Abstract: Systems, methods, and devices for additive manufacturing are provided. In some embodiments, a method includes: coupling a plurality of build platforms to a carrier; forming a plurality of dental appliances on the plurality of build platforms using an additive manufacturing process, where each build platform receives at least one dental appliance thereon; removing the plurality of build platforms from the carrier; performing post-processing of the plurality of dental appliances while the dental appliances remain on the respective build platforms, where the post-processing includes annealing; and separating the plurality of dental appliances from the respective build platforms.

Abstract: Systems, devices, and methods for additive manufacturing of objects are provided. In some embodiments, a device includes a build platform having a surface. The device can also include an overlay configured to be removably coupled to the surface of the build platform. The overlay may include a plurality of support structures extending above the surface of the build platform. Each support structure may be configured to couple to a portion of an additively manufactured object.

Abstract: Systems, devices, and methods for additive manufacturing of objects are provided. In some embodiments, a method includes applying a precursor material to a flexible substrate. The method can further include moving a carriage laterally along the flexible substrate, such that the carriage vertically displaces an active region of the flexible substrate downward and away from a remaining region of the flexible substrate and toward a build platform. The method can further include outputting energy toward the precursor material at the active region of the flexible substrate to form a portion of an object on the build platform, where the energy is directed down toward the active region.

Abstract: The present disclosure provides methods for recovering reactive diluent components from 3D printed crosslinked polymeric materials. The reactive diluent components can be recovered either as hydroxyl-containing compounds cleaved from pendant ester groups attached to the polymer backbone, or as (meth)acrylate monomers by cleavage of the polymer backbone itself. The recovered hydroxyl-containing compounds and (meth)acrylate monomers can be reused for the fabrication of new medical devices by 3D printing.

Abstract: Devices and methods for treating an intraoral cavity of a patient are provided. In some embodiments, a device includes a tissue scaffold configured to promote growth of oral tissue at a treatment site in the intraoral cavity of the patient, and a positioner. The positioner can include one or more cavities configured to receive one or more teeth of the patient, and an alignment element configured to temporarily couple to the tissue scaffold such that when the positioner is placed on the patient's teeth, the alignment element locates the tissue scaffold at the treatment site.

Abstract: Substrates and associated materials for additive manufacturing are provided. In some embodiments, a device for manufacturing an object from a curable material includes a substrate configured to support the curable material during an additive manufacturing process. The substrate can be at least partially transparent to a wavelength of energy that cures the curable material. The substrate can include a first layer with a first material configured to inhibit adhesion to the curable material. The substrate can also include a second layer with a second material having one or more of increased mechanical strength or increased heat resistance relative to the first material.

Abstract: This disclosure provides polymeric materials comprising weak crosslinking covalent bonds and/or weak crosslinking units comprising a weak covalent bond. Weak covalent bonds can be used in place of hydrogen bonds present in traditional polymeric materials (e.g., polyurethanes). Advantageously, the toughness can be controlled by varying the strength of weak covalent bonds and/or by varying the number of weak covalent crosslinks. Crosslinked materials applying the weak covalent crosslinking bonds can be used to create tough materials able to resist stress relaxation. Further, the present disclosure provides polymer chains and polymeric materials comprising inchain loops (also referred to herein as rings). The inchain loops comprise weak bonds and/or weak bridges comprising at least one weak bond.

Abstract: The present disclosure provides monomers and curable compositions comprising such monomers for preparing polymeric materials with controlled crystallinity. Orthodontic appliances made from these polymeric materials are also provided.

Abstract: Systems, methods, and devices for additive manufacturing are provided. In some embodiments, a method includes: coupling a plurality of build platforms to a carrier; forming a plurality of 3D objects on the plurality of build platforms using an additive manufacturing process, where each build platform receives at least one 3D object thereon; removing the plurality of build platforms from the carrier; performing post-processing of the plurality of 3D objects while the 3D objects remain on the respective build platforms; and separating the plurality of 3D objects from the respective build platforms.

Abstract: Systems, devices, and methods for additive manufacturing of objects are provided. In some embodiments, a device for supporting an object during an additive manufacturing process includes a build platform having a surface, and a plurality of support structures extending above the surface of the build platform. Each support structure can be configured to couple to a portion of an additively manufactured object. The device can also include a plurality of actuators, each actuator being configured to adjust a position of a corresponding support structure relative to the build platform.

