Patents by Inventor Alexander Ermoshkin
Alexander Ermoshkin has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11141910Abstract: 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.Type: GrantFiled: June 8, 2018Date of Patent: October 12, 2021Assignee: Carbon, Inc.Inventors: Joseph M. DeSimone, Alexander Ermoshkin, Nikita Ermoshkin, Edward T. Samulski
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Publication number: 20210308943Abstract: The present disclosure describes an apparatus (10) for additively manufacturing a three-dimensional object. The apparatus (10) includes a radiation source (13), a carrier (1) on which the three- dimensional object is made, an applicator assembly (3) configured to apply a polymerizable liquid, and a frame (8), with the applicator assembly and the radiation source connected to the frame. A first drive assembly (4) interconnects the applicator assembly and the frame and a second drive assembly (2) interconnects the carrier and the frame. The frame defines a build region (6) between the applicator assembly and the carrier. The applicator assembly includes a polymerizable liquid supply chamber, an application roller (11), and a metering roller (12). The applicator assembly may optionally include a post-metering roller (14). An apparatus comprising a first and a second applicator assembly and a smaller scale version of the apparatus are also described.Type: ApplicationFiled: October 30, 2019Publication date: October 7, 2021Inventors: Soren Rademacher, David Shirvanyants, Alexander Ermoshkin, Derek Alan Faust
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Publication number: 20210283383Abstract: 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.Type: ApplicationFiled: January 22, 2021Publication date: September 16, 2021Inventors: Joseph M. DeSimone, Alexander Ermoshkin, Nikita Ermoshkin, Edward T. Samulski
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Publication number: 20210162665Abstract: A build plate for a three-dimensional printer includes: a rigid, optically transparent, gas-impermeable planar base having an upper surface and a lower surface; and a flexible, optically transparent, gas-permeable sheet having an upper and lower surface, the sheet upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface positioned on the base upper surface. The build plate includes a gas flow enhancing feature configured to increase gas flow to the build surface.Type: ApplicationFiled: January 15, 2021Publication date: June 3, 2021Inventors: David Moore, John R. Tumbleston, Edward T. Samulski, Alexander Ermoshkin, Jason P. Rolland, Ariel M. Herrmann, Bob E. Feller
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Patent number: 11020898Abstract: 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.Type: GrantFiled: January 29, 2016Date of Patent: June 1, 2021Assignee: Carbon, Inc.Inventors: David Moore, John R. Tumbleston, Edward T. Samulski, Alexander Ermoshkin, Jason P. Rolland, Ariel M. Herrmann
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Publication number: 20210069965Abstract: 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 tType: ApplicationFiled: March 19, 2020Publication date: March 11, 2021Inventors: Joseph M. DeSimone, Alexander Ermoshkin, Edward T. Samulski
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Publication number: 20200398480Abstract: A method of making a three-dimensional object includes: (a) providing an apparatus comprising a radiation source, a carrier, and a movable belt positioned therebetween, with the belt comprised of an optically transparent material, and with the belt permeable to a polymerization inhibitor; (b) applying a polymerizable liquid to a first surface of the belt, and contacting a second surface of the belt to the polymerization inhibitor, (c) contacting a portion of the first surface to the carrier or the three dimensional object so that the belt adheres thereto with the polymerizable liquid positioned therebetween; (d) irradiating the polymerizable liquid with actinic radiation through the belt from the radiation source to polymerize the polymerizable liquid positioned therebetween; then (e) optionally separating the belt from the carrier or the three dimensional object; and then (f) repeating steps (b) through (e) until the three dimensional object is completed.Type: ApplicationFiled: September 3, 2020Publication date: December 24, 2020Inventors: Alexander Ermoshkin, Nikita Ermoshkin, Robert K. Pinschmidt, JR., Zachary Polizzi, Soren Rademacher, David Shirvanyants, Edward T. Samulski
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Patent number: 10792868Abstract: A method of making a three-dimensional object is carried out by: (a) providing an apparatus comprising a radiation source, a carrier on which the three dimensional object is made, and a movable belt positioned therebetween, the belt having a first surface and an opposite second surface, with the belt comprised of an optically transparent material, and with the belt permeable to a polymerization inhibitor; (b) applying a polymerizable liquid to the first surface of the belt, and contacting the second surface of the belt to the polymerization inhibitor, (c) contacting a portion of the belt first surface having the polymerizable liquid thereon to the carrier or the three dimensional object so that the belt adheres thereto with the polymerizable liquid positioned therebetween; (d) irradiating the polymerizable liquid with actinic radiation through the belt from the radiation source to polymerize the polymerizable liquid positioned therebetween; then (e) optionally separating the belt from the carrier or the threeType: GrantFiled: September 2, 2016Date of Patent: October 6, 2020Assignee: Carbon, Inc.Inventors: Alexander Ermoshkin, Nikita Ermoshkin, Robert K. Pinschmidt, Jr., Zachary Polizzi, Soren Rademacher, David Shirvanyants, Edward T. Samulski
