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WO2015197495A1 - Printing device and method for 3d printing - Google Patents

Printing device and method for 3d printing Download PDF

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Publication number
WO2015197495A1
WO2015197495A1 PCT/EP2015/063840 EP2015063840W WO2015197495A1 WO 2015197495 A1 WO2015197495 A1 WO 2015197495A1 EP 2015063840 W EP2015063840 W EP 2015063840W WO 2015197495 A1 WO2015197495 A1 WO 2015197495A1
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WO
WIPO (PCT)
Prior art keywords
silicone
liquid silicone
silicone material
printing
loaded
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2015/063840
Other languages
French (fr)
Inventor
Maarten VAN LIEROP
Rick Gerhardus NIJKAMP
Dave BEAUMONT
Hans KROES
Edward Theodorus Maria BERBEN
Godefridus Johannes Verhoeckx
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Koninklijke Philips NV
Original Assignee
Koninklijke Philips NV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Koninklijke Philips NV filed Critical Koninklijke Philips NV
Publication of WO2015197495A1 publication Critical patent/WO2015197495A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
    • B29C64/135—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses

Definitions

  • the invention concerns a printing device and a printing method for 3D printing of objects, and in particular optical elements.
  • the invention furthermore concerns optical elements printed by such a printing device and/or printing method.
  • 3D printing which is a rapidly developing technical area within which a wide variety of methods are known, provides for a higher degree of geometrical freedom when printing objects.
  • One 3D printing method which is particularly suitable for printing optical elements is VAT photo-polymerization (ASTM International Committee F42 (2012)) in which objects are 3D printed by means of photopolymerization. More particularly, liquid photopolymers are exposed to UV light to turn the liquid photopolymers into solids. This process is also known in publications as stereolithography.
  • WO 2012/166505 Al describes the use of stereolithography to produce door handles for vehicles. It is proposed to use an UV curable photopolymer in the form of a powder or water mixture and to cure the photopolymer by means of a UV laser immediately after deposition on a platform or on a previously cured layer, thereby building up the door handle in successive layers.
  • This method does not, however, alleviate the problems derived from UV curing, namely yellowing of the material over time as well as high temperature sensitivity, which in turn results in a shortened lifetime of the thus printed objects. It is noted that the abovementioned problems, while relevant for any printed object, are particularly cumbersome in connection with optical elements as the optical properties of such elements will also be negatively affected.
  • DE- 102010020158 discloses a method for 3D printing an object. This method makes use of a material that comprises an organo-polysiloxane compound.
  • the material is cured by focusing femtosecond infrared laser pulses on an interior volume within the bulk of the material to locally heat the material by two- or multi-photon absorption.
  • the latter induces a chemical curing process that normally requires irradiation with a shorter wavelength, such as ultraviolet radiation. Instead, the chemical curing process energy is now initiated by multi-photon absorption of infrared radiation.
  • this and other objects are achieved by means of a method for 3D printing an object, the method comprising the steps of:
  • the translation platform being adapted for performing a translatory movement in at least one direction, wherein the liquid silicone material (42) is capable of directly absorbing infrared radiation,
  • the method of the present invention makes use of a liquid silicone material that is capable of directly absorbing infrared radiation.
  • the term "directly absorbing” is used to distinguish the absorption process from an indirect absorption process such as multi-photon absorption.
  • Exposing an upper or lower surface of the liquid silicone material instead of an interior volume in the bulk of the material has several advantages. Firstly, the liquid silicone material does not have to be transparent for the radiation used.
  • the method of the invention uses a liquid silicone material that is capable of directly absorbing infrared radiation so that the exposed surface is heated and subsequently cured. Secondly, the method does not rely on a very small beam focus to provide sufficient energy density for curing the material.
  • the method of the present invention works much faster as it allows the use of a continuous beam of infrared radiation, which also means that the exposed surface of the liquid silicone material can be homogeneously heated in a predictable manner. Also, a continuous infrared laser beam can provide radiation of wavelengths well above 2,000 nm while pulsed infrared laser beams typically only provide radiation of a wavelength below about 2,000 nm. Thirdly, more control over the accuracy in the z-direction is obtained.
  • Curing within the bulk of a material typically provides a voxel height accuracy of about 0.5 mm. Compared to this, the present method can provide a much higher accuracy (for example 0.075 mm) by using a scraper to control layer height.
  • such a method allows for improved diversity management or late stage configuration of the objects as well as for customization according to desires, circumstances and needs. Also, the improved geometrical freedom allows for the addition of extra features in the bulk of the material as compared to previous methods such as the 2.5D method mentioned additionally.
  • optical elements examples of objects, such as for example optical elements, are given further below.
  • printing optical elements by means of a method according to the invention is particularly advantageous, as optical elements need to be very resistant to yellowing and need to have very low temperature sensitivity in order to function properly, especially over longer time periods.
  • the scanning device may be a scanning mirror, two mirrors, such as two orthogonally placed mirrors, an array of small mirrors (DLP), a phase modulator or any other device which deflects light.
  • DLP small mirrors
  • the step of providing a layer of a liquid silicone material on a translation platform of a 3D printing device is obtained by depositing or arranging the layer of liquid silicone material on the translation platform of a 3D printing device.
  • the step of providing a layer of a liquid silicone material on a translation platform of a 3D printing device is obtained by moving the translation platform in the at least one direction such as to lower the translation platform into the liquid silicone material.
  • the method comprises the further steps of arranging a substrate on the translation platform, and providing a layer of the liquid silicone material on the substrate.
  • the step of providing a layer of the liquid silicone material comprises scraping off excess liquid silicone material such as to form a layer of liquid silicone material of a predefined thickness.
  • the step of selectively curing the liquid silicone material in successive layers and the step of performing a translatory movement of the translation platform are performed simultaneously.
  • the IR radiation emitted by the light source comprises one or more wavelengths of between 700 nm and 1 mm, between 700 nm and 1000 nm, between 1000 nm and 1 100 nm, between 1400 nm and 1600 nm, between 1900 nm and 2100 nm, between 2900 nm and 3100 nm, between 4000 nm and 7000 nm, or between 9000 nm and 1 1.500 nm.
  • the IR radiation emitted by the light source comprises an intensity of at least 100 kW/mm 2 , at least 200 kW/mm 2 or at least 500 kW/mm 2 .
  • the IR radiation emitted by the light source comprises an intensity of between 1 kW/mm 2 to 10 kW/mm 2 or even of between 100 mW/mm 2 to 100 GW/mm 2 .
