A system for printing reduced volumes of test resin in an additive manufacturing process

Abstract

One variation of an additive manufacturing system includes: a build window arranged above a projection system; a build platform arranged opposite the build window and configured to drive toward the build window; a tray assembly; and the projection system. The tray assembly includes: a resin tray defining a primary resin reservoir of a total volume and configured to locate over the build window; a separation membrane tensioned across the resin tray; and a tray insert defining a secondary resin reservoir of a volume less than the total volume. The tray insert is configured to: transiently affix to the separation membrane over a target region; and contain a volume of resin within the secondary resin reservoir. The projection system is configured to project radiation toward the volume of the resin, contained within the secondary resin reservoir, to form a layer of a test coupon within the secondary resin reservoir.

Description

A SYSTEM FOR PRINTING REDUCED VOLUMES OF TEST RESIN IN AN ADDITIVE MANUFACTURING PROCESSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This Application claims the benefit of U.S. Provisional Application No. 63 / 627,477, filed on 31-JAN-2024, the contents of which are incorporated in their entirety by this reference.TECHNICAL FIELD

[0002] This invention relates generally to the field of additive manufacturing and more specifically to a new and useful system for printing reduced volumes of resins in the field of additive manufacturing.BRIEF DESCRIPTION OF THE FIGURES

[0003] FIGURES 1A and 1B are schematic representations of an additive manufacturing system;

[0004] FIGURES 2A and 2B are schematic representations of a tray assembly of the system;

[0005] FIGURE 3 shows schematic representations of variations of the system; and

[0006] FIGURE 4 is a schematic representation of a resin collection subsystem.DESCRIPTION OF THE EMBODIMENTS

[0007] The following description of embodiments of the invention is not intended to limit the invention to these embodiments but rather to enable a person skilled in the art to make and use this invention. Variations, configurations, implementations, example implementations, and examples described herein are optional and are not exclusive to the variations, configurations, implementations, example implementations, and examples they describe. The invention described herein can include any and all permutations of these variations, configurations, implementations, example implementations, and examples.1. System

[0008] As shown in FIGURES 1A-B, 2A-B and 3, an additive manufacturing system 100 includes: a build window 112 arranged above a projection system 116 and configured to pass radiation emitted by the projection system 116; a build platform 120 facing thebuild window 112 opposite the projection system 116 and operable over a range of positions above the build window 112; a tray assembly 140; a first tray insert 170 and a platform adapter 180.

[0009] As shown in Figures 2A and 2B, the tray assembly 140 includes a tray base 150 defining a tray aperture 154. The tray assembly 140 further includes: a separation membrane 160 tensioned across the tray aperture 154; and cooperating with the tray base 150 to define a primary resin reservoir 152 of a first reservoir volume. The tray assembly 140 is configured to be located adjacent to the build window 112: with the tray aperture 154 arranged about the build window 112; and with the separation membrane 160 extending over the build window 112.

[0010] The first tray insert 170 includes: a base flange 178 configured to bond to the separation membrane 160; and a continuous wall 176 extending upwardly from the base flange 178. The continuous wall 176 cooperates with the separation membrane 160 to define a first secondary resin reservoir 172 of a second reservoir volume less than the first reservoir volume.

[0011] The projection system 116 is configured to project radiation toward a first volume of a test resin, stored in the first secondary resin reservoir 172, to form a first layer of a first test coupon over the separation membrane 160.1.1 Variation: Tray Assembly

[0012] As shown in FIGURES 2A and 2B, the tray assembly 140 includes: a tray base 150 defining a tray aperture 154; and a separation membrane 160 tensioned across the tray aperture 154. The separation membrane 160 cooperates with the tray base 150 to define a primary resin reservoir 152 of a first reservoir volume. The tray assembly 140 is configured to be located adjacent to a build window 112 of an additive manufacturing system 100: with the tray aperture 154 arranged about the build window 112; and with the separation membrane 160 extending over the build window 112.

