Continuous Liquid Interface Production of 3D Objects: An Unconventional Technology and its Challenges and Opportunities

2017 ◽  
Author(s):  
Judah Balli ◽  
Subha Kumpaty ◽  
Vince Anewenter
Keyword(s):  
3D Printing ◽  
Industrial Applications ◽  
Research Literature ◽  
Liquid Interface ◽  
Layer By Layer ◽  
Support Structure ◽  
Practical Applications ◽  
3D Objects ◽  
Continuous Liquid Interface Production ◽  
Part Orientation

The purpose of this paper is to understand and research literature on the “continuous liquid interface production (CLIP)” of 3D objects to address the current challenges. This proprietary technology was originally owned by EiPi Systems but is now being developed by Carbon 3D. Unlike conventional rapid prototyping of printing layer-by-layer to print 3D objects, CLIP is achieved with an oxygen-permeable window made of proprietary glass membrane and the ultraviolet image projection plane below it, which allows the continuous liquid interface to produce 3D objects where photo-polymerization is restricted between the window and the polymerizing part. This process eliminates the time requirement in between the layers resulting in the faster production of 3D objects with a resolution less than 100 microns. It is a known factor that the “supports” play a vital role in any liquid based 3D printing techniques and this does not change in CLIP. In addition to the parameters of support structure like shape, size, strength, ease of removability, surface finish after removal of supports etc, CLIP needs to deal with different types of materials. The support structure needs to be designed according to the respective material’s properties. There are two broad categories of the materials available from Carbon 3D, prototyping resins, and engineering resins. While the prototyping resin is used for the cosmetic models and the engineering resins are used for the practical applications. There are 6 types of engineering resins developed for the end user; of these, EPU and CE are more challenging to work with. EPU parts needs more supports and careful handling till the completion of post processing as the material is soft. CE parts are fragile and needs more systematic handling to complete the successful production. Although printing parts of EPU and CE is more time consuming when compared to the normal CLIP process, they are worth for their unmatched industrial applications. None of the existing 3D printing technologies offers this quality. The support structure, orientation and pot life are the influencing parameters for all resins. In this study, it is statistically proven that by optimizing the part orientation with respect to the slicing of each layer and customized supports; parts are built way better than before. The part orientation is optimized by ensuring each layer is supporting the subsequent layer and minimizing the islands. It is noticed that the results are always better by tilting the part 5 to 10 degrees in both X and Y axis in the build setup and this applies for most of the straight geometrical parts. For parts of specific geometry which can create a vacuum while pulling up the part needs to be oriented in a different way or create a re-closable air passage that can prevent the vacuum being created.

Stress-Strain Behavior of an Octahedral and Octet-Truss Lattice Structure Fabricated Using the CLIP Technology

2017 ◽  
Vol 1142 ◽  
pp. 245-249 ◽  
Author(s):  
Anil Saigal ◽  
John Tumbleston
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Lattice Structure ◽  
Liquid Interface ◽  
Layer By Layer ◽  
Stress Strain ◽  
Strain Behavior ◽  
Octet Truss ◽  
Continuous Liquid Interface Production ◽  
Similar Density

In the rapidly growing field of additive manufacturing (AM), the focus in recent years has shifted from prototyping to manufacturing fully functional, ultralight, ultrastiff end-use parts. This research investigates the stress-strain behavior of an octahedral-and octet-truss lattice structured polyacrylate fabricated using Continuous Liquid Interface Production (CLIP) technology based on 3D printing and additive manufacturing processes. Continuous Liquid Interface Production (CLIP) is a breakthrough technology that grows parts instead of printing them layer by layer. Lattice structures such as the octahedral-and octet-truss lattice have recently attracted a lot of attention since they are often structurally more efficient than foams of a similar density made from the same material, and the ease with which these structures can now be produced using 3D printing and additive manufacturing. This research investigates the stress-strain behavior under compression of an octahedral-and octet-truss lattice structured polyacrylate fabricated using CLIP technology

scholarly journals 3D-printing on textiles – an investigation on adhesion properties of the produced composite materials

2021 ◽  
Vol 28 (6) ◽  
Author(s):  
Maryna Gorlachova ◽  
Boris Mahltig
Keyword(s):  
3D Printing ◽  
Adhesive Properties ◽  
Adhesion Properties ◽  
Practical Applications ◽  
3D Print ◽  
3D Objects ◽  
Textile Fabrics ◽  
Polylactide Acid ◽  
Polyamide 6.6 ◽  
Textile Sector