  • the liquid silicone material is chosen from the group comprising an optical grade silicone, a silicone with a refractive index of more than 1.35, a silicone rubber, a silicone elastomer, a reactive silicone, a loaded silicone and combinations thereof as the choice of refractive index affects the diffractive and refractive properties of the material.
  • liquid silicone material is loaded with any one or more of zirconium, zirconia, aluminum, alumina, silica, titanium, a titanium oxide, a phosphor luminescent material and a quantum dot material and combinations thereof.
  • a method for 3D printing of objects is obtained with which a wide variety of properties of the liquid silicone material may be adjusted according to desire.
  • properties include, but are not limited to, temperature sensitivity, curing temperature, hardness, strength, adhesion and how hydrophobic the liquid silicone material is.
  • a method for 3D printing of objects is obtained with which the printed object may be provided with advantageous properties determined by the material with which the silicone is loaded. For instance, loading the silicone material with particles of another material or element may influence the refractive index, the light reflective properties, the transparency and/or the absorption of the liquid silicone material and thereby of the object printed by means of the method according to the invention. Other properties such as hardness, strength, conductivity and temperature sensitivity may also be affected by loading the liquid silicone material.
  • the step of selectively curing the liquid silicone material comprises an exposure of the surface of the liquid silicone material to IR radiation having a duration of between 1 millisecond and 1 minute for each of the successive layers.
  • the exposure of the surface of the liquid silicone material to IR radiation may in other embodiments have a duration of up to as long as 1 hour.
  • the light source is a laser, thereby providing for a light source emitting a particularly well defined beam with a particularly well defined wavelength of radiation.
  • the light source is adapted for being adjustable with respect to the wavelength(s) and/or intensity of the emitted beam of IR radiation, and the method further comprises the step of adjusting the wavelength(s) and/or intensity of the emitted beam of IR radiation in accordance with the properties of the liquid silicone material.
  • the method comprises the further steps of arranging a LED and/or another object on the translation platform and printing the object directly or indirectly on the LED and/or the other object.
  • a method for 3D printing of objects is obtained with which a compound object may be provided in a particularly simple and time-efficient and thus also cost-efficient manner.
  • the above and other objects are achieved by means of a 3D printing device adapted for printing an object, the 3D printing device comprising:
  • a translation platform adapted for performing a translatory movement in at least one direction
  • a light source adapted for, in operation, emitting a beam of infrared (IR) radiation
  • a scanning device adapted for moving the beam of IR radiation across a surface of a liquid silicone material such as to selectively cure the liquid silicone material in successive layers according to a pre-defined pattern
  • the translation platform furthermore being adapted to perform the translatory movement of the translation platform in the at least one direction upon finishing the curing of each of the successive layers.
  • the IR radiation emitted by the light source comprises one or more wavelengths of between 700 nm and 1 mm, between 700 nm and 1000 nm, between 1000 nm and 1 100 nm, between 1400 nm and 1600 nm, between 1900 nm and 2100 nm, between 2900 nm and 3100 nm, between 4000 nm and 7000 nm, or between 9000 nm and
  • the liquid silicone material is a silicone chosen from the group comprising an optical grade silicone, a silicone with a refractive index of more than 1.4, a zirconium loaded silicone, a zirconia loaded silicone, an aluminum loaded silicone, an alumina loaded silicone, a silica loaded silicone, a titanium loaded silicone, a silicone loaded with a titanium oxide, a silicone loaded with a phosphor luminescent material, a silicone loaded with a quantum dot material, a silicone rubber, a silicone elastomer, a reactive silicone, a loaded silicone and combinations thereof.
  • the light source is adapted such that the wavelength(s) and/or intensity of the emitted beam of IR radiation are adjustable and/or the light source is a laser.
  • the device is adapted for printing the object directly or indirectly on a substrate and/or on a LED and/or another object.
  • the device comprises a device for providing a layer of liquid silicone material on the translation platform, e.g. by depositing or adding the layer of liquid silicone material on the translation platform.
  • Such a device may be any suitable device for providing a layer of liquid silicone material on the translation platform, such as but not limited to, a nozzle, a dispenser or the like.
  • the device comprises a device for scraping off excess liquid silicone material such as to form a layer of liquid silicone material of a predefined thickness.
  • the invention furthermore concerns an optical element manufactured by means of a method according to the first aspect of the invention and/or a device according to the second aspect of the invention.
  • such an optical element may be, but is not limited to, any one of a concave lens, a convex lens, a diffuser, a refractive element, a diffractive element, an optical filter, a reflector, a grating, a pinhole, a light guide, a mirror and any combination thereof and/or wherein the object is printed directly or indirectly on a LED.
  • the optical element is printed directly or indirectly on a LED and/or on another object or optical element.
  • Fig. 1 shows a cross-sectional view of a first embodiment of a 3D printing device according to the second aspect of the invention suitable for performing a method according to the first aspect of the invention.
  • Fig. 2 shows a perspective view of a second and more detailed embodiment of a 3D printing device according to the second aspect of the invention suitable for performing a method according to the first aspect of the invention.
  • Fig. 3 shows three optical elements in the form of lenses manufactured by means of a method according to the first aspect of the invention and/or a 3D printing device according to the second aspect of the invention.
  • Fig. 4 shows an alternative embodiment of an object manufactured by means of a method according to the first aspect of the invention and/or a 3D printing device according to the second aspect of the invention.
  • Fig. 1 shows a first embodiment of a 3D printing device 1 according to the invention.
  • the 3D printing device 1 generally comprises a vat 41 containing a liquid silicone material 42, a translation platform 2, a light source 31 adapted for, in operation, emitting a beam 33 of infrared (IR) radiation and a scanning device 32 adapted for moving the beam 33 across a surface 44 of the liquid silicone material 42.
  • IR infrared
  • the translation platform 2 comprises a piston 21 and a platform 22 and is adapted for performing a translatory movement in at least one direction illustrated on Fig. 2 by the arrow 51.
  • Such translation platforms may be of various constructions and are generally known in the art of 3D printing.
  • the translation platform 2 may be adapted for performing a translatory movement in more than one direction, for instance both in the direction illustrated on Fig. 2 by the arrow 51 and in one or more directions perpendicular to the direction illustrated in Fig. 2 by the arrow 5 lor in other words in a plane parallel to the platform 22.
  • a LED or another suitable light source may be arranged on the platform 22 prior to commencing the 3D printing process according to the invention such that the object may be printed directly onto the LED or other suitable light source. It is also feasible to arrange another suitable object on the platform 22 such that the object may be printed directly onto this object. For instance such an object may be a previously printed object, thus enabling the printing of compound objects.