[0013] The first tray insert 170 includes: a base flange 178 configured to bond to the separation membrane 160; and a continuous wall 176 extending upwardly from the base flange 178. The continuous wall 176 cooperates with the separation membrane 160 to define a first secondary resin reservoir 172 of a second reservoir volume less than the first reservoir volume.1.2 Variation: Tray Insert

[0014] As shown in FIGURES 1A-B, 2A-B and 3, a tray insert 170 includes: a base flange 178; an adhesive layer (not shown); and a continuous wall 176. The adhesive layer: is arranged across a side of the base flange 178; and is configured to bond the base flange 178 to a separation membrane 160 arranged over a build window 112 of an additive manufacturing system 100. The continuous wall 176: extends upwardly from the base flange 178 opposite the adhesive layer; and cooperates with the separation membrane 160 to define a resin reservoir 172 configured to store a first volume of resin over the separation membrane 160.1.3 Variation: Tray Insert + Build Platform Adapter

[0015] As shown in FIGURES 1A-B, 2A-B and 3, a system includes a tray insert 170 and a build platform adapter 180.

[0016] The tray insert 170 includes: a base flange 178 defining an insert aperture 174; an adhesive layer applied to a bottom surface of the base flange 178; and a continuous wall 176 of a target height and extending upward from the base flange 178 about the insert aperture 174. The base flange 178 defines a bottom surface configured to transiently affix to a separation membrane 160 - via the adhesive layer applied to the bottom surface - installed across a tray aperture 154 of a tray base 150 of a print machine including: a projector system 116 configured to project UV or near-UV light; a build window 112 arranged above the projector; a standard build platform 120 - of a fixed cross-section - transiently coupled to a platform actuator configured to locate the standard build platform 120 over a range of positions above the build window 112 during execution of a build cycle; the separation membrane 160 of a flexible material that is substantially transparent to ultraviolet light and exhibits low adherence to a resin compound; and the tray base 150 defining a primary resin reservoir 152 of a total volume, defining a tray aperture 154 configured to seat over the build window 112, and configured to hold the separation membrane 160 in tension across the tray aperture 154. The base flange 178 further defines the insert aperture 174: configured to seat over a target region of the separation membrane 160; and defining a first cross-section less than the fixed crosssection of the standard build platform 120. The tray insert 170 is configured to cooperate with the separation membrane 160 to define a secondary resin reservoir 172 of a target volume less than the total volume and configured to receive and retain the target volume of resin during execution of the build cycle.

[0017] The build platform adapter 180: is configured to transiently couple to the platform actuator of the print machine in replacement of the standard build platform 120;defines a planar surface configured to seat approximately parallel the build window 112 and vertically aligned to the target region of the separation membrane 160; and defines a second cross-section - less than the fixed cross-section of the standard build platform 120 - corresponding to the first cross-section of the insert aperture 174.

[0018] In one variation, the system 100 further includes a centering tool 190: configured to transiently insert into the tray base 150 during installation of the tray insert 170; defining an aperture of a third-cross-section corresponding to the first cross-section of the tray insert 170; and configured to receive the tray insert 170 within the aperture to locate the insert aperture 174 over the target region of the separation membrane 160 within the tray base 150.2. Applications

[0019] Generally, the system 100 includes: a flexible tray insert 170 configured to transiently affix to a separation membrane 160 arranged within a tray base 150 - integrated within an additive manufacturing machine (hereinafter a “print machine”) and of a standard tray volume - to form a barrier defining a reduced tray volume configured to receive and retain a volume of a test resin during execution of one or more build cycle(s) by the print machine; and a build platform adapter 180 configured to couple to a platform actuator arranged above the tray base 150 and insert into the reduced tray volume - nesting within the continuous wall 176 of the tray insert 170 - toward the separation membrane 160 to form a gap of a particular depth (e.g., within the tray insert 170) corresponding to a target resin layer depth defined for the build cycle.

[0020] The flexible tray insert 170 and the build platform adapter 180 can, therefore, both couple to an existing print machine to reduce a total size (e.g., volume, cross-section) of a resin reservoir of the print machine, thereby enabling printing of test coupons - formed via curing of layers of resin of a target thickness- with less total resin required for generating these test coupons, such as for developing and / or testing of new test resins and material properties associated with test coupons formed of these test resins. The flexible tray insert 170 and the build platform 120 can then be removed - following completion of one or more build cycle(s) - to enable printing of parts with greater volumes of resin poured into the full-sized tray base 150 absent the flexible tray insert 170.

