Additive manufacturing processes such as 3D printing use time-consuming, stepwise layer-by-layer approaches for object fabrication. We demonstrate the continuous production of monolithic polymeric parts with feature resolution below 100 micrometers. Continuous liquid interface production (CLIP) is achieved with an oxygen-permeable window below the ultraviolet image projection plane, which creates a “dead zone” (persistent liquid interface) where photopolymerization is inhibited between the window and the polymerizing part. We define critical control parameters and show that complex solid parts can be drawn out of the resin at rates of hundreds of millimeters per hour. These print speeds allow parts to be produced in minutes instead of hours.<br/>Additionally, we show that CLIP enables a wide range of new and exciting chemistries. These include: tough, resilient elastomers; rigid, tough, impact resistant plastics with excellent abrasion resistance; flexible materials capable of producing living hinges; high-temperature cyanate ester resins; and many more. Our materials are paving the way for functional prototyping and manufacturing across a range of industries including automotive, footwear, medical, aerospace, wearables, and countless others.<br/>The combination of rapid, layerless printing with high-performance engineering polymers having a range of mechanical properties represents a major step toward fulfilling the promise of additive manufacturing.

Future fabricated with light: Rethinking materials for 3D manufacturing

254th National Meeting (2017)

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