Abstract: A method of making a physical object having a desired geometry from a resin such as a dual cure resin by an additive manufacturing process such as a dual cure additive manufacturing process includes (a) entering into a processor a first input geometry for the physical object, the first input geometry corresponding to a desired geometry for the physical object; (b) modifying in the processor the first input geometry to a candidate inversely distorted input geometry for the physical object; (c) generating a simulated object from the candidate inversely distorted input geometry with a Multiphysics model simulation of the additive manufacturing process, the simulated object including distortions towards the desired geometry arising from the additive manufacturing process; (d) evaluating whether the simulated object sufficiently corresponds to the desired geometry for the physical object.

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.

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.

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.

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.

Abstract: An epoxy dual cure resin useful for additive manufacturing of three-dimensional objects includes: (i) a photoinitiator; (ii) monomers and/or prepolymers that are polymerizable by exposure to actinic radiation or light; (iii) optionally, a light absorbing pigment or dye; (iv) an epoxy resin; (v) optionally, but in some embodiments preferably, an organic hardener co-polymerizable with the epoxy resin; (vi) optionally but preferably a dual reactive compound having substituted thereon a first reactive group reactive with said monomers and/or prepolymers that are polymerizable by exposure to actinic radiation or light, and a second reactive group reactive with said epoxy resin (e.g., an epoxy acrylate); (vii) optionally a diluent; (viii) optionally a filler; and (ix) optionally, a co-monomer and/or a co-prepolymer. Methods of using the same in additive manufacturing are also described.

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.

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.

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.

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 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.

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.

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.

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.

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 define a build region therebetween. The method further includes filling said build region with a polymerizable liquid; continuously or intermittently irradiating said build region with light through said optically transparent member to form a solid polymer from said polymerizable liquid; applying a reduced pressure and/or polymer inhibitor-enriched gas to the polymerizable liquid through the optically transparent member to thereby reduce a gas content of the polymerizable liquid; and continuously or intermittently advancing (e.g., sequentially or concurrently with said irradiating step) said carrier away from said build surface to form said three-dimensional object from said solid polymer.

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.

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.

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 obj

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.

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.