[0021] In particular, the flexible tray insert 170 can include: an annular base flange178 defining a bottom surface configured to affix to a separation membrane 160 - spanning a tray aperture 154 of the tray base 150 - via an adhesive layer applied to thebottom surface; and a continuous wall 176 extending a target height upward from the annular base flange 178 and defining the reduced tray volume bounded by the continuous wall 176 and the separation membrane 160. This reduced tray volume can, therefore, receive a volume of resin exhibiting a greater resin depth than the same volume of resin occupying a total volume of the tray (e.g., absent the tray insert 170), thus enabling printing of a relatively greater number of layers at a target thickness.

[0022] Furthermore, the tray insert 170 can define a tray aperture 154 configured to frame a target region of the separation membrane 160 vertically aligned to the build platform adapter 180. In particular, the build platform adapter 180 can: be configured to transiently couple to the platform actuator - in replacement of a standard build platform 120 - to rigidly install along a vertical axis; and define a planar surface of a cross-section - less than a cross-sectional area of the standard build platform 120 - corresponding to a cross-section of the insert aperture 174 of the tray insert 170, such that the system 100 can actuate the build platform adapter 180 downward toward the separation membrane 160 and into the reduced tray volume without contacting the continuous wall 176 area of the insert aperture 174 of the tray insert 170.

[0023] In one implementation, the tray insert 170 can be affixed to the separation membrane 160 of the tray - and the build platform adapter 180 coupled to the platform actuator - for execution of a build cycle (e.g., via an additive manufacturing process) for a test coupon configured for testing various properties - such as mechanical properties, optical properties, and / or other material properties - of the test coupon and therefore a test resin implemented during one or more build cycle(s). In particular, by coupling the tray insert 170 to the separation membrane 160 and pouring resin into the reduced tray volume formed by the tray insert 170 - rather than pouring the resin into the total tray volume of the tray - a relatively small volume of test resin can instead be poured into the reduced tray volume and exhibit at least a threshold resin depth, thereby enabling curing of an increased quantity of layers at the target layer thickness without increasing a total volume of the test resin. Therefore, by minimizing a volume of test resin required to build a test coupon of the (cured) test resin, the system 100 can reduce costs and material waste associated with generating test coupons for testing properties of new test resins during development of these resins.

[0024] Furthermore, rather than print these test coupons on a smaller additive manufacturing print machine including a smaller tray base 150, the system 100 can be configured to print these test coupons - via installation of the tray insert 170 on the separation membrane 160 - and full-size parts (e.g., absent the tray insert 170) on thesame print machine. By printing a test coupon formed of a new test resin on the same print machine as a final (larger) part formed of the new test resin, the system 100 can: enable mapping of machine parameters and / or controls - implemented during printing of the test coupon - to actual production parameters and / or controls that may be implemented by the print machine during printing of the final part (e.g., absent the tray insert 170); reduce error due to incomplete and / or inaccurate mappings between a smaller print machine and a larger print machine; and reduce costs associated with implementing multiple print machines of varying sizes.2.1 Print Machine: Additive Manufacturing Process

[0025] Generally, the print machine selectively irradiates resin, via a stereolithographic process - such as a digital light process (hereinafter “DLP”) or a continuous digital light process (hereinafter “CDLP”) - to cure successive layers of a solid, physical object or set of objects (hereinafter “a build”). In a standard bottom-up stereolithographic additive manufacturing system 100, a layer of resin may tend to adhere (or “stick”) to the surface of a build window 112 within this print machine when photocured (e.g., via exposure to UV light); this layer of cured resin is then separated from the build window 112 prior to advancement of a build platform 120 (to which the build is adhered) and prior to introducing and photocuring a subsequent layer of resin. The resulting force from this separation can: deform the intermediate state of the ongoing build (in its “green” state) or newly formed layers of the build resulting in poor dimensional accuracy; increase the probability of build failure; and reduce print speeds, amongst other issues. The print machine reduces these separation forces via inclusion of a replaceable separation membrane 160 (laminated over the upper surface of the build window 112 during a photocuring phase of a build process), which functions to limit adhesion forces (e.g., Stefan adhesion and suction forces) between newly cured layers of the build and the build window 112. Additionally, the print machine includes a pressure regulation system (e.g., a compressor, pump, and / or valve system) to selectively inject fluid (e.g., gas or liquid) into an interstitial region 164 between the build window 112 and the separation membrane 160 to aid separation of a newly cured layer of the build from the separation membrane 160 and build window 112 during advancement of a build platform 120.

