Abstract: This disclosure provides low-viscosity resins for producing polymers with properties suitable for use in various mechanical appliances, such as orthodontic appliances (e.g., aligners). The low-viscosity resins may be photo-curable and can be used with direct fabrication methods and equipment. In various embodiments, the polymeric materials produced from the low-viscosity resins described herein have high toughness while remaining resistant to stress relaxation. Low-viscosity, photo-curable resins described herein have reduced hydrogen bonding in comparison to traditional materials (e.g., materials having high urethane content) used in orthodontic appliances.

Abstract: A system includes a build platform configured to support an object that is being formed from layers of resin. The system further includes one or more blades configured to provide the layers of resin to form the object on the build platform. At least a first blade of the one or more blades is configured to vibrate to reduce viscosity of the layers of resin.

Abstract: Systems for manufacturing objects are provided herein. In some embodiments, a system includes at least one sensor and at least one energy source configured to output energy. The system can further include a processor and a memory operably coupled to the processor and storing instructions that, when executed by the processor, cause the system to perform operations including receiving, from the at least one sensor, sensor data of an additively manufactured dental appliance having a plurality of appliance portions. The operations can further include determining, based on the sensor data, a location of a subset of the appliance portions on the additively manufactured dental appliance. The operations can further include applying the energy from the at least one energy source to the subset of the appliance portions so as to selectively modify one or more material properties of the subset of the appliance portions.

Abstract: A method for forming an ornamental indicia carrier may include forming a first print laminate comprising an oriented print layer. The oriented print layer may include a core layer, a first adhesion layer and a second adhesion layer. The method may also include forming a second print laminate coupled to the first print laminate. The second print laminate may include a pressure sensitive adhesive layer. The method may also include coupling an ink layer to one or more of the first adhesion layer, the second adhesion layer, or the pressure sensitive adhesive layer.

Abstract: Additively manufactured objects with exposed supports and associated methods are provided. In some embodiments, a method includes receiving one or more additively manufactured objects that are coupled to a plurality of support structures, where each support structure includes an exposed shoulder region that is accessible to an energy beam of a trimming system. The method can include identifying the locations of the exposed shoulder regions of the plurality of support structures, and directing the energy beam of the trimming system to the locations of the exposed shoulder regions of the plurality of support structures to cut at least partially through the exposed shoulder regions of the plurality of support structures.

Abstract: Methods for fabricating orthodontic appliances are provided. In some embodiments, a method includes: providing a polymerizable composition, the polymerizable composition including an initial ratio of a first polymerizable component to a second polymerizable component; and applying a holographic pattern of radiation to the polymerizable composition to form a portion of an orthodontic appliance. The portion can include: a first region including a first ratio of the first polymerizable component to the second polymerizable component, the first ratio being different from the initial ratio; and a second region including a second ratio of the first polymerizable component to the second polymerizable component, the second ratio being different from the initial ratio and the first ratio.

Abstract: An optical modulator including a driving module, waveguide(s), and differential electrodes is described. The driving module has a first number of differential inputs and a second number of differential outputs. The second number is equal to the first number multiplied by an even integer. The waveguide(s) include a thin film lithium-containing (TFLC) electro-optic material. Each of the waveguide(s) has multiple arms. The differential electrodes are coupled to the second number of differential outputs, each of the plurality of differential electrodes including a positive electrode and a negative electrode, at least a portion of an arm of the plurality of arms between a portion of the positive electrode and a portion of the negative electrode.

Abstract: The present disclosure provides photo-polymerizable monomers, photo-curable resins comprising one or more of such monomers, as well as polymeric materials formed from the photo-curable resins. Further provided herein are methods of producing the compositions and using the same for the fabrication of medical devices, such as orthodontic appliances.

Abstract: A method of three-dimensional (3D) printing includes heating a photo-curable material and extruding the photo-curable material from a nozzle of a dispenser to form a first layer of an object according to a digital file, wherein the first layer has a first shape specified by the digital file, and wherein the first shape has a first minimum line width based on a diameter of the nozzle. The method further includes directing a light beam onto the first layer according to the digital file or an additional digital file to cure a portion of the first layer, wherein the cured portion of the first layer has a second shape, wherein the second shape may comprise features that are smaller than the first shape. The light source is attached to the dispenser and is movable to adjust a direction of the light beam relative to the nozzle of the dispenser.