  • the LED, light source or other suitable object may be provided with a surface layer, e.g. a coating, or another intermediate element, and the object may be printed directly onto this layer or intermediate element and thus indirectly onto the LED or other suitable light source.
  • the scanning device 32 may be any suitable scanning device adapted for redirecting the beam 33 provided by the light source 31 such as to move the beam 33 across a surface 44 of the liquid silicone material 42.
  • the scanning device 32 is a mirror arranged such as to be tiltable by means of a suitable type of actuator (not shown) in a direction illustrated by the arrow 35.
  • Such scanning devices 32 as well as other suitable scanning devices are generally known in the art of 3D printing.
  • the beam 33 is kept stationary or even is a stationary beam (i.e. the scanning device 32 may then be omitted) and the platform 22 of the translation platform 2 is adapted to be movable in a plane parallel with the upper surface of the platform 22 and thus the liquid silicone material 44 and that curing is performed by moving the platform 22 in a predetermined pattern in the plane parallel with the upper surface of the platform 22.
  • the vat 41 may be any suitable type of vessel, container, receptacle or the like capable of containing a liquid silicone material 42 and of accommodating the platform 22 of the translation platform 2. Such vats 41 may be of various constructions and are generally known in the art of 3D printing.
  • the light source 3 1 may be any suitable light source adapted for emitting a beam 33 of IR radiation.
  • the light source 31 is an IR laser.
  • IR radiation is defined as electromagnetic radiation comprising a wavelength in the approximate interval of 700 nm to 1 mm.
  • the light source 31 is therefore adapted for emitting IR radiation having one or more wavelengths falling within the approximate interval of 700 nm to 1 mm.
  • the light source 31 is adapted for emitting IR radiation having one or more wavelengths falling within a narrower wavelength range, such as but not limited to between 700 nm and 1000 nm, between 1000 nm and 1 100 nm, between 1400 nm and 1600 nm, between 1900 nm and 2100 nm, between 2900 nm and 3100 nm, between 4000 nm and 7000 nm, or between 9000 nm and 1 1.500 nm.
  • the light source 31 is furthermore adapted for enabling the wavelength of the beam 33 of IR radiation to be adjusted.
  • the light source 31 may be chosen to emit IR radiation of a wavelength or wavelength range chosen in accordance with the curing properties of the particular liquid silicone material chosen. In some embodiments the wavelength or wavelength range of the beam 33 of IR radiation may be adjusted in accordance with the curing properties of the particular liquid silicone material chosen.
  • the beam 33 of IR radiation emitted by the light source 31 may comprise a predefined intensity, such as but not being limited to an intensity of at least 100 kW/mm 2 , at least 200 kW/mm 2 or at least 500 kW/mm 2 .
  • the light source 31 may be chosen and/or the intensity of the beam 33 of IR radiation may be adjusted in accordance with the curing properties of the particular liquid silicone material chosen.
  • the liquid silicone material 42 may be any suitable liquid silicone material capable of being cured by means of IR radiation. Many such liquid silicone materials are available on the market. Thus, the liquid silicone material 42 may be chosen freely according to the desired properties of the object to be printed.
  • a silicone material is a polymer including silicon in combination with carbon, hydrogen and oxygen and is also known as polymerized siloxane or
  • Silicone materials have many characteristics that make these materials advantageous in many applications. Such characteristics include low thermal conductivity, low chemical reactivity, low toxicity, being water repellant, being non-supportive to microbiological growth and being oxygen and ozone resistant. Furthermore, silicone materials have a high thermal stability, which makes these materials particularly well suited for IR curing.
  • Non-limiting examples of liquid silicone materials 42 are optical grade silicones, silicones with a refractive index of more than 1.4, silicone rubbers, silicone elastomers, reactive silicones, loaded silicones and combinations thereof.
  • Reactive silicones may for instance be obtained from the company Gelest, Inc. of Morrisville, Pennsylvania, USA.
  • the liquid silicone material 42 may be loaded with a wide variety of materials depending on the property it is desired to affect.
  • Non-limiting examples of possible loading materials are zirconium, zirconia, aluminum, alumina, silica, titanium, any titanium oxide a phosphor luminescent material, a quantum dot material and combinations thereof.
  • Fig. 2 a perspective view of a 3D printing device 10 according to a second embodiment of the invention is shown. In the following the 3D printing device 10 will be described with respect to the point on which it differs from that of Fig. 1.
  • the 3D printing device 10 differs from that of Fig. 1 in that the translation platform 2 comprises an elevator 23 rather than a piston 21 and furthermore comprises a sweeper 24.
  • the elevator executes the translatory movement of the platform 22 in the direction illustrated by the arrow 51.
  • the sweeper 24 is adapted to be movable in the direction illustrated by the arrow 52 such as to sweep across the surface 44 of the liquid silicone material 42 upon finishing each successive layer of the cured silicone structure 43. Thereby liquid silicone material 42 is distributed evenly on top of the uppermost layer of the successive layers of the cured silicone structure 43 forming a layer of a predefined thickness.
  • the 3D printing device 1 described in connection with Fig. 1 may also be provided with a sweeper such as the sweeper 24 described above.
  • the 3D printing device 10 furthermore differs from that of Fig. 1 in that an object, in Fig. 2 shown as two lenses 34, is arranged between the light source 31 and the scanning device 32.
  • an object serves the purpose of shaping the beam 33 of IR radiation, here by focusing it and optionally also collimating it, such as to enable a higher precision in the curing process and consequently a higher precision in the printing of the object.
  • the scanning device 32 is a mirror.
  • Figs. 3 and 4 examples of objects printed by means of a 3D printing device and/or a 3D printing method according to the invention are shown.
  • the 3D printing device and the 3D printing method according to the invention is as mentioned above particularly suitable for printing optical elements. It is noted that the examples shown in Fig. 3 and 4 are entirely non-limiting as any feasible object or structure may in principle be printed by means of a 3D printing device and/or a 3D printing method according to the invention.
  • Fig. 3 shows three so-called inverted lenses 6a, 6b and 6c.
  • the inverted lenses 6a, 6b and 6c are examples of shapes comprising an overhang and/or an undercut, such shapes being particularly simple to print by means of a 3D printing device and/or a 3D printing method according to the invention.
  • Fig. 4 shows a structure 7 comprising an upper surface and a lower surface connected by means of a number - here four - pillars or cylinders.
  • a structure 7 is an example of a shape comprising a structure which cannot readily be made by molding as it would not release from the mold.
  • Such a structure 7 is also particularly simple to print by means of a 3D printing device and/or a 3D printing method according to the invention.