[0026] In particular, the print machine includes a base assembly no and a tray assembly 140 that, while in an engaged configuration, fluidically seal (e.g., pneumatically or hydraulically seal within an operating pressure range) the interstitial region 164between the separation membrane 160 and the build window 112, thereby enabling inflation of this region by the pressure regulation system. The base assembly no defines the overall structure of the print machine and includes a set of electromechanical components such as the build window 112, the build platform 120, a projection system 116 (e.g., a UV or near UV projection system 116), a tray seat, a fluid distribution port, and the pressure regulation system. The structure of the base assembly 110: locates the build window 112 relative to the build platform 120 and preserves parallelism therebetween; locates the build window 112 relative to the projection system 116 and preserves alignment therebetween (e.g., parallelism, and depth of the build window 112 relative to the focal length of the projection system 116); and defines a window platform that elevates the build window 112 above the surrounding tray seat. The build window 112 spans (at least partially) an opening in the window platform and defines a rigid structure that is substantially transparent to ultraviolet light (e.g., borosilicate glass). Thus, the upper surface of the build window 112 defines a horizontal reference plane parallel to a lower surface of the build platform 120.

[0027] As shown in FIGURES 2A and 2B, the tray assembly 140 includes components - such as the tray base 150 and the separation membrane 160 - and is configured to fit onto the tray seat of the base assembly no in the engaged configuration, thereby positioning the separation membrane 160 over the build window 112 and sealing the interstitial region 164 (e.g., via a set of gaskets arranged on the tray assembly 140 and or the base assembly 110). In one implementation, the tray assembly includes: the tray base 150 defining the tray aperture 154; and the separation membrane 160 that cooperates with the tray base 150 to define a primary resin reservoir 152 of a reservoir volume.

[0028] In the engaged configuration, the tray assembly 140 tensions the separation membrane 160 over the build window 112 such that the separation membrane 160 can: laminate across the upper surface of the build window 112 in response to an evacuation of fluid from the interstitial region 164 between the separation membrane 160 and the upper surface of the build window 112; and can delaminate from the build window 112 in response to an injection of fluid into the interstitial region 164. Furthermore, the tray defines an interior volume, of which the separation membrane 160 forms the floor, which contains a reservoir of resin.

[0029] Prior to initiating a new build cycle to produce a new physical build, a user may install a separation membrane 160 - of a material, thickness, and / or elasticity matched to the resin chemistry selected for this new build and / or matched to a geometiy(e.g., “feature size”) of this new build - into the build tray and then install this tray assembly 140 onto the tray seat of the base assembly no, which repeatably locates the tray assembly 140 relative to the build window 112 and tensions the separation membrane 160 across the build window 112 to form a flat, repeatable surface offset and above the upper surface of the build window 112. Therefore, when the tray assembly 140 and the base assembly 110 are assembled, the build window 112 defines a reference plane (coincident with a focal play of the projection system 116) located relative to the build platform 120 and covered by a thin, flexible, transparent, separation membrane 160, which may both exhibit less adhesion to resin chemistries than the build window 112 and which may be deformed (e.g., inflated) to separate the separation membrane 160 from a layer of cured resin. Furthermore, the tray assembly 140 can define an interior volume configured to contain a curable resin, with a base of this interior volume formed by the separation membrane 160; the tray assembly 140 can, therefore, further function to contain a volume of resin and to isolate this resin from the build window 112 and the projection system 116 below, thereby simplifying both cleanup of the print machine after a build and switching between separation membrane 160 configured specifically for particular resin chemistries between builds.

