Abstract: The present disclosure provides a method of making an orthodontic article. The method includes (a) providing a photopolymerizable composition; (b) selectively curing the photopolymerizable composition using actinic radiation to form an article in the shape of an orthodontic article including a number of layers of at least one photopolymerized polymer; and (c) moving the article and thereby generating a mass inertial force in the uncured photopolymerizable composition. The article has a first surface, and no more than 75% of the first surface has a slope magnitude greater than 2.5 degrees. Orthodontic articles are also provided, including an orthodontic article that is prepared according to the method. Orthodontic articles having low extractable component content are further provided. The mass inertial force tends to form a coating layer of uncured photopolymerizable composition on the article, and curing the coating layer can form a surface having low slope magnitude.

Abstract: The disclosure provides a thermally stable melt processable thermoset polymer composition including at least one melt processable thermoset polymer, such as an epoxy, and at least one reinforcing filler, such as carbon nanotubes. Such compositions when 3D printed, exhibit improved Z-layer adhesion and modulus at melt temperature, a common related additive manufacturing problem, as compared to thermoset polymers without reinforcing filler and more conventional thermoplastic resin systems. Subsequent actinic cure of such compositions irreversibly and permanently cures the material thereby making it no longer melt processable.

Abstract: Infiltrated three-dimensional articles are provided. An article includes a first polymeric material having an exterior surface and an interior volume; and a second polymeric material that is a thermoplastic polymer or a reaction product of a polymerizable composition disposed in at least a portion of the interior volume of the first polymeric material to a depth from the exterior surface. Methods of making the articles are provided. A method includes curing a photopolymerizable composition containing at least one reactive component and at least one photoinitiator to form an additive manufactured three-dimensional structure of a first polymeric material having an exterior surface and an interior volume. The method further includes contacting at least a portion the three-dimensional structure with a fluid to form an infiltrated structure; and curing or drying the fluid of the infiltrated structure to form an infiltrated three-dimensional article.

Abstract: The present disclosure provides an orthodontic article including the reaction product of the polymerizable composition. Further, the present disclosure provides polymerizable compositions and methods of making an orthodontic article. The method includes obtaining a polymerizable composition and selectively curing the polymerizable composition to form an orthodontic article. Further, methods are provided, including receiving, by a manufacturing device having one or more processors, a digital object comprising data specifying an orthodontic article; and generating, with the manufacturing device by an additive manufacturing process, the orthodontic article based on the digital object. A system is also provided, including a display that displays a 3D model of an orthodontic article; and one or more processors that, in response to the 3D model selected by a user, cause a 3D printer to create a physical object of an orthodontic article.

Abstract: Foam-based pneumatic actuators can be formed in a state of mechanical compression prior to actuation. An actuator includes an elastomeric foam; a coating disposed on the elastomeric foam; and an elastomer seal disposed on the coating. The coating constrains the elastomeric foam and can be configured to break or fracture when the elastomeric foam inflates. The elastomer seal can be configured to be impermeable to the actuating fluid. Such a foam actuator can be used in a cardiac compression device. These foam actuators possess increased actuation deformation and an actuation exerted force for a given inflation pressure. A large deformation can be provided from materials having low ultimate strains.

Abstract: The present disclosure provides apparatuses and methods for manufacturing three-dimensional objects. Each additive manufacturing apparatus (1000, 2000, 3000) includes: a) a reservoir (1100, 2100, 3100) for receiving hardenable material; b) a first movable light engine (1200, 2200, 3200) providing a first light radiation configuration; a second light engine (1300, 2300, 3300) providing a second light radiation configuration that is different than the first light radiation configuration; and d) a light altering structure (1400, 2400, 3400). The light altering structure is located between the reservoir and light radiated from at least one of the first movable light engine or the second light engine. The first movable light engine is configured to radiate light onto a first focal plane (2220) within the reservoir containing the hardenable material and the second light engine is configured to radiate light onto a second focal plane (2320) within the reservoir containing the hardenable material.

Abstract: The present disclosure provides a photopolymerizable composition. The photopolymerizable composition includes a) 40-60 parts by weight of a monofunctional (meth)acrylate monomer, per 100 parts of the total photopolymerizable composition; b) a photoinitiator; and c) a polymerization reaction product of components. A cured homopolymer of the monofunctional (meth)acrylate monomer has a glass transition temperature of 125 degrees Celsius or greater. The polymerization reaction product of components includes i) a diisocyanate; ii) a hydroxy functional methacrylate; iii) a polycarbonate diol; and iv) a catalyst. The polymerization reaction product includes a polyurethane methacrylate polymer.