AbstractThe actual paper is related to adhesive properties of 3D objects printed on cotton textile fabrics. For practical applications of 3D prints in the textile sector, the adhesion of the printed object on the textile substrate is an important issue. In the current study, two different types of polymers are printed on cotton – polylactide acid (PLA) and polyamide 6.6 (Nylon). Altogether six cotton fabrics differing in structure, weight and thickness are evaluated. Also, the effect of washing and enzymatic desizing is investigated. For printing parameters, best results are gained for elevated process temperatures, intermediate printing speed and low Z-distance between printing head and substrate. Also, a textile treatment by washing and desizing can improve the adhesion of an afterwards applied 3D print. The presented results are quite useful for future developments of 3D printing applications on textile substrates, e.g. to implement new decorative features or protective functions.

scholarly journals Extrusion-Based 3D Printing of Ceramic Pastes: Mathematical Modeling and In Situ Shaping Retention Approach

Materials ◽  
2021 ◽  
Vol 14 (5) ◽  
pp. 1137
Author(s):  
Fuwen Hu ◽  
Tadeusz Mikolajczyk ◽  
Danil Yurievich Pimenov ◽  
Munish Kumar Gupta
Keyword(s):  
3D Printing ◽  
Digital Control ◽  
Digital Fabrication ◽  
Industrial Applications ◽  
Drying Kinetics ◽  
Ease Of Use ◽  
Layer By Layer ◽  
Thin Wall ◽  
Shape Retention

Extrusion-based three-dimensional (3D) printing methods are preferred and emerging approaches for freely digital fabrication of ceramics due to ease of use, low investment, high utilization of materials, and good adaptability to multi-materials. However, systematic knowledge still lacks an explanation for what is their 3D printability. Moreover, some uncontrollable factors including extrudate shape retention and nonuniform drying inevitably limit their industrial applications. The purpose of this research was to present a new shaping retention method based on mathematical synthesis modeling for extrusion-based 3D-printing of ceramic pastes. Firstly, the steady-state equilibrium equation of the extrusion process was derived to provide clearer theoretical indications than purely experimental methods. Furthermore, a mathematical description framework was synthesized to better understand the extrusion-based 3D-printing of ceramic pastes from several realms: pastes rheology, extrudability, shape-holdability, and drying kinetics. Secondly, for eliminating shaping drawbacks (e.g., deformation and cracks) originating from non-digital control factors, we put forward a digital shape-retention technology inspired by the generalized drying kinetics of porous materials, which was different from existing retention solutions, e.g., freezing retention, thermally induced gelation, and using removable support structures. In addition, we developed an in situ hot air flow drying device easily attached to the nozzle of existing 3D printers. Confirmatory 3D-printing experiments of thin-walled cone-shape benchmark parts and the fire arrowhead-like object clearly demonstrated that the presented shape-retention method not only upgraded layer-by-layer forming capability but also enabled digital control of extrudate solidification. In addition, many more experimental results statistically showed that both fully solid parts and purely thin-wall parts had higher dimensional accuracy and better surface quality than the offline drying method. The 3D printed ceramic products with complex profiled surfaces conceivably demonstrated that our improved extrusion-based 3D-printing process of ceramic pastes has game-changing potentials beyond the traditional craftsmanship capacity.

scholarly journals Layerless fabrication with continuous liquid interface production

2016 ◽  
Vol 113 (42) ◽  
pp. 11703-11708 ◽  
Author(s):  
Rima Janusziewicz ◽  
John R. Tumbleston ◽  
Adam L. Quintanilla ◽  
Sue J. Mecham ◽  
Joseph M. DeSimone
Keyword(s):  
Mechanical Properties ◽  
Continuous Production ◽  
Fundamental Principle ◽  
Liquid Interface ◽  
Layer By Layer ◽  
Multiple Indicators ◽  
Alternative Approach ◽  
Anisotropic Mechanical Properties ◽  
Continuous Liquid Interface Production ◽  
Surface Finish Effect

Despite the increasing popularity of 3D printing, also known as additive manufacturing (AM), the technique has not developed beyond the realm of rapid prototyping. This confinement of the field can be attributed to the inherent flaws of layer-by-layer printing and, in particular, anisotropic mechanical properties that depend on print direction, visible by the staircasing surface finish effect. Continuous liquid interface production (CLIP) is an alternative approach to AM that capitalizes on the fundamental principle of oxygen-inhibited photopolymerization to generate a continual liquid interface of uncured resin between the growing part and the exposure window. This interface eliminates the necessity of an iterative layer-by-layer process, allowing for continuous production. Herein we report the advantages of continuous production, specifically the fabrication of layerless parts. These advantages enable the fabrication of large overhangs without the use of supports, reduction of the staircasing effect without compromising fabrication time, and isotropic mechanical properties. Combined, these advantages result in multiple indicators of layerless and monolithic fabrication using CLIP technology.

