Abstract: The present disclosure relates to photo-polymerizable resins, methods of photo-polymerizing and foaming resins, and foamed polymeric materials. Some disclosed resins comprise: a first monomer; a second monomer; a photo-activated polymerization catalyst; and a thermally activated foaming agent. Some disclosed methods of preparing photo-polymerized and foamed materials comprise photo-polymerizing a resin with a thermally activated foaming agent to obtain a photo-polymerized polymer material; and heating the photo-polymerized polymer material at a heating temperature to obtain the photo-polymerized and foamed polymer material, wherein the thermally activated foaming agent has a foaming onset temperature, and the heating temperature is greater than or equal to the foaming onset temperature. Also disclosed are photo-polymerized and foamed materials. Further disclosed are polymeric structures having a foam.

Abstract: Disclosed are thermal interface materials having phase separated domains and methods of preparing the same. Exemplary polymer resins solubilize/disperse thermally conductive filler particles in the uncured resin, and, during the cure, the resin may phase separate from the thermally conductive filler particles to form domains of cured resin and domains of conductive filler. Exemplary cured systems comprise: metallic nanoparticles or an aromatic carbon based material, a polyfunctional surfactant, and a crosslinked polymer network; wherein the cured system has domains enriched with the metallic nanoparticles or the aromatic carbon based material and domains enriched with the crosslinked polymer network, and wherein the polyfunctional surfactant is covalently bonded with the crosslinked polymer network. Exemplary methods for making a cured system comprise: applying a magnetic field to form domains enriched with the metallic nanoparticles and domains enriched with the crosslinked polymer network.

Abstract: A system for producing a three-dimensional object from a fluid medium includes image processing units. The fluid medium is configured to solidify when subjected to a prescribed light stimulation. Each image processing unit includes at least one light emitting source configured to emit light, and at least one mirror system configured to reflect the light emitted by the light emitting source. The mirror system includes a manipulating system for adjusting the direction of the emitted light, a control system for controlling the manipulating system, and at least one optical element configured to manipulate the emitted light and to project the emitted light onto an area of a surface of the fluid medium to form an image on the surface. The image processing units are configured to form corresponding images on the surface, and are configured to be movable at least in a lateral direction relative to the surface.

Abstract: The present disclosure relates to the use of occluding fluids, such as a high-density fluid (a “z-fluid”) or a low-density fluid (an “a-fluid”), to displace resin within a vat during 3D printing. Further, an a-fluid may act as a protective boundary for a 3D printing resin wherein the a-fluid sits on top of the printing resin. Another embodiment of the disclosure provides a process of assessing which regions of a computer-aided design (CAD) model take advantage of a buoying force supplied by the occluding fluid, such that fewer support structures are needed for printing a final CAD model compared to printing the CAD model without the occluding fluid.

Abstract: The present disclosure relates to thiol-acrylate photopolymerizable resin compositions. The resin compositions may be used for additive manufacturing. One embodiment of the invention includes a photopolymerizable resin for additive manufacturing, the resin comprising: an acrylate oligomer; a methacrylate monomer; and a thiol wherein the resin may be configured to react by exposure to light to form a cured material. The resin may further comprise one or more oligomeric additives. For example, polyether oligomeric additives such as polytetrahydrofuran.

Abstract: A system for producing a three-dimensional object from a fluid medium includes image processing units. The fluid medium is configured to solidify when subjected to a prescribed light stimulation. Each image processing unit includes at least one light emitting source configured to emit light, and at least one minor system configured to reflect the light emitted by the light emitting source. The minor system includes a manipulating system for adjusting the direction of the emitted light, a control system for controlling the manipulating system, and at least one optical element configured to manipulate the emitted light and to project the emitted light onto an area of a surface of the fluid medium to form an image on the surface. The image processing units are configured to form corresponding images on the surface, and are configured to be movable at least in a lateral direction relative to the surface.

Abstract: The present disclosure relates to the use of occluding fluids, such as a high-density fluid (a “z-fluid”) or a low-density fluid (an “a-fluid”), to displace resin within a vat during 3D printing. Further, an a-fluid may act as a protective boundary for a 3D printing resin wherein the a-fluid sits on top of the printing resin. Another embodiment of the disclosure provides a process of assessing which regions of a computer-aided design (CAD) model take advantage of a buoying force supplied by the occluding fluid, such that fewer support structures are needed for printing a final CAD model compared to printing the CAD model without the occluding fluid.

Abstract: The present disclosure relates to the use of occluding fluids, such as a high-density fluid (a “z-fluid”) or a low-density fluid (an “a-fluid”), to displace resin within a vat during 3D printing. Further, an a-fluid may act as a protective boundary for a 3D printing resin wherein the a-fluid sits on top of the printing resin. Another embodiment of the disclosure provides a process of assessing which regions of a computer-aided design (CAD) model take advantage of a buoying force supplied by the occluding fluid, such that fewer support structures are needed for printing a final CAD model compared to printing the CAD model without the occluding fluid.