An additive manufacturing apparatus that includes a vat configured to receive a radiant-energy-curable resin and a method for using the vat. A floor defines at least a first portion and a sump wherein the first portion is above the sump. The first portion defines a build surface, at least some of which is transparent. A stage is positioned facing the build surface and is configured to hold a stacked arrangement of one or more cured layers of the radiant-energy-curable resin. One or more actuators are operable to change the relative positions of the vat and the stage. A radiant energy apparatus is positioned adjacent to the vat opposite to the stage and is operable to generate and project radiant energy on the radiant-energy-curable resin through the floor of the vat in a predetermined pattern. The additive manufacturing apparatus also includes a cleaning apparatus operable to transfer debris from the build surface to the sump.

A method of forming a three-dimensional object of polyurethane, polyurea, or copolymer thereof 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 at least one of: (i) a blocked or reactive blocked prepolymer, (ii) a blocked or reactive blocked diisocyanate, or (iii) a blocked or reactive blocked diisocyanate chain extender; (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 chain extender; and then (d) heating or microwave irradiating the three-dimensional intermediate sufficiently to form from the three-dimensional intermediate the three-dimensional object of polyurethane, polyurea, or copolymer thereof.

A device and method for preparing a locally heterogeneous smart composite material based on time-frequency regulated SAWs are provided. The method includes: mixing functional particles, a photosensitive liquid and a photoinitiator evenly; inputting periodic time-frequency regulated sinusoidal signals defined by a frequency, a duration, an interval time and a time difference to a pair of slanted-finger interdigital transducers, such that the pair of slanted-finger interdigital transducers are excited to produce corresponding standing SAWs; coupling and allowing the standing SAWs to enter a liquid tank to form a local sound field in the photosensitive liquid; forming, by the functional particles in the photosensitive liquid, a stable array distribution under the action of an acoustic radiation force of the local sound field; and turning on an UV light source for curing, thereby completing the preparation.

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 to create a subsequent build region between the polymerized region and the build surface while concurrently filling the subsequent build region with polymerizable liquid as in step (b). Apparatus for carrying out the method is also described.

A moulding device, for forming lenses by moulding, includes: a moulding element including indentations formed in a face of the moulding element; a transparent plate held with respect to the moulding element so as to form, with the indentations, a cavity intended to allow the formation of a plurality of lenses; at least one injection passage intended to allow moulding product to be introduced into the cavity, the injection passage being arranged between the transparent plate and the moulding element; a moulding product injector arranged so as to allow moulding product to be introduced into the injection passage. The injector is removable, and the moulding device is configured so as to allow the injector to be removed while at the same time keeping the transparent plate held with respect to the moulding element.

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, 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 to create a subsequent build region between the polymerized region and the build surface; (e) wherein the carrier has at least one channel formed therein, and the filling step is carried out by passing or forcing the polymerizable liquid into the build region through the at least one channel. Apparatus for carrying out the method is also described

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 component in the three-dimensional intermediate to form the three-dimensional object.

A mold, a molding apparatus, and a method for manufacturing articles or components is used to manufacture an article or component of the article that at least partially comprises an ultraviolet (UV) curable material. The mold and apparatus comprise at least one mold wall formed of a cyclic olefin copolymer, which is in contact with UV radiation curable material and allows the article or component of the article to be exposed to UV radiation for a period of time in order to provide for at least partial cure thereof.

A decorative optical element that has an appearance of a glass optical element includes an optically transparent body having a faceted globular portion defined by a solid volume of polymeric material. A luminaire, such as for a street light, employs the decorative optical element and an LED circuit board mounted to the circuit board.

A method and an apparatus of forming a three-dimensional object, wherein the method includes providing a carrier and an optically transparent member having a build surface, said carrier and said build surface defining a build region therebetween; 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, 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, said optically transparent member comprising a build plate for a three-dimensional printer comprising: an optically transparent first channel layer; an optically transparent, gas permeable second channel layer on the first channel layer; and a flexible, optically transparent, gas-permeable sheet having an upper and lower surface, the sheet upper surface comprising a build surface for forming a three-dimensional object, the sheet lower surface being positioned on the second channel layer.