application Number 17630953
Status Pending
Filing Date 2020-09-04
First Publication Date 2022-09-01
Owner Carbon, Inc. (USA)
Inventor
  • Kabaria, Hardik
  • Kurtz, Aidan
  • Sage, Robert G.
  • Burgess, Nicholas K.
  • Chen, Ruiqi

Abstract

An additively manufactured cushion includes an array of interconnected surface lattice unit cells. The surface lattice unit cells are comprised of a unit cell surface portion configured as a Schoen F-RD minimal surface unit cell, and the unit cell surface portion is comprised of a rigid, flexible, or elastic polymer. In some embodiments, the surface lattice unit cells have an average width of from 1 to 100 millimeters and an average volume fraction of from 5 or 10 percent to 50 or 60 percent.

IPC Classes  ?

  • F16F 7/12 - Vibration-dampers; Shock-absorbers using plastic deformation of members
  • B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
  • B29C 64/35 - Cleaning
  • B29C 64/264 - Arrangements for irradiation

61.

Bioabsorbable resin for additive manufacturing

      
Application Number 17753415
Grant Number 11466121
Status In Force
Filing Date 2020-09-16
First Publication Date 2022-08-25
Grant Date 2022-10-11
Owner Carbon, Inc. (USA)
Inventor
  • Gu, Xinyu
  • Chen, Sharon
  • Policastro, Gina Michelle
  • Hopson, Peyton
  • Donners, Jackie
  • Vendely, Michael
  • Harris, Jason L.

Abstract

Provided herein according to aspects of the present invention are resins that: (a) are suitable for use in additive manufacturing techniques such as bottom-up and top-down stereolithography, (b) produce objects that are bioresorbable, and (c) produce objects that are flexible or elastic (preferably at at least typical room temperatures of 25° C., and in some embodiments at typical human body temperatures of 37° C.). Such resins may include: (a) a bioresorbable polyester oligomer having reactive end groups; (b) non-reactive diluent; (c) optionally reactive diluent; and (d) a photoinitiator.

IPC Classes  ?

  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • C08F 2/46 - Polymerisation initiated by wave energy or particle radiation
  • C08F 2/50 - Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light with sensitising agents
  • C08G 61/04 - Macromolecular compounds containing only carbon atoms in the main chain of the macromolecule, e.g. polyxylylenes only aliphatic carbon atoms
  • C08G 63/08 - Lactones or lactides
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B29C 64/124 - 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
  • C08G 63/91 - Polymers modified by chemical after-treatment
  • C08F 290/06 - Polymers provided for in subclass
  • C08K 11/00 - Use of ingredients of unknown constitution, e.g. undefined reaction products
  • B29C 64/35 - Cleaning
  • B29C 71/00 - After-treatment of articles without altering their shape; Apparatus therefor

62.

Continuous three dimensional fabrication from immiscible liquids

      
Application Number 16675741
Grant Number RE049180
Status In Force
Filing Date 2019-11-06
First Publication Date 2022-08-23
Grant Date 2022-08-23
Owner Carbon, Inc. (USA)
Inventor
  • Robeson, Lloyd M.
  • Samulski, Edward T.
  • Ermoshkin, Alexander
  • Desimone, Joseph M.

Abstract

A method of forming a three-dimensional object is carried out by: providing a carrier and a pool of immiscible liquid, the pool having a liquid build surface, the carrier and the liquid build surface defining a build region therebetween; filling the build region with a polymerizable liquid, wherein the immiscible liquid is immiscible with the polymerizable liquid (in some embodiments wherein the immiscible liquid has a density greater than the polymerizable liquid); irradiating the build region through at least a portion of the pool of immiscible liquid to form a solid polymer from the polymerizable liquid and advancing the carrier away from the liquid build surface to form the three-dimensional object comprised of the solid polymer from the polymerizable liquid. Optionally, but in some embodiments preferably, the method is carried out while also continuously maintaining a gradient of polymerization zone between the liquid build surface and the solid polymer and in contact with each thereof, the gradient of polymerization zone comprising the polymerizable liquid in partially cured form.

IPC Classes  ?

  • B29C 64/124 - 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
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 64/245 - Platforms or substrates
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 64/20 - 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 - Details thereof or accessories therefor

63.

Divided resin cassettes for enhanced work flow in additive manufacturing of dental products and the like

      
Application Number 17597656
Grant Number 11518098
Status In Force
Filing Date 2020-07-14
First Publication Date 2022-08-18
Grant Date 2022-12-06
Owner Carbon, Inc. (USA)
Inventor Mcfarlane, Iain A.

Abstract

The present disclosure describes a resin cassette for an additive manufacturing apparatus. The resin cassette includes a light-transmissive window, a frame connected to and surrounding the window, and at least one dame connected to the frame. The frame and window form a well for receiving a light polymerizable resin. The dam extends over and continuously contacts the window and partitions the well into a plurality of independent build regions, each independent build region configured for receiving different light polymerizable resins. Additive manufacturing apparatuses and methods of concurrently making three-dimensional objects are also described.

IPC Classes  ?

  • B29C 64/259 - Enclosures for the building material, e.g. powder containers interchangeable
  • B29C 64/124 - 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
  • B29C 64/171 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects
  • B29C 64/245 - Platforms or substrates
  • B29C 64/227 - Driving means
  • A61C 13/00 - Dental prostheses; Making same
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 80/00 - Products made by additive manufacturing
  • B29L 31/00 - Other particular articles

64.

Three-dimensional printing with reciprocal feeding of polymerizable liquid

      
Application Number 17730589
Grant Number 11772324
Status In Force
Filing Date 2022-04-27
First Publication Date 2022-08-11
Grant Date 2023-10-03
Owner Carbon, Inc. (USA)
Inventor
  • Ermoshkin, Alexander
  • Shirvanyants, David
  • Phelps, Nordstrom Kirk
  • Ermoshkin, Nikita
  • Samulski, Edward T.
  • Desimone, Joseph M.

Abstract

Described herein are methods, systems and apparatus (including associated control methods, systems and apparatus), for the production of a three-dimensional object by “bottom up” additive manufacturing, in which a carrier is vertically reciprocated with respect to a build surface, to enhance or speed the refilling of the build region with a solidifiable liquid. In preferred (but not necessarily limiting) embodiments, the three-dimensional object is produced from a liquid interface by continuous liquid interface production (i.e., “CLIP”).

IPC Classes  ?