  • optical elements which may advantageously be printed by means of a 3D printing device and/or a 3D printing method according to the invention are concave lenses, convex lenses, diffusers, refractive elements, diffractive elements, optical filters, reflectors, gratings, pinhole structures, light guides, mirrors and even combinations of such elements.
  • curing of the liquid silicone material 42 is performed from the surface 44 of the liquid silicone material through the open upper end of the vat 41.
  • the surface of the liquid silicone material across which the beam 33 of IR radiation emitted by a light source 31 is moved in a pre-defined pattern to cure the layer of liquid silicone material may both be an upper and a lower surface of the liquid silicone material.
  • the vat 41 is preferably made of a material being at least partially transparent to IR radiation or at least to IR radiation of specific wavelengths.
  • the translation platform 2 is moved in the at least one direction such as to lower and submerge the translation platform 2 into the liquid silicone material 42 such as to allow the liquid silicone material to flow over the translation platform 2.
  • the translation platform 2 may be lowered into the liquid silicone material 42 to a depth corresponding to a predetermined layer thickness.
  • a layer of liquid silicone material 42 on the translation platform 2 of the 3D printing device 1, 10 by depositing or arranging the layer of liquid silicone material 42 on the translation platform 2 of the 3D printing device 1, 10 by means of a suitable device such as a nozzle or a dispenser.
  • the finished object is removed from the liquid silicone material and excess liquid silicone is removed from the finished object.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Ophthalmology & Optometry (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)

Abstract

The invention concerns a method for 3D printing an object (6, 7), the method comprising the steps of providing a layer of a liquid silicone material (42) on a translation platform (2) of a 3D printing device (1, 10) and/or on a previously cured layer of the liquid silicone material arranged on the translation platform, the translation platform being adapted for performing a translatory movement in at least one direction, selectively curing the liquid silicone material in successive layers by moving a beam (33) of IR radiation emitted by a light source (31) across a surface (44) of the liquid silicone material (42) in a pre-defined pattern by means of a scanning device (32), and performing a translatory movement of the translation platform in the at least one direction upon finishing the curing of each of the successive layers. The invention further concerns a corresponding 3D printing device (1, 10).

Description

Printing device and method for 3D printing
FIELD OF THE INVENTION
The invention concerns a printing device and a printing method for 3D printing of objects, and in particular optical elements. The invention furthermore concerns optical elements printed by such a printing device and/or printing method.
BACKGROUND OF THE INVENTION
It is known to make printable optical elements using acrylics cured by ultraviolet (UV) radiation in a 2.5D-process. Optical elements made by UV cured material, however, suffer from yellowing of the material thereby compromising their optical properties over time as well as from a high temperature sensitivity demanding low operating temperatures when using the optical elements, all due to the use of acrylics and of curing by UV radiation. Furthermore, 2.5D-printing is limited in geometrical freedom.
3D printing, which is a rapidly developing technical area within which a wide variety of methods are known, provides for a higher degree of geometrical freedom when printing objects. One 3D printing method which is particularly suitable for printing optical elements is VAT photo-polymerization (ASTM International Committee F42 (2012)) in which objects are 3D printed by means of photopolymerization. More particularly, liquid photopolymers are exposed to UV light to turn the liquid photopolymers into solids. This process is also known in publications as stereolithography.
WO 2012/166505 Al describes the use of stereolithography to produce door handles for vehicles. It is proposed to use an UV curable photopolymer in the form of a powder or water mixture and to cure the photopolymer by means of a UV laser immediately after deposition on a platform or on a previously cured layer, thereby building up the door handle in successive layers.
This method does not, however, alleviate the problems derived from UV curing, namely yellowing of the material over time as well as high temperature sensitivity, which in turn results in a shortened lifetime of the thus printed objects. It is noted that the abovementioned problems, while relevant for any printed object, are particularly cumbersome in connection with optical elements as the optical properties of such elements will also be negatively affected.
DE- 102010020158 discloses a method for 3D printing an object. This method makes use of a material that comprises an organo-polysiloxane compound. The material is cured by focusing femtosecond infrared laser pulses on an interior volume within the bulk of the material to locally heat the material by two- or multi-photon absorption. The latter induces a chemical curing process that normally requires irradiation with a shorter wavelength, such as ultraviolet radiation. Instead, the chemical curing process energy is now initiated by multi-photon absorption of infrared radiation. However, it is still the same chemical curing process as occurs upon irradiation with high-energy (ultraviolet) radiation, which means that also this method does not alleviate the problems already mentioned above, being yellowing of the material over time as well as high temperature sensitivity.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome this problem, and to provide a method and a device for 3D printing of objects with a high degree of geometrical freedom, with which the material does not yellow and with which objects having low temperature sensitivity may be obtained.
According to a first aspect of the invention, this and other objects are achieved by means of a method for 3D printing an object, the method comprising the steps of:
providing a layer of a liquid silicone material on a translation platform of a 3D printing device and/or on a previously cured layer of the liquid silicone material arranged on the translation platform, the translation platform being adapted for performing a translatory movement in at least one direction, wherein the liquid silicone material (42) is capable of directly absorbing infrared radiation,
exposing an upper or lower surface of the liquid silicone material to a beam of infrared radiation emitted by a light source in order to selectively cure the liquid silicone material in successive layers from the surface, wherein the beam is moved across the surface in a pre-defined pattern by means of a scanning device, and
performing a translatory movement of the translation platform in the at least one direction upon finishing the curing of each of the successive layers.
The method of the present invention makes use of a liquid silicone material that is capable of directly absorbing infrared radiation. In the context of the present invention, the term "directly absorbing" is used to distinguish the absorption process from an indirect absorption process such as multi-photon absorption. By selectively curing the liquid silicone material in successive layers by moving a beam of the infrared radiation emitted by the light source across a surface of the liquid silicone material in a pre-defined pattern by means of a scanning device, a method for 3D printing an object is obtained with which the material of the object does not yellow over time and with which objects having a longer life time may be obtained.
By providing a layer of a liquid silicone material on a translation platform of a 3D printing device, and thus by printing the object in a silicone material, a method for 3D printing an object is obtained with which objects not yellowing over time and particularly having a low temperature sensitivity may be obtained. This in turn contributes to prolonging the life time of the objects printed by means of the method according to the invention.
Thereby a method for 3D printing of objects with a high degree of geometrical freedom, with which the material does not yellow and with which objects having low temperature sensitivity is obtained.