[0030] Thus, the print machine can then execute a build cycle: to selectively photocure volumes of resin proximal to the separation membrane 160 via the projection system 116; to drive fluid between the separation membrane 160 and the build window 112 via the pressure regulation system, thereby exerting distributed upward force on the build and alleviating adhesion forces (e.g., Stefan adhesion and suction forces) between the separation membrane 160 and the build window 112; to vertically retract the build platform 120 to separate the separation membrane 160 from the build window 112, to peel the separation membrane 160 from the newly cured layer of the build, and to make space to photocure a successive layer of resin; to relaminate the separation membrane 160 against the build window 112; and to actuate the build platform 120 to a new position prior to photocuring a successive layer. Thus, the print machine can reduce separation forces on a build and expand options for curable resin chemistries with minimal actuation of mechanical components, thereby increasing build speed, reducing system wear, and increasing repeatability across individual resin layers and across individual builds, when compared to existing additive manufacturing systems 100.Print Machine Components

[0031] The print machine includes two subassemblies of electromechanical components that, when engaged in an engaged configuration, can execute a “bottom -up” DLP process. Generally, the print machine includes a base assembly no and a tray assembly 140. A user may: assemble the tray assembly 140 by inserting a separation membrane 160 into the tray base 150; and engage the tray assembly 140 with the base assembly no before the print machine executes a build cycle. The print machine can then execute a build cycle via an embedded computational device running computer code (hereinafter the “controller”), which electronically actuates the build platform 120 (e.g., via a linear actuation system) and controls the projection system 116 and the pressure regulation system to selectively cure volumes of resin and to separate these cured volumes of resin from the build window 112 and separation membrane 160.

[0032] The print machine can proceed through multiple physical arrangements of the components in order to cure a build (e.g., a set of physical, 3D objects) from the resin contained within the tray assembly 140. In a lamination phase, the print machine reduces the pressure (i.e. draws a vacuum / evacuates fluid from) in the interstitial layer between the separation membrane 160 and the build window 112, thereby fully laminating the separation membrane 160 against the build window 112 and preventing formation of bubbles or wrinkles that may disrupt the reference surface for the print machine.

[0033] During the lamination phase, the print machine can photocure a selective volume of resin above the laminated surface of the separation membrane 160. Subsequent to the lamination phase, the print machine can execute a separation process including a pressurization phase, a retraction phase, and a relamination phase.

[0034] In the pressurization phase, the print machine injects fluid into the interstitial region 164, thereby generating separation between the separation membrane 160 and the build window 112 in order to reduce adhesion forces (e.g., Stefan adhesion, suction forces) between the newly cured layer of the build and the build window 112. In the retraction phase, the print machine actuates the build platform 120 upward and away from the build window 112: to separate the separation membrane 160 from the build window 112; to peel the separation membrane 160 from the newly cured layer of the build; and to make space to photocure a successive layer of resin. In the relamination phase, the print machine evacuates fluid from the interstitial region 164 in order to peel the separation membrane 160 from the newly cured layer of the build and to relaminate the separation membrane 160 against the build window 112 in preparation for curing a successive layer of the build.

[0035] Thus, the print machine can repeat this process cycle to cure successive layers of the resin, thereby constructing a three-dimensional build.4. Flexible Tray Insert

[0036] Generally, the system 100 can include a flexible tray insert 170 (hereinafter a “tray insert 170”) - defining an inner volume less than a maximum volume of the standard tray - configured to: transiently affix to the separation membrane 160; and receive and retain a volume of resin within the inner volume and prevent resin from flowing into an outer reservoir 158 of the tray base 150 surrounding the tray insert 170 within the tray base 150.

[0037] In one implementation, the tray insert 170 includes a base flange 178 and a continuous wall 176 extending upward from the base flange 178. In particular, the base flange 178 defines: an insert aperture 174 of a target cross-section; an inner perimeter; and an outer perimeter. The continuous wall 176: extends upward from the inner perimeter of the base flange 178; and defines a target height that - in combination with the target cross-section of the insert aperture 174 - defines a maximum resin capacity (e.g., a maximum volume) of the tray insert 170, as shown in FIGURES 2A and 2B. More specifically, the continuous wall 176 cooperates with the separation membrane 160 to define a secondary resin reservoir 172 of a second reservoir volume less than the primary reservoir volume. In this implementation, the secondary resin reservoir 172 is configured to store a volume of resin over the separation membrane.

[0038] In one implementation, the tray base 150 includes a tray wall 156 extending upwardly from the tray base 150 and circumscribing the primary resin reservoir 152, the primary resin reservoir 152 defining an outer volume greater than the inner volume of the secondary insert reservoir 172, as shown in FIGURE 1A. In this implementation, the tray insert 170 includes the continuous wall 176 circumscribing the secondary resin reservoir 172 and inset from the tray wall 156.