  • B29C 64/124 - 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B29C 64/264 - Arrangements for irradiation
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29K 105/00 - Condition, form or state of moulded material

65.

Systems and methods for resin recovery in additive manufacturing

      
Application Number 17569641
Grant Number 11731345
Status In Force
Filing Date 2022-01-06
First Publication Date 2022-08-11
Grant Date 2023-08-22
Owner Carbon, Inc. (USA)
Inventor
  • Converse, Courtney F.
  • Light, Allison
  • Powell, W. Ryan
  • Wojtaszek, Mateusz Marek

Abstract

A method of producing multiple batches of objects by stereolithography, includes the steps of: (a) dispensing an initial or subsequent batch of dual cure resin into a stereolithography apparatus, the resin including a light polymerizable component and a heat polymerizable component; (b) producing an intermediate object by light polymerization of the resin in the apparatus, wherein the intermediate object retains excess resin on a surface thereof; then (c) separating excess resin from the intermediate object; (d) blending the excess resin with additional dual cure resin to produce a subsequent batch of dual cure resin; (e) repeating steps (a) through (c), and optionally repeating step (d), to produce additional object(s); and (f) baking the objects, together or separately, to produce multiple batches of objects.

IPC Classes  ?

  • B29C 64/124 - 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
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/176 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects sequentially
  • B29C 64/357 - Recycling
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

66.

Vapor spin cleaning of additively manufactured parts

      
Application Number 17719827
Grant Number 11491725
Status In Force
Filing Date 2022-04-13
First Publication Date 2022-07-28
Grant Date 2022-11-08
Owner Carbon, Inc. (USA)
Inventor
  • Feller, Bob E.
  • Powell, W. Ryan
  • Kaufman, Mark O.

Abstract

A method of cleaning residual resin from an additively manufactured object, includes: (a) enclosing an additively manufactured object in an inner chamber of a centrifugal separator, the additively manufactured object including a light polymerized resin with a surface coating of viscous, unpolymerized, residual resin; (b) flooding the chamber with a volatile organic solvent vapor without contacting liquid organic solvent to the object, the vapor present in an amount sufficient to reduce the viscosity of the residual resin; and (c) spinning the additively manufactured object in the chamber to centrifugally separate at least a first portion of the residual resin from the object.

IPC Classes  ?

  • B08B 7/04 - Cleaning by methods not provided for in a single other subclass or a single group in this subclass by a combination of operations
  • B29C 64/35 - Cleaning
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B08B 3/08 - Cleaning involving contact with liquid the liquid having chemical or dissolving effect
  • B08B 5/00 - Cleaning by methods involving the use of air flow or gas flow
  • B08B 7/02 - Cleaning by methods not provided for in a single other subclass or a single group in this subclass by distortion, beating, or vibration of the surface to be cleaned

67.

Dual precursor resin systems for additive manufacturing with dual cure resins

      
Application Number 17655227
Grant Number 11833744
Status In Force
Filing Date 2022-03-17
First Publication Date 2022-06-30
Grant Date 2023-12-05
Owner Carbon, Inc. (USA)
Inventor
  • Rolland, Jason P.
  • Cushen, Julia D.

Abstract

A method of forming a dual cure three-dimensional object by additive manufacturing may be carried out by mixing a first precursor liquid and a second precursor liquid to produce a polymerizable liquid comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component (e.g., a second reactive component) that is different from the first component (e.g., that does not contain a cationic photoinitiator, or is further solidified by a different physical mechanism, or further reacted, polymerized or chain extended by a different chemical reaction). In the foregoing: (i′) at least one reactant of the second solidifiable component is contained in the first precursor liquid, and (ii′) at least one reactant or catalyst of the second solidifiable component is contained in the second precursor liquid. Once mixed, the three-dimensional object may be formed from the resin by a dual cure additive manufacturing process.

IPC Classes  ?

  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B29C 64/124 - 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
  • B29C 64/135 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • G03F 7/00 - Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printed surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
  • G03F 7/16 - Coating processes; Apparatus therefor
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • C08L 63/00 - Compositions of epoxy resins; Compositions of derivatives of epoxy resins
  • B33Y 10/00 - Processes of additive manufacturing

68.

MOISTURE CONTROLLING LATTICE LINERS FOR HELMETS AND OTHER WEARABLE ARTICLES

      
Application Number 17692354
Status Pending
Filing Date 2022-03-11
First Publication Date 2022-06-23
Owner Carbon, Inc. (USA)
Inventor
  • Light, Allison
  • Day, Ananda
  • Jameel, Mohamed Imran
  • Powell, W. Ryan

Abstract

A helmet liner includes: (a) an open lattice body portion comprised of a polymer, the body portion having opposite face portions and a circumferential side portion; (b) a helmet contact surface portion formed on one of the face portions; and (c) a skin contact portion formed on the other of the face portions, the skin contact portion configured with the lattice body portion so air can circulate through both the body portion and the skin contact portion.

IPC Classes  ?

  • A42B 3/12 - Cushioning devices
  • A42B 3/06 - Impact-absorbing shells, e.g. of crash helmets

69.

Resin extractor for additive manufacturing

      
Application Number 17683784
Grant Number 11897198
Status In Force
Filing Date 2022-03-01
First Publication Date 2022-06-16
Grant Date 2024-02-13
Owner Carbon, Inc. (USA)
Inventor
  • Murillo, Michael
  • Dachs, Ii, Gregory W.
  • Feller, Bob E.

Abstract

A method of separating excess resin from at least one object, includes: (a) stereolithographically producing at least one object on at least one carrier platform, each carrier platform having a planar build surface to which at least one object is connected, each object carrying excess resin on a surface thereof; then (b) mounting each carrier platform to a rotor; (c) centrifugally separating excess resin from each object by spinning the rotor with each carrier platform connected thereto while each object remains connected to each carrier platform; and then (d) removing each carrier platform from the rotor with each object thereon, with excess resin separated therefrom.

IPC Classes  ?

  • B29C 64/35 - Cleaning
  • B29C 64/124 - 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
  • B29C 64/245 - Platforms or substrates
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing

70.