Abstract: The apparatus (1000) includes a housing (110), a chamber (120) disposed in the housing, at least two light emitting diodes (LEDs) (130) disposed within the housing (110), and a user interface (140) disposed on an exterior (112) of the housing. The chamber (120) is adaptable to each of an open, closed, and hermetically sealed configuration. The chamber (120) includes a material transparent to actinic radiation and light from the LEDs (130) enters the chamber from more than one direction. The user interface (140) includes a display (142) and program switches (144) configured to adjust at least three operational parameters of the apparatus. The apparatus (1000) further includes a vacuum pump (150) operatively coupled to the chamber (120). The system includes the apparatus (1000) and an article (180). An article includes layers of at least one photopolymerized crosslinked composition and a low extractable component content.

Abstract: Polymerizable compositions suitable for use for 3D printed (e.g. orthodontic) articles, especially orthodontic alignment trays, are described. The polymerizable composition comprises a) 30-70 parts by weight of (meth)acrylate monomer(s); and b) urethane (meth)acrylate polymer; wherein the reaction product comprises at least 1 wt. % polymerized units of a multifunctional compound comprising pendent cyclic moieties. The orthodontic article comprises the reaction product of a polymerizable composition as described herein. The urethane (meth)acrylate polymer typically comprises polymerized units of a multifunctional compound comprising pendent cyclic moieties and/or at least one (meth)acrylate monomer comprises polymerized units of a multifunctional compound comprising pendent cyclic moieties. Also described are methods of making an article, non-transitory machine-readable medium comprising data representing a three-dimensional model of an article, and systems.

Abstract: In one embodiment, an orthodontic article is described comprising the reaction product of a polymerizable composition comprising: a) 30-70 parts by weight of monofunctional (meth)acrylate monomer, wherein a cured homopolymer of at least one monofunctional (meth)acrylate monomer has a Tg of at least 30, 35, 40, 45, 50, 55, or 60° C.; and b) urethane (meth)acrylate polymer comprising polymerized units of an aliphatic polyester diol. Also described are polymerizable compositions, as well as methods and systems for making an article utilizing 3D printing.

Abstract: The present disclosure provides a method of making an orthodontic article. The method includes (a) providing a photopolymerizable composition; (b) selectively curing the photopolymerizable composition using actinic radiation to form an article in the shape of an orthodontic article including a number of layers of at least one photopolymerized polymer; and (c) moving the article and thereby generating a mass inertial force in the uncured photopolymerizable composition. The article has a first surface, and no more than 75% of the first surface has a slope magnitude greater than 2.5 degrees. Orthodontic articles are also provided, including an orthodontic article that is prepared according to the method. Orthodontic articles having low extractable component content are further provided. The mass inertial force tends to form a coating layer of uncured photopolymerizable composition on the article, and curing the coating layer can form a surface having low slope magnitude.

Abstract: An orthodontic article is described comprising a cured composition comprising the reaction product of free-radically polymerizable resin comprising at least one monomer, oligomer and/or polymer, comprising at least two (meth)acryl moieties; a monofunctional reactive diluent; and a polymer or macromolecule comprising a free-radical photoinitiator group. The polymer or macromolecule has a molecular weight of at least 500 g/mole. In one embodiment, the cured composition comprises a first and second photoinitiator wherein at least one is a polymer or macromolecule. Also described are photopolymerizable compositions and methods.

Abstract: The present disclosure provides methods of making a hydrated orthodontic article is provided. One method includes a) providing a photopolymerizable composition; b) selectively curing the photopolymerizable composition using actinic radiation to form an article in the shape of an orthodontic article having a plurality of layers of at least one photopolymerized polymer; and c) exposing the article to water by submersion in water, thereby hydrating the article. A sheet of the at least one photopolymerized polymer has a bending modulus when hydrated of 100 MPa or greater and 2200 MPa or less. Another method includes exposing the orthodontic article to water vapor and hermetically sealing the hydrated orthodontic article in a container. Hydrated orthodontic articles are also provided, including an orthodontic article that is prepared according to one of the methods.