[0039] In particular, the tray wall 156 cooperates with the tray base 150, the separation membrane 160, and the continuous wall 176 of the tray insert 170 to define an outer reservoir 158 of a reservoir volume. The secondary resin reservoir 172 is configured to transiently contain a volume of a resin within the secondary resin reservoir 172 and prevent flow of the resin into the outer reservoir 158.

[0040] In some implementations, the external perimeter of the upper edge of the continuous wall 176 includes a horizontally protruding lip enabling a better-controlled collection of the material comprised in the inner volume of the tray insert 170, forinstance, after one or more build cycles have been performed. The horizontally protruding lip may further include one or more gutters extending from the inner volume of the tray insert 170 to the outer perimeter of the horizontally protruding lip to ease directing the flow of the collected material into a collecting vessel (e.g. glass beaker) of a resin collection subsystem (FIGURE 4).

[0041] Generally, the base flange 178 defines a substantially flat, annular section (e.g. square annulus, rectangular annulus or circular annulus): defining a bottom surface configured to seat flush with and facing the separation membrane 160 in an affixed configuration, in which the tray insert 170 is affixed to the separation membrane 160; and defining an upper surface - opposite the bottom surface - facing the build platform 120 in the affixed configuration. The continuous wall 176 extends upward from the base flange 178 along the inner perimeter and to a target height, thereby defining a reduced tray volume - bounded by the separation membrane 160 and the continuous wall 176 - less than a standard tray volume of the standard tray.

[0042] In one implementation, the base flange 178 is configured to bond to the tray assembly 140. In particular, the base flange 178 defines a bottom surface including an adhesive layer: arranged across the base flange 178 opposite the continuous wall 176; and configured to transiently adhere the base flange 178 to the separation membrane 160 arranged over the build window 112. More specifically, the tray insert 170 is configured to transiently affix to the separation membrane 160, tensioned over the tray base 150, with the insert aperture 174 arranged over a target region of the separation membrane 160.

[0043] The tray insert 170 can therefore be formed of a material configured to: be inert (e.g. no substantial chemical interaction) with the tested materials; withstand standard operating conditions (e.g., temperature, pressure) during execution of build cycles at the print machine; and expand and retract with the separation membrane 160 during lamination and delamination of the separation membrane 160 from the build window 112. For example, the tray insert 170 can be formed of a material (e.g., rubber) defining: no substantial chemical reaction with (meth)acrylic-based formulations; a maximum temperature rating (e.g., 120 degrees Celsius) exceeding a maximum temperature of resin in the tray during execution of the build cycle; and define a target flexibility configured to enable expansion and retraction of the tray with the separation membrane 160 during pressurization and relamination phases of the build cycle.4.1 Material Development Configuration + Production Configuration

[0044] Generally, by coupling the tray insert 170 to the separation membrane 160 and pouring resin into the secondary resin reservoir 172 (i.e., reduced tray volume) formed by the tray insert 170 - rather than pouring the resin into the total tray volume of the tray - a relatively small volume of test resin can instead be poured into the secondary resin reservoir 172 and exhibit at least a threshold resin depth, thereby enabling curing of an increased quantity of layers at the target layer thickness without increasing a total volume of the test resin.

[0045] In one implementation, the tray base 150 of the tray assembly 140 defines the tray aperture 154 of a first width. Additionally, in this implementation, the continuous wall 176 of the tray insert 170 encloses an insert aperture 174 of a second width less than the first width. Furthermore, the build window 112 defines a third width greater than the first width and less than the second width.

[0046] In this implementation, in a material development configuration (i.e., with the tray insert 170 bonded to the separation membrane 160), the projection system 116 is configured to project radiation toward the build window 112 over a first area bounded by the tray insert 170 to form a first layer of a test coupon over the separation membrane 160, the first layer of the test coupon spanning a fourth width less than the second width.