Abstract: Methods for manufacturing objects are provided herein. In some embodiments, a method includes receiving a digital data set representing an object, and applying energy to a curable material based on the digital data set to form the object. The object can include at least two object portions formed from the curable material using different energy application parameters. The method can further include removing residual curable material from the object. A different amount of the residual curable material can be removed from each of the at least two object portions. After the residual curable material is removed, the at least two object portions can each have different material properties.

Abstract: Systems, devices, and methods for additive manufacturing of objects are provided. In some embodiments, a system for fabricating an object includes a flexible substrate, a carriage coupled to the flexible substrate, an actuator, at least one recoater supported by the carriage, and an energy source. The flexible substrate can be configured to carry a precursor material. The carriage can vertically displace an active region of the flexible substrate away from a remaining region of the flexible substrate and toward a build platform. The actuator can be configured to move the carriage relative to the flexible substrate. The at least one recoater can be configured to apply the precursor material to the flexible substrate. The energy source can be configured to output energy toward the precursor material at the active region of the flexible substrate to form a portion of an object on the build platform.

Abstract: Materials and additively manufactured objects including mechanically interlocking elements are provided. In some embodiments, a method includes forming a dental appliance at least partially out of a composite material. The composite material can include an interlocking structure having a plurality of interlocking elements. The interlocking structure can have a first mechanical property. The composite material can also include a matrix surrounding at least a portion of the interlocking structure. The matrix can have a second mechanical property different from the first mechanical property.

Abstract: A 3D printer comprises a platform, a dispenser, and a light source. The dispenser comprises a nozzle to extrude photo-curable material onto the platform to form a first layer according to one or more digital files. The first shape of the one or more extruded photo-curable materials corresponds to a first minimum line width that is based on a diameter of the nozzle. The light source is to emit a light beam directed onto the first layer according to the one or more digital files to cure a portion of the first layer. A first cured layer of the one or more photo-curable materials corresponds to a second shape of a first layer of a 3D printed orthodontic aligner specified by the one or more digital files. The second shape has a second minimum line width that is smaller than the first minimum line width.

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: Provided herein are systems and processes to control multiple temperatures in additive manufacturing. Such temperature control adjusts polymer properties and facilitates processing of materials to form 3D objects. The systems and processed disclosed herein also facilitate the processing of typically difficult-to-process materials and deliver such materials to a photocuring zone configured to photopolymerize materials into 3 dimensional objects with a layer-by-layer process. Such processes can include the steps of heating a resin to a flowable temperature, applying the resin to a carrier, cooling the film to increase viscosity or to solidify the resin, and applying the film containing the resin onto an area being printed, then photocuring the film. Also provided herein are resins and related polymer materials having properties that are tunable with exposure to more than one temperature zone. The formed polymers can include multiple regions of polymer material, each independently having distinct properties.

Abstract: The present disclosure provides novel polymerizable compositions that can produce coating layers on polymeric materials thereby imparting excellent stain resistance. Further provided herein are methods of producing polymerizable coatings, coated devices, and coated polymeric materials. Also provided herein are methods of using polymer coated materials, and coated polymeric materials fabricated via additive manufacturing processes (e.g., via 3D printing), such as orthodontic appliances with increased stain resistance.

Abstract: Methods and systems for additive manufacturing of objects are provided. In some embodiments, a method includes receiving a digital representation of an object to be fabricated via an additive manufacturing process; identifying an internal portion of the object that would be unstable during the additive manufacturing process without an internal support structure, based on the digital representation; modifying the digital representation of the object to remove at least part of the internal portion; and generating instructions for fabricating the object via the additive manufacturing process, based on the modified digital representation.

Abstract: Materials and additively manufactured objects including mechanically interlocking elements are provided. In some embodiments, a dental appliance includes an appliance body made at least partially out of a composite material. The composite material can include an interlocking structure having a plurality of interlocking elements. The interlocking structure can have a first mechanical property. The composite material can also include a matrix surrounding at least a portion of the interlocking structure. The matrix can have a second mechanical property different from the first mechanical property.

Abstract: Dental appliances with aesthetic features and associated methods and systems are provided. In some embodiments, a dental appliance includes a shell having a plurality of cavities, the shell configured to reposition a patient's teeth from a first tooth arrangement toward a second tooth arrangement. The dental appliance can also include a mask region integrally formed with the shell. The mask region can be configured to cover at least one tooth of the patient's teeth and can depict the at least one tooth according to a target tooth arrangement.