Abstract: The present disclosure provides a photopolymerizable composition. The photopolymerizable composition includes a) 40-60 parts by weight of a monofunctional (meth)acrylate monomer, per 100 parts of the total photopolymerizable composition; b) a photoinitiator; and c) a polymerization reaction product of components. A cured homopolymer of the monofunctional (meth)acrylate monomer has a glass transition temperature of 125 degrees Celsius or greater. The polymerization reaction product of components includes i) a diisocyanate; ii) a hydroxy functional methacrylate; iii) a polycarbonate diol; and iv) a catalyst. The polymerization reaction product includes a polyurethane methacrylate polymer.

Abstract: Orthodontic articles and polymerizable resin compositions are described. The orthodontic article comprises a cured composition comprising the reaction product of free-radically polymerizable resin comprising 30 to 70 wt. %, inclusive, of at least one urethane component, and 25 to 70 wt. %, inclusive, of reactive diluent(s) comprising at least one monofunctional (meth)acrylate monomer. The polymerizable resin comprises no greater than 35 wt. % of reactive diluent(s) having a high affinity for water. Reactive diluent(s) such as monofunctional (meth)acrylate monomers having a high affinity for water have low log P values. In one embodiment, the polymerizable resin comprises at least one acidic monomer.

Abstract: An orthodontic article is described comprising the reaction product of a free-radically polymerizable resin; a first free-radical photoinitiator having sufficient absorbance at a first wavelength range; and a second free-radical initiator selected from a second photoinitiator having sufficient absorbance at a second wavelength range, wherein the second wavelength range is different than the first wavelength range, or a thermal free-radical initiator. In some embodiments, a 1 g/liter acetonitrile solution, at a pathlength of 1 cm, has an absorbance of greater than 0.01, 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, or 0.10 at a wavelength of the first wavelength range when measured with a spectrophotometer. In some embodiments, the first free-radical photoinitiator exhibits a maximum absorbance at a wavelength of the range of 370-380 nm or 320-330 nm and/or comprises photoinitiator groups selected from acyl phosphine oxide or alkyl amine acetophenone.

Abstract: The present disclosure provides an orthodontic article including the reaction product of the polymerizable composition. Further, the present disclosure provides polymerizable compositions and methods of making an orthodontic article. The method includes obtaining a polymerizable composition and selectively curing the polymerizable composition to form an orthodontic article. Further, methods are provided, including receiving, by a manufacturing device having one or more processors, a digital object comprising data specifying an orthodontic article; and generating, with the manufacturing device by an additive manufacturing process, the orthodontic article based on the digital object. A system is also provided, including a display that displays a 3D model of an orthodontic article; and one or more processors that, in response to the 3D model selected by a user, cause a 3D printer to create a physical object of an orthodontic article.

Abstract: The present disclosure provides an orthodontic article including the reaction product of the photopolymerizable composition. The photopolymerizable composition includes i) a monofunctional (meth)acrylate monomer whose cured homopolymer has a glass transition temperature of 90 degrees Celsius or greater; ii) a photoinitiator; and iii) a polymerization reaction product of components. The components include 1) an isocyanate; 2) a (meth)acrylate mono-ol; 3) a polycarbonate diol; and 4) a catalyst. Further, the present disclosure provides a method of making an orthodontic article. The method includes obtaining a photopolymerizable composition and selectively curing the photopolymerizable composition to form an orthodontic article.

Abstract: The present disclosure provides a photopolymerizable composition. The photopolymerizable composition includes a) 40-60 parts by weight of a monofunctional (meth)acrylate monomer, per 100 parts of the total photopolymerizable composition; b) a photoinitiator; and c) a polymerization reaction product of components. A cured homopolymer of the monofunctional (meth)acrylate monomer has a glass transition temperature of 125 degrees Celsius or greater. The polymerization reaction product of components includes i) a diisocyanate; ii) a hydroxy functional methacrylate; iii) a polycarbonate diol; and iv) a catalyst. The polymerization reaction product includes a polyurethane methacrylate polymer.

Abstract: Foam-based pneumatic actuators can be formed in a state of mechanical compression prior to actuation. An actuator includes an elastomeric foam; a coating disposed on the elastomeric foam; and an elastomer seal disposed on the coating. The coating constrains the elastomeric foam and can be configured to break or fracture when the elastomeric foam inflates. The elastomer seal can be configured to be impermeable to the actuating fluid. Such a foam actuator can be used in a cardiac compression device. These foam actuators possess increased actuation deformation and an actuation exerted force for a given inflation pressure. A large deformation can be provided from materials having low ultimate strains.