FORCE-REGULATED ADDITIVE MANUFACTURING

      
Application Number US2021062783
Publication Number 2022/125881
Status In Force
Filing Date 2021-12-10
Publication Date 2022-06-16
Owner CARBON, INC. (USA)
Inventor
  • Truong, Ronald
  • Yang, Daniel Jiaji

Abstract

A method of forming a three-dimensional object (31) includes the steps of: (a) providing an apparatus including a carrier (15), a light transmissive window (12) having a build surface, polymerizable liquid (21) on the build surface, and a growing object (31) on the carrier, the growing object produced by light polymerization of the polymerizable liquid; (b) vertically reciprocating the carrier (15) with respect to the build surface in an upstroke and a downstroke, the downstroke being shorter than the upstroke, to form a build region between the growing object and the build surface, and to fill the build region with the polymerizable liquid, while also: (i) sensing force exerted between the carrier and the build surface through the growing object (31) and the polymerizable liquid (21) during the upstroke; and (ii) modifying the speed, acceleration, or both speed and acceleration of the upstroke in response to the sensed force so that the sensed force approaches a predetermined target force; then (c) irradiating the build region with light through the light transmissive window to form a new portion of the object from the polymerizable liquid on the growing object; and then (d) repeating steps (b) through (c) to form additional portions on the growing object until the three-dimensional object is formed.

IPC Classes  ?

  • B29C 64/124 - 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
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/245 - Platforms or substrates
  • B29C 64/321 - Feeding
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

71.

PARTIAL DENTURES AND METHODS OF MAKING THE SAME

      
Application Number 17651336
Status Pending
Filing Date 2022-02-16
First Publication Date 2022-06-02
Owner CARBON, INC. (USA)
Inventor Herring, Marie K.

Abstract

Provided herein is a method of making a flexible partial denture, which may include: (a) producing a partial denture base by additive manufacturing (e.g., bottom-up or top-down stereolithography) from a dual cure resin, with the dual cure resin comprising a light polymerizable component and a heat polymerizable component, with the denture base including at least one tooth socket; (b) inserting an acrylic artificial tooth into each at least one tooth socket to produce an assembled intermediate product; and then (c) baking said assembled intermediate product for a time sufficient to cure said heat polymerizable component in said denture base and retained dual cure resin, bond said tooth into each at least one socket with said retained dual cure resin, and produce said flexible partial denture. A flexible partial denture produced and resin formulations useful for the same are also provided.

IPC Classes  ?

  • A61C 13/00 - Dental prostheses; Making same
  • A61C 13/01 - Bases
  • A61C 13/10 - Fastening of artificial teeth to artificial base material, e.g. to palates or to adjacent artificial tooth
  • A61K 6/891 - Compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • A61K 6/62 - Photochemical radical initiators
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • B29C 64/30 - Auxiliary operations or equipment
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing

72.

BIORESORBABLE 3D PRINTED ADHESION BARRIERS

      
Application Number 17518990
Status Pending
Filing Date 2021-11-04
First Publication Date 2022-05-12
Owner Carbon, Inc. (USA)
Inventor
  • Kabaria, Hardik
  • Meyer, Eleanor R.
  • Pollack, Steven Kenneth

Abstract

An adhesion barrier is comprised of, consists of, or consists essentially of a sheet having a top surface and a bottom surface. The sheet includes either (i) interconnected links or (ii) interconnected, vertically aligned, partitions. The links form pores or the partitions form pores, with the pores extending from the top surface through the bottom surface. The sheet is comprised of, consists of, or consists essentially of a flexible or elastic polymer.

IPC Classes  ?

  • A61B 90/00 - Instruments, implements or accessories specially adapted for surgery or diagnosis and not covered by any of the groups , e.g. for luxation treatment or for protecting wound edges
  • A61L 31/12 - Composite materials, i.e. layered or containing one material dispersed in a matrix of the same or different material
  • A61L 31/14 - Materials characterised by their function or physical properties

73.

Low viscosity dual cure additive manufacturing resins

      
Application Number 17606157
Grant Number 11518089
Status In Force
Filing Date 2020-04-21
First Publication Date 2022-05-12
Grant Date 2022-12-06
Owner Carbon, Inc. (USA)
Inventor
  • Wright, Andrew Gordon
  • Chen, Kai
  • Feller, Bob E.

Abstract

Provided herein according to some embodiments is a dual cure additive manufacturing resin, comprising: (i) a light polymerizable component, (ii) a photoinitiator, (iii) a heat polymerizable component, and (iv) a non-reactive diluent, which resin is useful for the production of three-dimensional objects by additive manufacturing. Methods of using the same are also provided.

IPC Classes  ?

  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • H05B 6/00 - Heating by electric, magnetic or electromagnetic fields
  • H05B 7/00 - Heating by electric discharge
  • B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
  • C08F 2/46 - Polymerisation initiated by wave energy or particle radiation
  • C08F 2/50 - Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light with sensitising agents
  • C08G 61/04 - Macromolecular compounds containing only carbon atoms in the main chain of the macromolecule, e.g. polyxylylenes only aliphatic carbon atoms
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • C08F 222/10 - Esters
  • C08F 2/48 - Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light
  • C08F 220/34 - Esters containing nitrogen
  • C08G 18/48 - Polyethers
  • C08G 18/67 - Unsaturated compounds having active hydrogen
  • C08G 18/75 - Polyisocyanates or polyisothiocyanates cyclic cycloaliphatic
  • C08G 65/08 - Saturated oxiranes
  • C08J 3/24 - Crosslinking, e.g. vulcanising, of macromolecules
  • C08J 3/28 - Treatment by wave energy or particle radiation
  • C08K 3/22 - Oxides; Hydroxides of metals
  • C08K 5/06 - Ethers; Acetals; Ketals; Ortho-esters
  • C08K 5/10 - Esters; Ether-esters
  • C08K 5/17 - Amines; Quaternary ammonium compounds
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing

74.

MASS CUSTOMIZATION IN ADDITIVE MANUFACTURING

      
Application Number 17439592
Status Pending
Filing Date 2020-04-20
First Publication Date 2022-05-12
Owner Carbon, Inc. (USA)
Inventor
  • Kabaria, Hardik
  • Kurtz, Aidan

Abstract

A method for the production of an object by additive manufacturing includes inputting a boundary shape and desired mechanical properties for said object, subdividing said boundary shape into work cells, providing lattices in a database, each lattice including a geometry and a mechanical property, filling a first one of said work cells with a lattice from the database, the lattice selected based on the correspondence of the mechanical properties of said lattice to said desired mechanical properties of said object, filling the remaining ones of said work cells with lattices from said database to produce a filled boundary shape, each said lattice selected based on the correspondence of the mechanical properties of said lattice to the desired mechanical properties of the object and the compatibility of adjacent lattices in adjacent work cells with one another, then performing a modification operation on the lattice of a work cell.