Mass Customization: Reuse of Digital Slicing for Additive Manufacturing

2017 ◽  
Vol 17 (2) ◽  
Author(s):  
Tsz-Ho Kwok ◽  
Hang Ye ◽  
Yong Chen ◽  
Chi Zhou ◽  
Wenyao Xu
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Mass Customization ◽  
Three Dimensional ◽  
Small Variation ◽  
Liquid Interface ◽  
Homogeneous Group ◽  
Experimental Results ◽  
Continuous Liquid Interface Production ◽  
Very High

Additive manufacturing, also known as three-dimensional (3D) printing, enables production of complex customized shapes without requiring specialized tooling and fixture, and mass customization can then be realized with larger adoption. The slicing procedure is one of the fundamental tasks for 3D printing, and the slicing resolution has to be very high for fine fabrication, especially in the recent developed continuous liquid interface production (CLIP) process. The slicing procedure is then becoming the bottleneck in the prefabrication process, which could take hours for one model. This becomes even more significant in mass customization, where hundreds or thousands of models have to be fabricated. We observe that the customized products are generally in a same homogeneous class of shape with small variation. Our study finds that the slicing information of one model can be reused for other models in the same homogeneous group under a properly defined parameterization. Experimental results show that the reuse of slicing information has a maximum of 50 times speedup, and its utilization is dropped from more than 90% to less than 50% in the prefabrication process.

Continuous liquid interface production of 3D objects

Science ◽  
2015 ◽  
Vol 347 (6228) ◽  
pp. 1349-1352 ◽  
Author(s):  
J. R. Tumbleston ◽  
D. Shirvanyants ◽  
N. Ermoshkin ◽  
R. Janusziewicz ◽  
A. R. Johnson ◽  
...  
Keyword(s):  
Liquid Interface ◽  
3D Objects ◽  
Continuous Liquid Interface Production

scholarly journals Multimodal Freezing System for Cryogenic 3D Printing

2021 ◽  
Author(s):  
Pushkar Prakash Kamble ◽  
Subodh Chavan ◽  
Rajendra Hodgir ◽  
Gopal Gote ◽  
K P Karunakaran ◽  
...  
Keyword(s):  
3D Printing ◽  
Heat Removal ◽  
Layer By Layer ◽  
Vapor Compression ◽  
Cooling Rates ◽  
Co2 Gas ◽  
3D Objects ◽  
Rapid Injection ◽  
Vapor Compression Refrigeration ◽  
High Cooling Rates

Abstract Cryogenic 3D Printing (Cryo-3DP) creates 3D objects by deposition-then-freezing of aqueous solutions of various materials layer-by-layer. The process generally takes place at the temperature ranging from -20 °C to -25°C. At the beginning of the process, cryo-3DP demands a high cooling rate to reduce the work envelope’s temperature rapidly. After the work envelope reaches the working temperature (-20 to -25°C), lower cooling rates are enough. The proposed multimodal freezing system uses two modes of cooling. Rapid injection of the CO2 gas in the chamber is suitable for achieving high cooling rates (0.5 °Cs-1) initially and Vapor Compression Refrigeration (VCR) for sustained heat removal from the system (0.5 °Cmin-1). The results show that the proposed multimodal system performs faster than the conventional system.

Mass Customization: Reuse of Digital Slicing for Additive Manufacturing

2016 ◽  
Author(s):  
Tsz-Ho Kwok ◽  
Hang Ye ◽  
Yong Chen ◽  
Chi Zhou ◽  
Wenyao Xu
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Mass Customization ◽  
Small Variation ◽  
Liquid Interface ◽  
Fabrication Process ◽  
Homogeneous Group ◽  
Experimental Results ◽  
Continuous Liquid Interface Production ◽  
Very High

Additive manufacturing, also known as 3D printing, enables production of complex customized shapes without requiring specialized tooling and fixture, and mass customization can then be realized with larger adoption. The slicing procedure is one of the fundamental tasks for 3D printing, and the slicing resolution has to be very high for fine fabrication, especially in the recent developed Continuous Liquid Interface Production (CLIP) process. The slicing procedure is then becoming the bottleneck in the pre-fabrication process, which could take hours for one model. This becomes even more significant in mass customization, where hundreds or thousands of models have to be fabricated. We observe that the customized products are generally in a same homogeneous class of shape with small variation. Our study finds that the slicing information of one model can be reused for other models in the same homogeneous group under a properly defined parameterization. Experimental results show that the reuse of slicing information have a maximum of 50 times speedup, and its utilization is dropped from more than 90% to less than 50% in the pre-fabrication process.

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