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Patent number: 10737438Abstract: A method of forming a three-dimensional object is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween, with the carrier positioned adjacent and spaced apart from the build surface at a start position; then (b) forming an adhesion segment of the three-dimensional object (c) optionally but preferably forming a transition segment of the three dimensional object; and then (d) forming a body segment of the three dimensional object. In each case, the segment can be formed by: (i) filling the build region with a polymerizable liquid, (ii) continuously or intermittently irradiating the build region with light through the optically transparent, and (iii) continuously or intermittently advancing the carrier away from the build surface, to thereby form that segment from the polymerizable liquid.Type: GrantFiled: October 29, 2018Date of Patent: August 11, 2020Assignee: Carbon, Inc.Inventors: Alexander Ermoshkin, David Shirvanyants, John R. Tumbleston
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Patent number: 10710305Abstract: The present invention relates to methods and an apparatus for the fabrication of solid three-dimensional objects from liquid polymerizable materials.Type: GrantFiled: May 7, 2018Date of Patent: July 14, 2020Assignee: Carbon, Inc.Inventors: Joseph M. DeSimone, Alexander Ermoshkin, Edward T. Samulski
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Patent number: 10668709Abstract: A method of forming a three-dimensional object (17) includes: providing a carrier (18) and an optically transparent member (15) having a build surface, the carrier (18) and the build surface defining a build region therebetween; filling the build region with a polymerizable liquid (16); irradiating the build region with light (12) through the optically transparent member (15) to form a solid polymer from the polymerizable liquid; and advancing the carrier (18) away from the build surface to form the three-dimensional object (17) from the solid polymer. The carrier (18) includes at least one retain and release (34) feature that is configured to: i) retain the three-dimensional object (17) formed from the solid polymer on the carrier (18) in a first state; and ii) facilitate release of the three-dimensional object (17) formed from the solid polymer from the carrier (18) in a second state.Type: GrantFiled: August 12, 2015Date of Patent: June 2, 2020Assignee: Carbon, Inc.Inventors: Alexander Ermoshkin, David Shirvanyants, Joseph M. DeSimone, Nordstrom Kirk Phelps, Jason P. Rolland
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Patent number: 10661501Abstract: 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. An apparatus to perform the method is also disclosed.Type: GrantFiled: June 18, 2015Date of Patent: May 26, 2020Assignee: Carbon, Inc.Inventors: Joseph M. DeSimone, Nordstrom Kirk Phelps, Alexander Ermoshkin
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Publication number: 20200139617Abstract: A method of forming a three-dimensional object, comprises 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 while concurrently advancing the carrier away from the build surface to form the three-dimensional object from the solid polymer, while also concurrently: (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 comprising the polymerizable liquid in partially cured form. Apparatus for carrying out the method is also described.Type: ApplicationFiled: November 29, 2018Publication date: May 7, 2020Inventors: Joseph M. DeSimone, Alexander Ermoshkin, Nikita Ermoshkin, Edward T. Samulski
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Patent number: 10618215Abstract: 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, 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 createType: GrantFiled: November 29, 2018Date of Patent: April 14, 2020Assignee: Carbon, Inc.Inventors: Joseph M. DeSimone, Alexander Ermoshkin, Nikita Ermoshkin, Edward T. Samulski
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Patent number: 10596755Abstract: 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 tType: GrantFiled: August 20, 2018Date of Patent: March 24, 2020Assignee: Carbon, Inc.Inventors: Joseph M. DeSimone, Alexander Ermoshkin, Edward T. Samulski
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Patent number: 10569465Abstract: 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 the carrier away from the build surface to form the three-dimensional object from the solid polymer. The irradiating step is carried out with a plurality of tiled images projected into the build region, and each tiled image includes an array of projected pixels. An apparatus to perform the method is also discloses.Type: GrantFiled: June 18, 2015Date of Patent: February 25, 2020Assignee: Carbon, Inc.Inventors: Joseph M. DeSimone, Nordstrom Kirk Phelps, Alexander Ermoshkin
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Patent number: 10538030Abstract: A method of forming a three-dimensional object useful as a casting mold 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 liquid photocurable ceramic resin; 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.Type: GrantFiled: May 9, 2016Date of Patent: January 21, 2020Assignee: Carbon, Inc.Inventors: Joseph M. DeSimone, Edward T. Samulski, Alexander Ermoshkin, Philip M. DeSimone
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Publication number: 20200009852Abstract: 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”).Type: ApplicationFiled: September 16, 2019Publication date: January 9, 2020Inventors: Alexander Ermoshkin, David Shirvanyants, Nordstrom Kirk Phelps, Nikita Ermoshkin, Edward T. Samulski, Joseph M. DeSimone
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Publication number: 20190389127Abstract: 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.Type: ApplicationFiled: June 8, 2018Publication date: December 26, 2019Inventors: Joseph M. DeSimone, Alexander Ermoshkin, Nikita Ermoshkin, Edward T. Samulski
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Patent number: 10471699Abstract: Described herein are methods and apparatus for the production of a three-dimensional object by “bottom up” additive manufacturing, in which a carrier (112) 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 embodiments, the three-dimensional object is produced from a liquid interface by continuous liquid interface production (i.e., “CLIP”).Type: GrantFiled: June 18, 2015Date of Patent: November 12, 2019Assignee: Carbon, Inc.Inventors: Alexander Ermoshkin, David Shirvanyants, Nordstrom Kirk Phelps, Nikita Ermoshkin, Edward T. Samulski, Joseph M. DeSimone