IPC Classes  ?

  • B29C 64/386 - Data acquisition or data processing for additive manufacturing
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing

75.

Dual cure resin for the production of moisture-resistant articles by additive manufacturing

      
Application Number 17441921
Grant Number 11555095
Status In Force
Filing Date 2020-03-16
First Publication Date 2022-05-12
Grant Date 2023-01-17
Owner Carbon, Inc. (USA)
Inventor
  • Grover, Ikpreet S.
  • Menyo, Matthew S.

Abstract

Provided herein is a dual cure resin useful for the production of objects by stereolithography, said resin comprising a mixture of: (a) a light-polymerizable component; and (b) a heat-polymerizable component, said heat-polymerizable component comprising: (i) a dicyclopentadiene-containing polyepoxide resin; (ii) a cyanate ester resin; (iii) an epoxy-reactive toughening agent; and (iv) a core shell rubber toughener.

IPC Classes  ?

  • C08L 63/00 - Compositions of epoxy resins; Compositions of derivatives of epoxy resins
  • C08J 3/24 - Crosslinking, e.g. vulcanising, of macromolecules
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B29C 64/124 - 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
  • B29C 64/35 - Cleaning
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • C08F 283/10 - Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass on to polymers containing more than one epoxy radical per molecule
  • C08G 59/24 - Di-epoxy compounds carbocyclic
  • C08F 285/00 - Macromolecular compounds obtained by polymerising monomers on to preformed graft polymers
  • B29K 63/00 - Use of epoxy resins as moulding material

76.

PRODUCTION OF LOW DENSITY PRODUCTS BY ADDITIVE MANUFACTURING

      
Application Number 17645538
Status Pending
Filing Date 2021-12-22
First Publication Date 2022-04-21
Owner Carbon, Inc. (USA)
Inventor
  • Poelma, Justin
  • Rolland, Jason P.

Abstract

Provided herein according to some embodiments is polymerizable liquid useful for the production of a three-dimensional object by additive manufacturing, said polymerizable liquid comprising a mixture of: (a) at least one photopolymerizable component; (b) a photoinitiator; (c) at least one heat polymerizable component; and (d) heat expandable microspheres. A method of making a three-dimensional object from such a polymerizable liquid by additive manufacturing and objects so produced are also provided.

IPC Classes  ?

  • B29C 64/124 - 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
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control

77.

Dual cure resins for additive manufacturing

      
Application Number 17645540
Grant Number 11820072
Status In Force
Filing Date 2021-12-22
First Publication Date 2022-04-21
Grant Date 2023-11-21
Owner Carbon, Inc. (USA)
Inventor
  • Pinschmidt, Jr., Robert K
  • Wright, Andrew Gordon
  • Rolland, Jason P.

Abstract

Provided herein is a resin product useful for the production of three-dimensional objects by additive manufacturing, and methods using the same. The resin may include a reactive blocked prepolymer comprising a prepolymer blocked with reactive blocking groups; a polyol; a photoinitiator; and at least one organometallic catalyst. A packaged product useful for the production of three-dimensional objects by additive manufacturing, the product comprising a single container having a single chamber and a resin in the chamber with all components mixed together, is also provided.

IPC Classes  ?

  • B29C 35/04 - Heating or curing, e.g. crosslinking or vulcanising using liquids, gas or steam
  • C08F 2/46 - Polymerisation initiated by wave energy or particle radiation
  • C08F 2/50 - Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light with sensitising agents
  • C08G 61/04 - Macromolecular compounds containing only carbon atoms in the main chain of the macromolecule, e.g. polyxylylenes only aliphatic carbon atoms
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B01J 31/12 - Catalysts comprising hydrides, coordination complexes or organic compounds containing organic compounds or metal hydrides containing organo-metallic compounds or metal hydrides
  • C08F 2/44 - Polymerisation in the presence of compounding ingredients, e.g. plasticisers, dyestuffs, fillers
  • C08F 4/50 - Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths, or actinides selected from alkaline earth metals, zinc, cadmium, mercury, copper, or silver
  • C08G 18/08 - Processes
  • C08G 18/10 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
  • C08G 18/22 - Catalysts containing metal compounds

78.

VAPOR SPIN CLEANING OF ADDITIVELY MANUFACTURED PARTS

      
Application Number US2021052804
Publication Number 2022/076235
Status In Force
Filing Date 2021-09-30
Publication Date 2022-04-14
Owner CARBON, INC. (USA)
Inventor
  • Feller, Bob, E.
  • Powell, W., Ryan
  • Kaufman, Mark, O.

Abstract

A method of cleaning residual resin from an additively manufactured object, includes: (a) enclosing an additively manufactured object in an inner chamber of a centrifugal separator, the additively manufactured object including a light polymerized resin with a surface coating of viscous, unpolymerized, residual resin; (b) flooding the chamber with a volatile organic solvent vapor without contacting liquid organic solvent to the object, the vapor present in an amount sufficient to reduce the viscosity of the residual resin; and (c) spinning the additively manufactured object in the chamber to centrifugally separate at least a first portion of the residual resin from the object.

IPC Classes  ?

  • B29C 64/35 - Cleaning
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B29C 71/00 - After-treatment of articles without altering their shape; Apparatus therefor

79.

Resin viscosity detection in additive manufacturing

      
Application Number 17553083
Grant Number 11597158
Status In Force
Filing Date 2021-12-16
First Publication Date 2022-04-07
Grant Date 2023-03-07
Owner Carbon, Inc. (USA)
Inventor
  • Deetz, Joshua D.
  • Wood, Catherine E.
  • Truong, Ronald A.

Abstract

A method of measuring the viscosity of a resin in a bottom-up additive manufacturing apparatus, includes the steps of: (a) providing an additive manufacturing apparatus including a build platform and a light transmissive window, said build platform and said window defining a build region there between, with said window carrying a resin; (b) advancing said build platform and said window towards one another until said build platform contacts said resin; (c) detecting the force exerted on said build platform by said resin; and (d) generating in a processor a viscosity measure of said resin from said detected force.

IPC Classes  ?

  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • G01N 11/10 - Investigating flow properties of materials, e.g. viscosity or plasticity; Analysing materials by determining flow properties by moving a body within the material
  • G01L 5/00 - Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/245 - Platforms or substrates
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B29C 64/124 - 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
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • G01N 11/00 - Investigating flow properties of materials, e.g. viscosity or plasticity; Analysing materials by determining flow properties

80.