Exposing an upper or lower surface of the liquid silicone material instead of an interior volume in the bulk of the material (also referred to as a voxel) has several advantages. Firstly, the liquid silicone material does not have to be transparent for the radiation used. The method of the invention uses a liquid silicone material that is capable of directly absorbing infrared radiation so that the exposed surface is heated and subsequently cured. Secondly, the method does not rely on a very small beam focus to provide sufficient energy density for curing the material. Because such processes are intrinsically slow when large areas/volumes need to be cured (beam focus needs to be moved throughout the complete volume), the method of the present invention works much faster as it allows the use of a continuous beam of infrared radiation, which also means that the exposed surface of the liquid silicone material can be homogeneously heated in a predictable manner. Also, a continuous infrared laser beam can provide radiation of wavelengths well above 2,000 nm while pulsed infrared laser beams typically only provide radiation of a wavelength below about 2,000 nm. Thirdly, more control over the accuracy in the z-direction is obtained.
Curing within the bulk of a material typically provides a voxel height accuracy of about 0.5 mm. Compared to this, the present method can provide a much higher accuracy (for example 0.075 mm) by using a scraper to control layer height.
Furthermore, such a method allows for improved diversity management or late stage configuration of the objects as well as for customization according to desires, circumstances and needs. Also, the improved geometrical freedom allows for the addition of extra features in the bulk of the material as compared to previous methods such as the 2.5D method mentioned additionally.
Examples of objects, such as for example optical elements, are given further below. Compared to other objects, printing optical elements by means of a method according to the invention is particularly advantageous, as optical elements need to be very resistant to yellowing and need to have very low temperature sensitivity in order to function properly, especially over longer time periods.
Furthermore, it is noted that the scanning device may be a scanning mirror, two mirrors, such as two orthogonally placed mirrors, an array of small mirrors (DLP), a phase modulator or any other device which deflects light.
In an embodiment the step of providing a layer of a liquid silicone material on a translation platform of a 3D printing device is obtained by depositing or arranging the layer of liquid silicone material on the translation platform of a 3D printing device.
In an embodiment the step of providing a layer of a liquid silicone material on a translation platform of a 3D printing device is obtained by moving the translation platform in the at least one direction such as to lower the translation platform into the liquid silicone material.
In an embodiment the method comprises the further steps of arranging a substrate on the translation platform, and providing a layer of the liquid silicone material on the substrate.
Thereby a method for 3D printing of objects is obtained with which the object may be printed directly onto another material or object thus obtaining compound objects and/or objects fitted to a particular material or ground shape.
In an embodiment the step of providing a layer of the liquid silicone material comprises scraping off excess liquid silicone material such as to form a layer of liquid silicone material of a predefined thickness.
Thereby a method for 3D printing of objects is obtained with which the individual layers may be provided with a predefined exact thickness according to desire, need and/or purpose, thus providing for an additional design parameter for printing objects.
In an embodiment the step of selectively curing the liquid silicone material in successive layers and the step of performing a translatory movement of the translation platform are performed simultaneously.
Thereby a method for 3D printing of objects is obtained which is faster to perform as compared to the existing methods. In an embodiment the IR radiation emitted by the light source comprises one or more wavelengths of between 700 nm and 1 mm, between 700 nm and 1000 nm, between 1000 nm and 1 100 nm, between 1400 nm and 1600 nm, between 1900 nm and 2100 nm, between 2900 nm and 3100 nm, between 4000 nm and 7000 nm, or between 9000 nm and 1 1.500 nm.
Thereby a method for 3D printing of objects is obtained with which the light source emits IR radiation with one or more wavelengths enabling a particularly fast, durable and/or efficient curing of the liquid elastomer material.
In an embodiment the IR radiation emitted by the light source comprises an intensity of at least 100 kW/mm2, at least 200 kW/mm2 or at least 500 kW/mm2.
In an embodiment the IR radiation emitted by the light source comprises an intensity of between 1 kW/mm 2 to 10 kW/mm 2 or even of between 100 mW/mm 2 to 100 GW/mm2.
Thereby a method for 3D printing of objects is obtained with which the light source emits IR radiation with an intensity enabling a particularly fast, durable and/or efficient curing of the liquid elastomer material.
In an embodiment the liquid silicone material is chosen from the group comprising an optical grade silicone, a silicone with a refractive index of more than 1.35, a silicone rubber, a silicone elastomer, a reactive silicone, a loaded silicone and combinations thereof as the choice of refractive index affects the diffractive and refractive properties of the material.
In an embodiment the liquid silicone material is loaded with any one or more of zirconium, zirconia, aluminum, alumina, silica, titanium, a titanium oxide, a phosphor luminescent material and a quantum dot material and combinations thereof.
By choosing an optical grade silicone a method for 3D printing of objects is obtained with which optical elements of a particularly high quality may be obtained.
By choosing a silicone with a refractive index of more than 1.35 a method for 3D printing of objects is obtained with which for instance lenses and diffractive elements of a particularly high quality may be obtained.
By choosing a silicone elastomer or a silicone rubber a method for 3D printing of objects is obtained with which the printed object may be provided with a particularly high flexibility and a particularly high resistance to stress and strain.
By choosing a reactive silicone a method for 3D printing of objects is obtained with which a wide variety of properties of the liquid silicone material may be adjusted according to desire. Such properties include, but are not limited to, temperature sensitivity, curing temperature, hardness, strength, adhesion and how hydrophobic the liquid silicone material is.
By choosing a loaded silicone, e.g. a silicone loaded with any one or more of the above-mentioned materials, a method for 3D printing of objects is obtained with which the printed object may be provided with advantageous properties determined by the material with which the silicone is loaded. For instance, loading the silicone material with particles of another material or element may influence the refractive index, the light reflective properties, the transparency and/or the absorption of the liquid silicone material and thereby of the object printed by means of the method according to the invention. Other properties such as hardness, strength, conductivity and temperature sensitivity may also be affected by loading the liquid silicone material.
In an embodiment the step of selectively curing the liquid silicone material comprises an exposure of the surface of the liquid silicone material to IR radiation having a duration of between 1 millisecond and 1 minute for each of the successive layers. Thereby a method for 3D printing of objects is obtained which is faster and more efficient as the curing process is faster and more efficient.
It is noted, however, that the exposure of the surface of the liquid silicone material to IR radiation may in other embodiments have a duration of up to as long as 1 hour.
In an embodiment the light source is a laser, thereby providing for a light source emitting a particularly well defined beam with a particularly well defined wavelength of radiation.
In an embodiment the light source is adapted for being adjustable with respect to the wavelength(s) and/or intensity of the emitted beam of IR radiation, and the method further comprises the step of adjusting the wavelength(s) and/or intensity of the emitted beam of IR radiation in accordance with the properties of the liquid silicone material.