Abstract: A method for fabricating an oral appliance may include forming, using a 3D additive manufacturing process, a polymeric shell having a plurality of teeth engaging structures shaped to engage the teeth of the patient and forming, using the 3D additive manufacturing process, a force generating component coupled to the plurality of teeth engaging structures, the force generating component may be configured to generate a force in response to a stimulus in order to reposition one or more teeth of the patient. The polymeric shell, the plurality of teeth engaging structures, and the force generating component may include a sequentially polymerized plurality of layers directly fabricated together using the 3D additive manufacturing process.

Abstract: A method of three-dimensional (3D) printing includes heating a photo-curable material and extruding the photo-curable material from a nozzle to form a first layer of an object according to a digital file, wherein the first layer has a first shape specified by the digital file, and wherein the first shape has a first minimum line width based on a diameter of the nozzle. The method further includes directing a light beam onto the first layer according to the digital file or an additional digital file to cure a portion of the first layer, wherein the cured portion of the first layer has a second shape, wherein the second shape may comprise features that are smaller than the first shape.

Abstract: The present disclosure provides curable compositions comprising one or more of polymerizable liquid crystalline compounds or polymerizable polyesters with disrupted crystallinity, as well as polymeric materials formed from the curable compositions. Further provided herein are methods of producing the compositions and using the same for the fabrication of medical devices, such as orthodontic appliances.

Abstract: Systems for fabricating orthodontic appliances are provided. In some embodiments, a system includes a build platform configured to receive a polymerizable composition, the polymerizable composition including a first polymerizable component and a second polymerizable component, the polymerizable composition characterized by an initial ratio of the first polymerizable component to the second polymerizable component.

Abstract: Methods for manufacturing objects are provided herein. In some embodiments, a method includes receiving a dental appliance formed using an additive manufacturing process, the dental appliance including a plurality of appliance portions. The method can include identifying, based on sensor data, a location of a subset of the appliance portions on the dental appliance. The method can further include applying energy to a subset of the appliance portions to selectively modify one or more material properties of the subset of the appliance portions.

Abstract: A pulley block that includes a first side plate, a second side plate and an axle received in the first side plate and the second side plate. The axle is fixed with the first side plate and in a floating relationship with the second side plate such that the second side plate is retained on the axle and capable of rotating around the axle. The axle defines a central opening configured for receiving a soft shackle and a pulley supported on the axle between the first side plate and the second side plate in a longitudinal direction of the axle. The pulley is configured for receiving a winch line around an outer perimeter thereof. Also a method of installing a winch line on such a pulley block.

Abstract: Systems for printing ink onto three-dimensionally (3D) printed articles are provided. In some embodiments, a system includes a fabrication platform configured to fabricate a 3D printed article from a pre-polymer; an inkjet device configured to apply an ink to a portion of the 3D printed article; a heater configured to heat the portion of the 3D printed article and the applied ink to an elevated temperature; and an energy source configured to cure the applied ink after the portion of the 3D printed article with the applied ink has been maintained at the elevated temperature for a soak time.

Abstract: A method for forming dental appliance having an ornamental indicia carrier may include forming a polymeric shell, forming a first adhesive layer configured to be adhered to the polymeric shell, the first adhesive layer including a pressure sensitive adhesive layer, forming a first adhesion layer over the first adhesive layer, and applying a colorant between the first adhesion layer and the pressure sensitive adhesive layer.

Abstract: Systems and methods for additive manufacturing are provided. In some embodiments, a method for additive manufacturing includes forming a portion of an additively manufactured object within a reservoir of curable material by scanning a plurality of energy beams of a plurality of energy sources through a plurality of respective scanning regions in the curable material. The scanning regions can overlap at one or more object locations, such that a combined energy dosage delivered to the one or more object locations by two or more of the energy beams is greater than or equal to a threshold dosage for solidifying the curable material. The method can further include advancing the reservoir of curable material relative to the energy sources. The forming and advancing processes can be repeated to fabricate the additively manufactured object.

Abstract: A method for processing a substrate includes forming a first hardmask layer over a target layer and a second hardmask layer over the first hardmask layer, and patterning the second hardmask layer. The method further includes forming a tone inversion mask between portions of the patterned second hardmask layer, removing the patterned second hardmask layer, patterning the first hardmask layer using the tone inversion mask as an etching mask, and etching the target layer using the patterned first hardmask layer as another etching mask.

Abstract: The present disclosure provides methods, systems, devices, and kits for creating composite materials from a single resin, the composite materials having multiple continuous phases. The disclosure includes a process to three-dimensionally print objects (e.g., orthodontic appliances) with composite properties. In some aspects, the composite properties are formed from a single formulation with components that, when processed, have hard and soft continuous phases. In some aspects, the composite properties are formed by separately processing the hard phase components and the soft phase components. In some aspects, the composite materials and devices are three-dimensionally printed using the processed material.