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.

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.

Abstract: A method of cleaning residual resin from an additively manufactured object, including: producing by additive manufacturing at least one object on at least one carrier platform; operatively connecting each object to a rotor including connecting the at least one carrier platform to a dynamic mount; separating 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 each object about first and second axes during the spinning to enhance the centrifugally separating the residual resin from each object. The rotating step may be carried out with first and second actuators contacting and engaging the dynamic mount to rotate the dynamic mount and each object about the first and second axes.

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.

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”).

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 t

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.

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.

Abstract: Provided 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, the 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.

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.

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.

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.

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) irradiati

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.

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.

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.

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.

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.

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 compone

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.