Thereby a method for 3D printing of objects is obtained with which the wavelength(s) and/or intensity of the emitted beam of IR radiation may be adapted to be in accordance with the properties of the liquid silicone material and with which the curing of the liquid elastomer material is thus particularly efficient.
In an embodiment the method comprises the further steps of arranging a LED and/or another object on the translation platform and printing the object directly or indirectly on the LED and/or the other object. Thereby a method for 3D printing of objects is obtained with which an LED, or in principle another suitable light source, may be provided with primary and/or secondary optics in a particularly simple and time-efficient and thus also cost-efficient manner.
Furthermore, a method for 3D printing of objects is obtained with which a compound object may be provided in a particularly simple and time-efficient and thus also cost-efficient manner.
According to a second aspect of the invention, the above and other objects are achieved by means of a 3D printing device adapted for printing an object, the 3D printing device comprising:
a translation platform adapted for performing a translatory movement in at least one direction,
a light source adapted for, in operation, emitting a beam of infrared (IR) radiation, and
a scanning device adapted for moving the beam of IR radiation across a surface of a liquid silicone material such as to selectively cure the liquid silicone material in successive layers according to a pre-defined pattern,
the translation platform furthermore being adapted to perform the translatory movement of the translation platform in the at least one direction upon finishing the curing of each of the successive layers.
In an embodiment the IR radiation emitted by the light source comprises one or more wavelengths of between 700 nm and 1 mm, between 700 nm and 1000 nm, between 1000 nm and 1 100 nm, between 1400 nm and 1600 nm, between 1900 nm and 2100 nm, between 2900 nm and 3100 nm, between 4000 nm and 7000 nm, or between 9000 nm and
2 2
1 1.500 nm and/or an intensity of at least 100 kW/mm , at least 200 kW/mm , at least 500 kW/mm 2 , between 1 kW/mm 2 to 10 kW/mm 2 or between 100 mW/mm 2 to 100 GW/mm 2.
In an embodiment the liquid silicone material is a silicone chosen from the group comprising an optical grade silicone, a silicone with a refractive index of more than 1.4, a zirconium loaded silicone, a zirconia loaded silicone, an aluminum loaded silicone, an alumina loaded silicone, a silica loaded silicone, a titanium loaded silicone, a silicone loaded with a titanium oxide, a silicone loaded with a phosphor luminescent material, a silicone loaded with a quantum dot material, a silicone rubber, a silicone elastomer, a reactive silicone, a loaded silicone and combinations thereof. In an embodiment the light source is adapted such that the wavelength(s) and/or intensity of the emitted beam of IR radiation are adjustable and/or the light source is a laser.
In an embodiment the device is adapted for printing the object directly or indirectly on a substrate and/or on a LED and/or another object.
In an embodiment the device comprises a device for providing a layer of liquid silicone material on the translation platform, e.g. by depositing or adding the layer of liquid silicone material on the translation platform.
Such a device may be any suitable device for providing a layer of liquid silicone material on the translation platform, such as but not limited to, a nozzle, a dispenser or the like.
In an embodiment the device comprises a device for scraping off excess liquid silicone material such as to form a layer of liquid silicone material of a predefined thickness.
The invention furthermore concerns an optical element manufactured by means of a method according to the first aspect of the invention and/or a device according to the second aspect of the invention.
In an embodiment such an optical element may be, but is not limited to, any one of a concave lens, a convex lens, a diffuser, a refractive element, a diffractive element, an optical filter, a reflector, a grating, a pinhole, a light guide, a mirror and any combination thereof and/or wherein the object is printed directly or indirectly on a LED.
In an embodiment the optical element is printed directly or indirectly on a LED and/or on another object or optical element.
It is noted that the invention relates to all possible combinations of features recited in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
This and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing embodiment(s) of the invention.
Fig. 1 shows a cross-sectional view of a first embodiment of a 3D printing device according to the second aspect of the invention suitable for performing a method according to the first aspect of the invention.
Fig. 2 shows a perspective view of a second and more detailed embodiment of a 3D printing device according to the second aspect of the invention suitable for performing a method according to the first aspect of the invention. Fig. 3 shows three optical elements in the form of lenses manufactured by means of a method according to the first aspect of the invention and/or a 3D printing device according to the second aspect of the invention.
Fig. 4 shows an alternative embodiment of an object manufactured by means of a method according to the first aspect of the invention and/or a 3D printing device according to the second aspect of the invention.
DETAILED DESCRIPTION
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which currently preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and fully convey the scope of the invention to the skilled person.
Fig. 1 shows a first embodiment of a 3D printing device 1 according to the invention. The 3D printing device 1 generally comprises a vat 41 containing a liquid silicone material 42, a translation platform 2, a light source 31 adapted for, in operation, emitting a beam 33 of infrared (IR) radiation and a scanning device 32 adapted for moving the beam 33 across a surface 44 of the liquid silicone material 42.
The translation platform 2 comprises a piston 21 and a platform 22 and is adapted for performing a translatory movement in at least one direction illustrated on Fig. 2 by the arrow 51. Such translation platforms may be of various constructions and are generally known in the art of 3D printing. In some embodiments the translation platform 2 may be adapted for performing a translatory movement in more than one direction, for instance both in the direction illustrated on Fig. 2 by the arrow 51 and in one or more directions perpendicular to the direction illustrated in Fig. 2 by the arrow 5 lor in other words in a plane parallel to the platform 22.
In one embodiment a LED or another suitable light source may be arranged on the platform 22 prior to commencing the 3D printing process according to the invention such that the object may be printed directly onto the LED or other suitable light source. It is also feasible to arrange another suitable object on the platform 22 such that the object may be printed directly onto this object. For instance such an object may be a previously printed object, thus enabling the printing of compound objects. In a further embodiment the LED, light source or other suitable object may be provided with a surface layer, e.g. a coating, or another intermediate element, and the object may be printed directly onto this layer or intermediate element and thus indirectly onto the LED or other suitable light source.
The scanning device 32 may be any suitable scanning device adapted for redirecting the beam 33 provided by the light source 31 such as to move the beam 33 across a surface 44 of the liquid silicone material 42. In one advantageous embodiment shown in more detail in Fig. 2 the scanning device 32 is a mirror arranged such as to be tiltable by means of a suitable type of actuator (not shown) in a direction illustrated by the arrow 35. Such scanning devices 32 as well as other suitable scanning devices are generally known in the art of 3D printing.
In an alternative it is feasible that the beam 33 is kept stationary or even is a stationary beam (i.e. the scanning device 32 may then be omitted) and the platform 22 of the translation platform 2 is adapted to be movable in a plane parallel with the upper surface of the platform 22 and thus the liquid silicone material 44 and that curing is performed by moving the platform 22 in a predetermined pattern in the plane parallel with the upper surface of the platform 22.