PRODUCTION OF CUSTOM GARMENTS BY ADDITIVE MANUFACTURING

      
Application Number 17483028
Status Pending
Filing Date 2021-09-23
First Publication Date 2022-03-31
Owner Carbon, Inc. (USA)
Inventor
  • Salemeh, Sarah
  • Alexandraki, Eleni
  • Fortner, Shawn

Abstract

A method of making a support garment, comprising: (a) receiving, into a computing system, a 3D image of a human body portion; (b) generating in said computing system an initial virtual 3D model of a support garment in a configuration corresponding to said 3D image, said garment having an outer surface, an inner (body facing) surface, and a thickness dimension therebetween, (c) generating from said initial virtual 3D model a flattening virtual 3D model of said support garment in said computing system, the flattened virtual model in a configuration for additive manufacturing thereof with either said outer surface or said inner surface adhered to a generally planar build platform; and (d) identifying a first zone of either said initial or said flattened virtual 3D model; (e) modifying (before or after step (c), preferably after step (c)) said first zone of said virtual 3D model to comprise a perforated sheet.

IPC Classes  ?

  • A41C 5/00 - Machines, appliances, or methods for manufacturing corsets or brassières
  • A41C 3/00 - Brassières
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing

81.

ADDITIVE MANUFACTURING METHOD INCLUDING THERMAL MODELING AND CONTROL

      
Application Number 17450575
Status Pending
Filing Date 2021-10-12
First Publication Date 2022-03-31
Owner Carbon, Inc. (USA)
Inventor
  • Laaker, Kyle
  • Feller, Bob E.
  • Panzer, Matthew

Abstract

Various embodiments described herein provide a method of making an object from a three-dimensional geometry file and a light polymerizable resin on a light-transmissive window by projection of light through the window in a bottom-up stereolithography process. The method may comprise: slicing the file into a series of sequential images. Temperature fluctuations in the resin may be calculated for at least some of the sequential images upon light polymerization thereof based on sequential exposure of the resin to light, the light corresponding to the series of sequential images. During producing of the object, the production may be modified based on the calculated temperature fluctuations by: (i) reducing production speed during at least a portion of the production; (ii) activating a window cooler during at least a portion of the production; or (iii) increasing production speed during at least a portion of the production.

IPC Classes  ?

  • G06F 30/10 - Geometric CAD
  • B29C 64/124 - 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
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

82.

EPOXY DUAL CURE RESIN FOR THE PRODUCTION OF MOISTURE-RESISTANT ARTICLES BY ADDITIVE MANUFACTURING

      
Application Number US2021051061
Publication Number 2022/066565
Status In Force
Filing Date 2021-09-20
Publication Date 2022-03-31
Owner CARBON, INC. (USA)
Inventor
  • Grover, Ikpreet Singh
  • Donovan, Brian R.
  • Menyo, Matthew S.

Abstract

(i) (ii) (iii)(i) (ii) (iii) (iv) (iv) optionally, an epoxy-reactive toughening agent.

IPC Classes  ?

  • C08G 59/42 - Polycarboxylic acids; Anhydrides, halides, or low-molecular-weight esters thereof
  • C08G 59/32 - Epoxy compounds containing three or more epoxy groups
  • B33Y 10/00 - Processes of additive manufacturing

83.

Additive manufacturing method and apparatus for the production of dental crowns and other objects

      
Application Number 17594007
Grant Number 11376787
Status In Force
Filing Date 2020-04-23
First Publication Date 2022-03-24
Grant Date 2022-07-05
Owner Carbon, Inc. (USA)
Inventor
  • Rademacher, Soren
  • Shirvanyants, David
  • Land, Stephen Paul
  • Bibb, Iii, Henry Quarles
  • Ermoshkin, Alexander

Abstract

The present disclosure describes an additive manufacturing apparatus. The apparatus includes a chamber (11) having a planar circumferential top edge portion (12) defining a chamber orifice (13); a stage (15) movably positioned in the chamber (11), the two together configured to receive a viscous resin; a dispenser (30) facing the stage (15) and operatively associated therewith, the dispenser (30) configured to apply a planar coating of viscous resin; a primary drive (22) operatively associated with the dispenser (30) and chamber (11), the primary drive (22) configured to move the dispenser (30) across the chamber orifice (13); a light engine (40) facing the stage (15) and operatively associated therewith, the light engine (40) configured to expose a coating of resin on the stage (15) planar top surface (12) to patterned light; and a stage drive (24) operatively associated with the stage (15) and configured to retract the stage (15) into the chamber (11), following exposure of a coating of resin. Methods of making a three-dimensional object by additive manufacturing are also described.

IPC Classes  ?

  • B29C 64/218 - Rollers
  • B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
  • B29C 64/245 - Platforms or substrates
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/255 - Enclosures for the building material, e.g. powder containers
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 80/00 - Products made by additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29L 31/00 - Other particular articles

84.

Bonded surface coating methods for additively manufactured products

      
Application Number 17455495
Grant Number 11813795
Status In Force
Filing Date 2021-11-18
First Publication Date 2022-03-10
Grant Date 2023-11-14
Owner Carbon, Inc. (USA)
Inventor
  • Rolland, Jason P.
  • Menyo, Matthew S.
  • Desimone, Joseph M.

Abstract

Provided is a method of making a cured object having a surface coating bonded thereto, which may include: providing an intermediate object produced in an additive manufacturing process such as stereolithography by light polymerization of a dual cure resin, the resin comprising a mixture of (i) a light polymerizable first component, and (ii) a second component that is different from the first component; applying a first reactive coating composition to a surface portion of the object to form a first coating thereon; optionally, but in some embodiments preferably, applying a second reactive coating composition to the first coating to form a second coating thereon; and heating the object at (and for) a time and to a temperature sufficient to bond the first coating to the surface portion, and bond the second coating when present to the first coating, and form the cured object having a surface coating bonded thereto.

IPC Classes  ?

  • B29C 64/30 - Auxiliary operations or equipment
  • B29C 64/307 - Handling of material to be used in additive manufacturing
  • B29C 64/124 - 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
  • B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C 71/02 - Thermal after-treatment
  • B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B33Y 10/00 - Processes of additive manufacturing

85.

