In an example implementation, a method of printing a multi-structured three-dimensional (3D) object includes forming a layer of sinterable material. The method includes processing a first portion of the sinterable material using first set of processing parameters and processing a second portion of the sinterable material using a second set of processing parameters. The processed first and second portions form, respectively, parts of a first and second structure of a multi-structured 3D object.

This invention relates to printable high strength/toughness polymerizable material systems for making dental products such as artificial teeth, dentures, splints, veneers, inlays, onlays, orthodontic appliances, aligners, copings, frame patterns, crowns and bridges and the like. A DLP, stereolithography, modified or their modification and combination based printer is used to cure polymerizable material in several different methods of this invention to build-up the object. The resulting three-dimensional object has good dimensional stability.

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, intermittently irradiating the build region with light through the optically transparent member to form a solid polymer from the polymerizable liquid, and continuously or intermittently advancing the carrier away from the build surface to form the three-dimensional object from the solid polymer. In some embodiments, the filling, irradiating, and/or advancing steps are carried out while also concurrently: (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 comprising the polymerizable liquid in partially cured form.

Three-dimensional effect or structure with a strong bond may be achieved on any surface such as on wood, stone, paper, ceramic, and rubber/polymer, sponge/foam, cloth, and glass, cement, building structures or metals. Before application of tile 3D structure, the surface is first prepared with at least on a layer that can bind a subsequent layer. This tie (compatible) layer material may comprise of the adhesive layer and another tie (compatible) layer such as thermoplastic film or coating. 3D printing filament materials with a different set of properties are combined using unique methods, apparatus to produce new structures, effects or parts with a unique combination of properties. Continuous application of tie layer and 3D printing for unique small or large objects can be achieved.

A method for additive manufacturing includes: at a build tray arranged over a build window and containing a resin reservoir of a resin, heating the resin reservoir toward a target bulk resin temperature less than a heat deflection temperature of the resin in a photocured state; at a resin interface between a surface of the build window and the resin reservoir, heating an interface layer of the resin reservoir toward a target reaction temperature; and, in response to the resin reservoir exhibiting a first temperature proximal the target bulk resin temperature and to the interface layer exhibiting a second temperature proximal the target reaction temperature: at the resin interface, selectively photocuring a first volume of the resin to form a first layer of a build adhered to a build platform; and retracting the build platform away from the build window.

A method for additive manufacturing includes: at a build tray arranged over a build window and containing a resin reservoir of a resin, heating the resin reservoir toward a target bulk resin temperature less than a heat deflection temperature of the resin in a photocured state; at a resin interface between a surface of the build window and the resin reservoir, heating an interface layer of the resin reservoir toward a target reaction temperature; and, in response to the resin reservoir exhibiting a first temperature proximal the target bulk resin temperature and to the interface layer exhibiting a second temperature proximal the target reaction temperature: at the resin interface, selectively photocuring a first volume of the resin to form a first layer of a build adhered to a build platform; and retracting the build platform away from the build window.

An additive manufacturing machine includes: a resin support which has at least a portion which is transparent, wherein the resin support defines a build surface; a material depositor operable to deposit a resin which is radiant-energy-curable onto the build surface; at least two build stations, each build station including: a stage positioned adjacent the build zone and configured to hold a stacked arrangement of one or more cured layers of the resin; one or more actuators operable to manipulate a relative position of the stage and the build surface; and at least one radiant energy apparatus positioned opposite to the stage, and operable to generate and project radiant energy in a predetermined pattern.

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. Often, the polyurethane methacrylate polymer has a weight average molecular weight of 8,000 g/mol or greater. The present disclosure further provides an article and methods thereof.

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.

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.