The vat 41 may be any suitable type of vessel, container, receptacle or the like capable of containing a liquid silicone material 42 and of accommodating the platform 22 of the translation platform 2. Such vats 41 may be of various constructions and are generally known in the art of 3D printing.
Irrespective of the embodiment, the light source 3 1 may be any suitable light source adapted for emitting a beam 33 of IR radiation. In one advantageous embodiment the light source 31 is an IR laser.
Generally, IR radiation is defined as electromagnetic radiation comprising a wavelength in the approximate interval of 700 nm to 1 mm. In one embodiment the light source 31 is therefore adapted for emitting IR radiation having one or more wavelengths falling within the approximate interval of 700 nm to 1 mm. In other embodiments the light source 31 is adapted for emitting IR radiation having one or more wavelengths falling within a narrower wavelength range, such as but not limited to between 700 nm and 1000 nm, between 1000 nm and 1 100 nm, between 1400 nm and 1600 nm, between 1900 nm and 2100 nm, between 2900 nm and 3100 nm, between 4000 nm and 7000 nm, or between 9000 nm and 1 1.500 nm. In some embodiments the light source 31 is furthermore adapted for enabling the wavelength of the beam 33 of IR radiation to be adjusted. In some embodiments the light source 31 may be chosen to emit IR radiation of a wavelength or wavelength range chosen in accordance with the curing properties of the particular liquid silicone material chosen. In some embodiments the wavelength or wavelength range of the beam 33 of IR radiation may be adjusted in accordance with the curing properties of the particular liquid silicone material chosen.
Furthermore, the beam 33 of IR radiation emitted by the light source 31 may comprise a predefined intensity, such as but not being limited to an intensity of at least 100 kW/mm2, at least 200 kW/mm2 or at least 500 kW/mm2.
In some embodiments the light source 31 may be chosen and/or the intensity of the beam 33 of IR radiation may be adjusted in accordance with the curing properties of the particular liquid silicone material chosen.
Irrespective of the embodiment, the liquid silicone material 42 may be any suitable liquid silicone material capable of being cured by means of IR radiation. Many such liquid silicone materials are available on the market. Thus, the liquid silicone material 42 may be chosen freely according to the desired properties of the object to be printed.
Generally, a silicone material is a polymer including silicon in combination with carbon, hydrogen and oxygen and is also known as polymerized siloxane or
polysiloxane. Other materials may be added as well. Silicone materials have many characteristics that make these materials advantageous in many applications. Such characteristics include low thermal conductivity, low chemical reactivity, low toxicity, being water repellant, being non-supportive to microbiological growth and being oxygen and ozone resistant. Furthermore, silicone materials have a high thermal stability, which makes these materials particularly well suited for IR curing.
Non-limiting examples of liquid silicone materials 42 are optical grade silicones, silicones with a refractive index of more than 1.4, silicone rubbers, silicone elastomers, reactive silicones, loaded silicones and combinations thereof.
Reactive silicones may for instance be obtained from the company Gelest, Inc. of Morrisville, Pennsylvania, USA.
The liquid silicone material 42 may be loaded with a wide variety of materials depending on the property it is desired to affect. Non-limiting examples of possible loading materials are zirconium, zirconia, aluminum, alumina, silica, titanium, any titanium oxide a phosphor luminescent material, a quantum dot material and combinations thereof. Turning now to Fig. 2 a perspective view of a 3D printing device 10 according to a second embodiment of the invention is shown. In the following the 3D printing device 10 will be described with respect to the point on which it differs from that of Fig. 1.
The 3D printing device 10 differs from that of Fig. 1 in that the translation platform 2 comprises an elevator 23 rather than a piston 21 and furthermore comprises a sweeper 24. The elevator executes the translatory movement of the platform 22 in the direction illustrated by the arrow 51. The sweeper 24 is adapted to be movable in the direction illustrated by the arrow 52 such as to sweep across the surface 44 of the liquid silicone material 42 upon finishing each successive layer of the cured silicone structure 43. Thereby liquid silicone material 42 is distributed evenly on top of the uppermost layer of the successive layers of the cured silicone structure 43 forming a layer of a predefined thickness. It is noted that the 3D printing device 1 described in connection with Fig. 1 may also be provided with a sweeper such as the sweeper 24 described above.
The 3D printing device 10 furthermore differs from that of Fig. 1 in that an object, in Fig. 2 shown as two lenses 34, is arranged between the light source 31 and the scanning device 32. Such an object serves the purpose of shaping the beam 33 of IR radiation, here by focusing it and optionally also collimating it, such as to enable a higher precision in the curing process and consequently a higher precision in the printing of the object.
In the embodiment shown in Fig. 2 the scanning device 32 is a mirror.
Turning now to Figs. 3 and 4, examples of objects printed by means of a 3D printing device and/or a 3D printing method according to the invention are shown. In general the 3D printing device and the 3D printing method according to the invention is as mentioned above particularly suitable for printing optical elements. It is noted that the examples shown in Fig. 3 and 4 are entirely non-limiting as any feasible object or structure may in principle be printed by means of a 3D printing device and/or a 3D printing method according to the invention.
Fig. 3 shows three so-called inverted lenses 6a, 6b and 6c. The inverted lenses 6a, 6b and 6c are examples of shapes comprising an overhang and/or an undercut, such shapes being particularly simple to print by means of a 3D printing device and/or a 3D printing method according to the invention.
Fig. 4 shows a structure 7 comprising an upper surface and a lower surface connected by means of a number - here four - pillars or cylinders. Such a structure 7 is an example of a shape comprising a structure which cannot readily be made by molding as it would not release from the mold. Such a structure 7 is also particularly simple to print by means of a 3D printing device and/or a 3D printing method according to the invention.
Other non-limiting examples of optical elements which may advantageously be printed by means of a 3D printing device and/or a 3D printing method according to the invention are concave lenses, convex lenses, diffusers, refractive elements, diffractive elements, optical filters, reflectors, gratings, pinhole structures, light guides, mirrors and even combinations of such elements.
In the embodiments described herein curing of the liquid silicone material 42 is performed from the surface 44 of the liquid silicone material through the open upper end of the vat 41. In an alternative it is feasible to cure the liquid silicone material by IR radiation through the bottom of the vat 41, and thus from the surface of the liquid silicone material opposite to the surface 44.
Thus the surface of the liquid silicone material across which the beam 33 of IR radiation emitted by a light source 31 is moved in a pre-defined pattern to cure the layer of liquid silicone material may both be an upper and a lower surface of the liquid silicone material.