Apparatuses for additively manufacturing three-dimensional objects

      
Application Number 17519652
Grant Number 11654625
Status In Force
Filing Date 2021-11-05
First Publication Date 2022-02-24
Grant Date 2023-05-23
Owner Carbon, Inc. (USA)
Inventor
  • Rademacher, Soren
  • Shirvanyants, David
  • Ermoshkin, Alexander
  • Faust, Derek Alan

Abstract

The present disclosure describes an apparatus for additively manufacturing a three-dimensional object. The apparatus includes a radiation source, a carrier on which the three-dimensional object is made, an applicator assembly configured to apply a polymerizable liquid, and a frame, with the applicator assembly and the radiation source connected to the frame. A first drive assembly interconnects the applicator assembly and the frame and a second drive assembly interconnects the carrier and the frame. The frame defines a build region between the applicator assembly and the carrier. The applicator assembly includes a polymerizable liquid supply chamber, an application roller, and a metering roller. The applicator assembly may optionally include a post-metering roller. An apparatus comprising a first and a second applicator assembly and a smaller scale version of the apparatus are also described.

IPC Classes  ?

  • B29C 64/218 - Rollers
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 64/214 - Doctor blades
  • B29C 64/321 - Feeding
  • B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
  • B29C 64/343 - Metering
  • B29C 64/35 - Cleaning

86.

Systems and apparatuses for additive manufacturing with process update and lock down

      
Application Number 17421199
Grant Number 11982991
Status In Force
Filing Date 2019-12-13
First Publication Date 2022-02-24
Grant Date 2024-05-14
Owner Carbon, Inc. (USA)
Inventor
  • Tumbleston, John R.
  • Laaker, Kyle
  • Truong, Ronald A.
  • Goldman, Roy
  • Parmar, Abhishek

Abstract

An additive manufacturing system may include an additive manufacturing apparatus on which a process of producing a three-dimensional object from a material can be performed; an additive manufacturing process controller operatively associated with the additive manufacturing apparatus; and a first memory device operatively associated with the additive manufacturing process controller. The first memory device may include first and second stable release process programs each comprising a first subset of operations executable by said process controller. The system may include a second memory device comprising another stable release process program comprising a second subset of operations executable by said process controller. The system may include a selector configured to choose one of the stable release process programs to run on said process controller when producing a three-dimensional object on the additive manufacturing apparatus.

IPC Classes  ?

  • G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

87.

Build plate assemblies for continuous liquid interphase printing having lighting panels and related methods, systems and devices

      
Application Number 17491966
Grant Number 11993015
Status In Force
Filing Date 2021-10-01
First Publication Date 2022-01-20
Grant Date 2024-05-28
Owner CARBON, INC. (USA)
Inventor
  • Feller, Bob E.
  • Hermann, Ariel M.
  • Tumbleston, John R.
  • Moore, David
  • Dachs, Ii, Gregory W.

Abstract

A build plate assembly for a three-dimensional printer includes: a lighting panel having individually addressable pixels configured to selectively emit light and/or transmit light from illumination below the pixels to a top surface top surface of the lighting panel; a rigid, optically transparent, gas-impermeable planar screen or base having an upper surface having an uneven surface topology and a lower surface that is affixed to the top surface of the lighting panel; and a flexible, optically transparent, gas-permeable sheet having upper and lower surfaces, the upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface positioned opposite the base, wherein the build plate is configured to permit gas flow to the build surface.

IPC Classes  ?

  • B29C 64/245 - Platforms or substrates
  • B29C 64/124 - 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
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B29C 64/135 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

88.

Serially curable resins useful in additive manufacturing

      
Application Number 17464964
Grant Number 11654620
Status In Force
Filing Date 2021-09-02
First Publication Date 2021-12-23
Grant Date 2023-05-23
Owner Carbon, Inc. (USA)
Inventor
  • Herring, Marie K.
  • Menyo, Matthew S.

Abstract

Provided is a method of forming a three-dimensional object, which may include the steps of: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid that comprises a reactive blocked monomer and/or prepolymer comprising a self-polymerizing monomer and/or prepolymer blocked with a light-polymerizable blocking group; (c) irradiating the build region with light through said optically transparent member to form a solid polymer scaffold from the reactive blocked monomer and/or prepolymer and also advancing the carrier away from the build surface to form a three-dimensional intermediate; and then (d) heating and/or microwave irradiating, the three-dimensional intermediate sufficiently to degrade the scaffold and regenerate the monomer and/or prepolymer in de-blocked form, which monomer and/or prepolymer in turn self-polymerize, to form said three-dimensional object.

IPC Classes  ?

  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
  • B29C 64/295 - Heating elements
  • B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
  • B29K 105/00 - Condition, form or state of moulded material
  • B29K 105/16 - Fillers
  • B29K 75/00 - Use of polyureas or polyurethanes as moulding material

89.

REVERSIBLE THERMOSETS FOR ADDITIVE MANUFACTURING

      
Application Number 17465248
Status Pending
Filing Date 2021-09-02
First Publication Date 2021-12-23
Owner Carbon, Inc. (USA)
Inventor
  • Poelma, Justin
  • Rolland, Jason P.
  • Curvers, Rick Hubertus Nicolas
  • Desimone, Joseph M.

Abstract

Provided herein is a method of recycling additively manufactured articles or recovered coating material that comprises a crosslinked polymer formed from a single-cure resin comprising a reactive blocked prepolymer, into a regenerated resin useful for additive manufacturing. Recyclable light-polymerizable resins, methods of making recyclable objects from such resins, and methods for sustainable manufacturing are also provided.

IPC Classes  ?

  • B29B 17/04 - Disintegrating plastics
  • B29B 17/00 - Recovery of plastics or other constituents of waste material containing plastics

90.

Window thermal profile calibration in additive manufacturing

      
Application Number 17298149
Grant Number 11498274
Status In Force
Filing Date 2019-11-22
First Publication Date 2021-12-16
Grant Date 2022-11-15
Owner Carbon, Inc. (USA)
Inventor
  • Mohsenizadeh, Daniel N.
  • Laaker, Kyle
  • Truong, Ronald A.

Abstract

a) having a build surface on which an object can be produced, and with said optically transparent member having at least one thermal profile associated therewith; and then (b) modifying said at least one adjustable parameter by said controller based on said at least one thermal profile of said optically transparent member; and then (c) producing the object on said build surface from a light-polymerizable liquid by bottom-up stereolithography.

IPC Classes  ?

  • B29C 64/245 - Platforms or substrates
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
  • B29C 64/124 - 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
  • B29C 64/295 - Heating elements
  • B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

91.