It is noted that in this case the vat 41 is preferably made of a material being at least partially transparent to IR radiation or at least to IR radiation of specific wavelengths.
Furthermore, in the embodiments described herein providing a layer of liquid silicone material 42 on the translation platform 2 of the 3D printing device 1, 10 is performed by moving the translation platform 2 in the at least one direction such as to lower and submerge the translation platform 2 into the liquid silicone material 42 such as to allow the liquid silicone material to flow over the translation platform 2. In some embodiments the translation platform 2 may be lowered into the liquid silicone material 42 to a depth corresponding to a predetermined layer thickness.
Alternatively, it is feasible to provide a layer of liquid silicone material 42 on the translation platform 2 of the 3D printing device 1, 10 by depositing or arranging the layer of liquid silicone material 42 on the translation platform 2 of the 3D printing device 1, 10 by means of a suitable device such as a nozzle or a dispenser.
In a final step of the method according to the invention, the finished object is removed from the liquid silicone material and excess liquid silicone is removed from the finished object. The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims.
Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage.

Claims

CLAIMS:
1. A method for 3D printing an object (6, 7), the method comprising the steps of:
providing a layer of a liquid silicone material (42) on a translation platform (2) of a 3D printing device (1, 10) and/or on a previously cured layer of the liquid silicone material (42) arranged on the translation platform (2), the translation platform (2) being adapted for performing a translatory movement in at least one direction, wherein the liquid silicone material (42) is capable of directly absorbing infrared radiation,
exposing an upper or lower surface (44) of the liquid silicone material (42) to a beam (33) of infrared radiation emitted by a light source (31) in order to selectively cure the liquid silicone material (42) in successive layers from the surface (44), wherein the beam (33) is moved across the surface (44) in a pre-defined pattern by means of a scanning device (32), and
performing a translatory movement of the translation platform (2) in the at least one direction upon finishing the curing of each of the successive layers.
2. A method according to claim 1, the method comprising the further steps of:
arranging a substrate on the translation platform, and
providing a layer of the liquid silicone material on the substrate.
3. A method according to any one of the above claims, wherein the step of providing a layer of the liquid silicone material comprises scraping off excess liquid silicone material such as to form a layer of liquid silicone material of a predefined thickness.
4. A method according to any one of the above claims, wherein the step of selectively curing the liquid silicone material in successive layers and the step of performing a translatory movement of the translation platform are performed simultaneously.
5. A method according to any one of the above claims, wherein the infrared radiation emitted by the light source comprises one or more wavelengths of between 700 nm and 1 mm, between 700 nm and 1000 nm, between 1000 nm and 1 100 nm, between 1400 nm and 1600 nm, between 1900 nm and 2100 nm, between 2900 nm and 3100 nm, between 4000 nm and 7000 nm, or between 9000 nm and 1 1.500 nm, and/or wherein the IR radiation emitted by the light source comprises an intensity of at least 100 kW/mm , at least 200 kW/mm 2 , at least 400 kW/mm 2 , between 1 kW/mm 2 to 10 kW/mm 2 or between 100 mW/mm2 to 100 GW/mm2.
6. A method according to any one of the above claims, wherein the liquid silicone material is chosen from the group comprising an optical grade silicone, a silicone with a refractive index of more than 1.35, a silicone rubber, a silicone elastomer, a reactive silicone, a loaded silicone, a silicone loaded with any one or more of zirconium, zirconia, aluminum, alumina, silica, titanium, a titanium oxide, a phosphor luminescent material and a quantum dot material, and combinations thereof.
7. A method according to any one of the above claims, wherein the step of selectively curing the liquid silicone material comprises an exposure of the surface of the liquid silicone material to infrared radiation having a duration of between 1 millisecond and 1 minute for each of the successive layers.
8. A method according to any one of the above claims, wherein the light source is adapted for being adjustable with respect to the wavelength(s) and/or intensity of the emitted beam of infrared radiation, and wherein the method further comprises the step of adjusting the wavelength(s) and/or intensity of the emitted beam of infrared radiation in accordance with the properties of the liquid silicone material and/or wherein the light source is a laser.
9. A method according to any one of the above claims, and further comprising the steps of arranging a LED and/or another object on the translation platform and printing the object directly or indirectly on the LED and/or other object.
10. A 3D printing device (1, 10) adapted for printing an object (6, 7), the 3D printing device comprising:
a translation platform (2) adapted for performing a translatory movement in at least one direction,
a light source (31) adapted for, in operation, emitting a beam (33) of infrared radiation, and
a scanning device (32) adapted for moving the beam of infrared radiation across an upper or lower surface (44) of a liquid silicone material (42) according to a predefined pattern such as to selectively cure the liquid silicone material in successive layers from the surface (44),
the translation platform furthermore being adapted to perform the translatory movement of the translation platform in the at least one direction upon finishing the curing of each of the successive layers.
1 1. A device according to claim 10, wherein the infrared radiation emitted by the light source comprises one or more wavelengths of between 700 nm and 1 mm, between 700 nm and 1000 nm, between 1000 nm and 1 100 nm, between 1400 nm and 1600 nm, between 1900 nm and 2100 nm, between 2900 nm and 3100 nm, between 4000 nm and 7000 nm, or between 9000 nm and 1 1.500 nm, and/or wherein the infrared radiation emitted by the light
2 2
source comprises an intensity of at least 100 kW/mm , at least 200 kW/mm , at least 400 kW/mm 2 , between 1 kW/mm 2 to 10 kW/mm 2 or between 100 mW/mm 2 to 100 GW/mm 2.
12. A device according to any one of claims 10 and 1 1, wherein the liquid silicone material is a silicone chosen from the group comprising an optical grade silicone, a silicone with a refractive index of more than 1.35, a zirconium loaded silicone, a zirconia loaded silicone, an aluminum loaded silicone, an alumina loaded silicone, a silica loaded silicone, a titanium loaded silicone, a silicone loaded with a titanium oxide, a silicone loaded with a phosphor luminescent material, a silicone loaded with a quantum dot material, a silicone rubber, a silicone elastomer, a reactive silicone, a loaded silicone and combinations thereof.
13. A device according to any one of claims 10 to 12, wherein the light source is adapted such that the wavelength(s) and/or intensity of the emitted beam of infrared radiation are adjustable and/or wherein the light source is a laser.
14. A device according to any one of claims 10 to 13, wherein the device is adapted for printing the object directly or indirectly on a substrate and/or on a LED and/or on another object.
15. An optical element manufactured by means of a method according to any one of claims 1 to 9 or by means of a device according to any one of claims 10 to 13.
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