Apparatus and methods for controlled validation of additive manufacturing systems

      
Application Number 17315899
Grant Number 11548219
Status In Force
Filing Date 2021-05-10
First Publication Date 2021-11-18
Grant Date 2023-01-10
Owner Carbon, Inc. (USA)
Inventor
  • Truong, Ronald A.
  • Tumbleston, John R.
  • Laaker, Kyle
  • Feller, Bob E.
  • Deetz, Joshua D.

Abstract

A method of improving production performance of an additive manufacturing system includes obtaining a first production plan and a second production plan, different from the first production plan, for the manufacture of a plurality of objects using a fleet of additive manufacturing apparatus, automatically generating a first allocation of a first quantity of the plurality of objects to the fleet of additive manufacturing apparatus using the first production plan, automatically generating a second allocation of a second quantity of the plurality of objects to the fleet of additive manufacturing apparatus using the second production plan, comparing a production performance of the first and second quantity of the plurality of objects after being manufactured by the fleet of additive manufacturing apparatus, and based on the comparison of the production performance, automatically regenerating the first and second allocations to change the first and second quantities.

IPC Classes  ?

  • B29C 64/176 - Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects sequentially
  • B29C 64/124 - 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
  • B33Y 50/00 - Data acquisition or data processing for additive manufacturing
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B29C 64/386 - Data acquisition or data processing for additive manufacturing

92.

SHOCK ABSORBING LATTICE STRUCTURE PRODUCED BY ADDITIVE MANUFACTURING

      
Application Number 17283116
Status Pending
Filing Date 2019-10-17
First Publication Date 2021-11-04
Owner Carbon, Inc. (USA)
Inventor
  • Kabaria, Hardik
  • Kurtz, Aidan

Abstract

An energy absorbing lattice structure having a predetermined energy absorbing load vector, may include, in combination, a first lattice substructure comprised of a first set of interconnected struts, and, interwoven with said first lattice substructure, a second lattice substructure comprised of a second set of interconnected struts.

IPC Classes  ?

  • F16F 7/12 - Vibration-dampers; Shock-absorbers using plastic deformation of members
  • B33Y 80/00 - Products made by additive manufacturing

93.

FILM APPLICATOR APPARATUS FOR ADDITIVE MANUFACTURING BUILD PLATFORMS AND RELATED SYSTEMS

      
Application Number US2021026347
Publication Number 2021/221877
Status In Force
Filing Date 2021-04-08
Publication Date 2021-11-04
Owner CARBON, INC. (USA)
Inventor
  • Light, Allison
  • Lau, Daniel T.
  • Rosenberg, David Thomas
  • Powell, William Ryan

Abstract

The present disclosure is directed to an applicator apparatus (20) for applying a release film (31) to a planar build surface of an additive manufacturing build platform (30). The applicator apparatus includes a chassis having a top plate (21), at least one build platform alignment member (25) on the top plate configured for positioning the build platform on the top plate with the planar build surface thereof facing upward, a roller carrier (22) connected to the chassis and configured with the top plate to pass over the planar build surface, and a roller (23) connected to the roller carrier and configured to press against a release film positioned on the planar build surface of the build platform. A system for applying and removing a release film to and from a planar build surface of an additive manufacturing build platform is also described herein.

IPC Classes  ?

  • B29C 64/218 - Rollers
  • B29C 37/00 - Component parts, details, accessories or auxiliary operations, not covered by group or
  • B29C 64/223 - Foils or films, e.g. for transferring layers of building material from one working station to another
  • B29C 64/245 - Platforms or substrates
  • B29C 64/314 - Preparation
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
  • B29C 63/02 - Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
  • B32B 37/00 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B 37/18 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
  • B32B 38/18 - Handling of layers or the laminate

94.

FILM REMOVER APPARATUS FOR ADDITIVE MANUFACTURING BUILD PLATFORMS AND RELATED METHODS

      
Application Number US2021027008
Publication Number 2021/221900
Status In Force
Filing Date 2021-04-13
Publication Date 2021-11-04
Owner CARBON, INC. (USA)
Inventor
  • Lau, Daniel T.
  • Rosenberg, David Thomas
  • Light, Allison
  • Powell, William Ryan

Abstract

The present disclosure is directed to an apparatus (120) for removing a release film (31) or additively manufactured object (201) adhered to a planar build surface of an additive manufacturing build platform (30). The apparatus includes a chassis having a top plate (121), at least one build platform alignment member on the top plate configured for positioning the build platform on the top plate with the planar build surface thereof facing upward, a blade carrier (122) connected to the chassis and configured with the top plate to pass over the planar build surface of the build platform, and a blade (128) connected to the blade carrier (122) and configured, when a build platform is positioned on said top plate, to press against the planar build surface and scrape the release film or additively manufactured object adhered to the planar build surface off that surface. Methods of manufacturing at least one object on a planar build surface of an additive manufacturing build platform are also described herein.

IPC Classes  ?

  • B29C 64/236 - Driving means for motion in a direction within the plane of a layer
  • B29C 37/00 - Component parts, details, accessories or auxiliary operations, not covered by group or
  • B29C 64/245 - Platforms or substrates
  • B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
  • B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling

95.

METHODS OF MAKING A THREE-DIMENSIONAL OBJECT

      
Application Number US2021029122
Publication Number 2021/222086
Status In Force
Filing Date 2021-04-26
Publication Date 2021-11-04
Owner CARBON, INC. (USA)
Inventor Poelma, Justin

Abstract

(a)(i)(ii)(iii)(iv)(iv) a photoinitiator; (b) producing a three-dimensional intermediate from said polymerizable liquid by stereolithography (11); (c) optionally cleaning (12) said intermediate; and (d) heating (13) a surface of said three-dimensional intermediate to activate the inhibited ROMP catalyst, polymerize the cyclic olefin monomer and/or prepolymer by frontal ring-opening metathesis polymerization and form said three- dimensional object. Resins, build platforms (20) and apparatus useful for performing the method are also provided.

IPC Classes  ?

  • B29C 64/124 - 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
  • B29C 64/245 - Platforms or substrates
  • B29C 64/295 - Heating elements
  • B29C 64/30 - Auxiliary operations or equipment
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B33Y 70/00 - Materials specially adapted for additive manufacturing
  • C08G 61/08 - Macromolecular compounds containing only carbon atoms in the main chain of the macromolecule, e.g. polyxylylenes only aliphatic carbon atoms prepared by ring-opening of carbocyclic compounds of carbocyclic compounds containing one or more carbon-to-carbon double bonds in the ring

96.

Delayed action catalysts for dual cure additive manufacturing resins

      
Application Number 17234019
Grant Number 11655329
Status In Force
Filing Date 2021-04-19
First Publication Date 2021-10-28
Grant Date 2023-05-23
Owner Carbon, Inc. (USA)
Inventor Wright, Andrew Gordon

Abstract

Provided herein is a dual cure resin useful for the production of an object by additive manufacturing, comprising or consisting essentially of: (a) a photoinitiator; (b) not more than 5, 10 or 20 ppm of a polyurethane catalyst (e.g., tin, tertiary amine, bismuth, zinc, zirconium, or nickel catalysts); (c) a polyol; (d) free (i.e., unblocked) polyisocyanate; and (e) blocked polyisocyanate, the isocyanate groups of which are blocked by reaction with an amine (meth)acrylate blocking agent. Methods of making an object with the resin are also provided.

IPC Classes  ?

  • C08F 2/46 - Polymerisation initiated by wave energy or particle radiation
  • C08F 2/50 - Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light with sensitising agents
  • C08G 61/04 - Macromolecular compounds containing only carbon atoms in the main chain of the macromolecule, e.g. polyxylylenes only aliphatic carbon atoms
  • C08G 18/48 - Polyethers
  • C08G 18/16 - Catalysts
  • C08G 18/73 - Polyisocyanates or polyisothiocyanates acyclic
  • B33Y 70/00 - Materials specially adapted for additive manufacturing

97.

Resin extractor for additive manufacturing

      
Application Number 17371833
Grant Number 11478988
Status In Force
Filing Date 2021-07-09
First Publication Date 2021-10-28
Grant Date 2022-10-25
Owner Carbon, Inc. (USA)
Inventor
  • Murillo, Michael
  • Dachs, Ii, Gregory W.
  • Feller, Bob E.

Abstract

A method of separating excess resin from at least one object, includes: (a) stereolithographically producing at least one object on at least one carrier platform, each carrier platform having a planar build surface to which at least one object is connected, each object carrying excess resin on a surface thereof; then (b) mounting each carrier platform to a rotor; (c) centrifugally separating excess resin from each object by spinning the rotor with each carrier platform connected thereto while each object remains connected to each carrier platform; and then (d) removing each carrier platform from the rotor with each object thereon, with excess resin separated therefrom.

IPC Classes  ?

  • B29C 64/35 - Cleaning
  • B29C 64/124 - 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
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/245 - Platforms or substrates

98.

BUILD PLATES FOR CONTINUOUS LIQUID INTERFACE PRINTING HAVING PERMEABLE BASE AND ADHESIVE FOR INCREASING PERMEABILITY AND RELATED METHODS, SYSTEMS AND DEVICES

      
Application Number 17245218
Status Pending
Filing Date 2021-04-30
First Publication Date 2021-10-21
Owner Carbon, Inc. (USA)
Inventor
  • Moore, David
  • Tumbleston, John R.
  • Samulski, Edward T.
  • Ermoshkin, Alexander
  • Rolland, Jason P.
  • Herrmann, Ariel M.

Abstract

A build plate for a three-dimensional printer includes a rigid, optically transparent, gas-permeable planar base having an upper surface and an opposing lower surface; a gas permeable adhesive layer on the base upper surface; and a flexible, optically transparent, gas-permeable sheet having upper and lower surfaces, the upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface positioned on the adhesive layer opposite the base.

IPC Classes  ?

  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 10/00 - Processes of additive manufacturing
  • B29C 64/264 - Arrangements for irradiation
  • B29C 64/245 - Platforms or substrates

99.

Spin cleaning method and apparatus for additive manufacturing

      
Application Number 17272470
Grant Number 11919236
Status In Force
Filing Date 2019-09-26
First Publication Date 2021-10-21
Grant Date 2024-03-05
Owner Carbon, Inc. (USA)
Inventor
  • Day, Ananda Rose
  • Kwok, Kenton J.
  • Tucker, William James

Abstract

A method of separating excess resin from at least one object includes: (a) stereolithographically producing at least one object, each object having at least one retention feature (32) formed thereon, each object carrying excess resin on a surface thereof; then (b) mounting each object on at least one transfer frame (21), each transfer frame having at least one retention member (22) that mates with the retention feature; (c) connecting each transfer frame to a rotor with the at least one object carried thereon; (d) centrifugally separating excess resin from each object by spinning the rotor with each transfer frame connected thereto while the at least one object remains connected to each transfer frame by the retention feature; then (e) removing each transfer frame from the rotor, with excess resin separated from each at least one object thereon.

IPC Classes  ?

  • B29C 64/35 - Cleaning
  • B08B 3/08 - Cleaning involving contact with liquid the liquid having chemical or dissolving effect
  • B08B 7/00 - Cleaning by methods not provided for in a single other subclass or a single group in this subclass
  • B08B 7/02 - Cleaning by methods not provided for in a single other subclass or a single group in this subclass by distortion, beating, or vibration of the surface to be cleaned
  • B08B 7/04 - Cleaning by methods not provided for in a single other subclass or a single group in this subclass by a combination of operations
  • B29C 64/129 - 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 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
  • B29C 64/357 - Recycling
  • B33Y 30/00 - 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 - Details thereof or accessories therefor
  • B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
  • B33Y 10/00 - Processes of additive manufacturing

100.

Window Variability Correction in Additive Manufacturing

      
Application Number 17365380
Status Pending
Filing Date 2021-07-01
First Publication Date 2021-10-21
Owner Carbon, Inc. (USA)
Inventor
  • Chimmalgi, Anant
  • Zhang, Jiayao
  • Bennett, James Michael Ian
  • Feller, Bob E.

Abstract

A method of making an object on a bottom-up stereolithography apparatus is provided. The apparatus includes a light source, a drive assembly, and a controller operatively associated with the light source and the drive assembly, with the light source and/or the drive assembly having at least one adjustable parameter that is adjustable by the controller. The method includes installing a removable window cassette on the apparatus in a configuration through which the light source projects, the window cassette comprising an optically transparent member having a build surface on which an object can be produced, and with the optically transparent member having and at least one variable property therein; and then modifying the at least one adjustable parameter by the controller based on the at least one variable optical property of the window; and then producing the object on the build surface from a light-polymerizable liquid by bottom-up stereolithography.

IPC Classes  ?

  • B29C 64/124 - 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
  • B33Y 10/00 - Processes of additive manufacturing
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