[0047] Additionally, in this implementation, in a production configuration (i.e., with the tray insert 170 separated from the separation membrane 160), the projection system 116 is configured to project radiation toward the build window 112 over a second area, greater than the first area, bounded by the build window 112 to form a second layer of a part (e.g., a full-sized part) over the separation membrane 160, the second layer of the part spanning a fifth width less than the third width and greater than the second width. Therefore, the system 100 can minimize the volume of test resin required to build a test coupon of the (cured) test resin, thereby reducing costs and material waste associated with generating test coupons for testing properties of new test resins during development of these resins.4.2 Tray Insert Replaceability

[0048] Generally, the tray insert 170 can be installed prior to execution of a build cycle for a coupon (e.g., a test part) formed of a test resin. In particular, the tray insert 170 can include an adhesive layer applied to the bottom surface of the base flange 178 of the tray insert 170 and configured to bond to the separation membrane 160 to affix the bottom surface - and therefore the tray insert 170 - to the separation membrane 160 across the contact area. The system 100 can then execute the build cycle accordingly to generate thecoupon formed of the (cured) test resin. In response to completion of the build cycle, the tray insert 170 can be either maintained in place for another build cycle or removed and / or discarded.

[0049] In one implementation, a second tray insert 170 can be installed - in replacement of the first tray insert 170 - in preparation for execution of a next build cycle for a next coupon formed of the test resin and / or a different test resin.

[0050] In one example, a first tray insert 170 defines: a first insert aperture 174 of a first cross-sectional area; and a first secondary resin reservoir 172 of a first reservoir volume configured to transiently contain a first volume of a resin within the first secondary resin reservoir 172 based on the first reservoir volume. In this example, the first tray insert 170 is configured to transiently affix to the separation membrane 160 with the first insert aperture 174 arranged over a first target region of the separation membrane 160.

[0051] Additionally, in this example, a second tray insert 170 defines: a second insert aperture 174 of a second cross-sectional area different from (e.g., greater than, less than) the first cross-sectional area of the first insert aperture 174 (and less than the cross- sectional area of the standard build platform 120); and a second secondary resin reservoir 172 of a second reservoir volume, different from (e.g., greater than, less than) the first reservoir volume of the first primary resin reservoir 152. In particular, the second tray insert 170 is configured to: transiently affix to the separation membrane 160, in replacement of the first tray insert 170, with the second insert aperture 174 arranged over a second target region, different from the first target region, of the separation membrane 160; and transiently contain a second volume, different from (e.g., greater than, less than) the first volume, of the resin based on the second reservoir volume.

[0052] In one implementation, a second tray insert 170 can be installed - concurrently with the first tray insert 170 - in preparation for execution of a next build cycle to concurrently form multiple test coupons of the test resin and / or a different test resin.

[0053] For example, in the preceding example, the second tray insert 170 includes: a second base flange 178 configured to bond to the separation membrane 160 adjacent the first tray insert 170; and a second continuous wall 176 cooperating with the separation membrane 160 to define a second secondary resin reservoir 172 of a third reservoir volume less than the primary reservoir volume. Additionally, in this example, the projection system is configured to: project radiation toward the first volume of the test resin, stored in the first secondary resin reservoir 172, to form the first layer of the firsttest coupon over the separation membrane 160 during a build cycle; and project radiation toward a second volume of a second resin, stored in the second secondary resin reservoir 172, to form a second layer of a second test coupon over the separation membrane 160 during the build cycle.

[0054] In one implementation, the second tray insert 170 can be installed - in replacement of the first tray insert 170 - in preparation for execution of a build cycle for a next coupon formed of a different test resin. In particular, the second tray insert 170 can be installed to enable generation of different test coupons according to different print parameters (e.g., print speed, resin temperature).

[0055] For example, in the preceding example, the projection system 116 is configured to, in a first configuration with the first tray insert 170 transiently affixed to the separation membrane 160, project radiation toward a first volume of a first resin, transiently contained within the first secondary resin reservoir 172, according to a first set of print parameters to form a first set of layers of the first test coupon within the first secondary resin reservoir 172.

[0056] The projection system 116 is further configured to, in a second configuration with the second tray insert 170 transiently affixed to the separation membrane 160 in replacement of the first tray insert 170, project radiation toward a second volume of a second resin, different from the first resin and transiently contained within the second secondary resin reservoir 172, according to a second set of print parameters, different from the first set of print parameters, to form a second set of layers of a second test coupon within the second secondary resin reservoir 172.4.2 Tray Insert Removal

[0057] In one implementation, in preparation for execution of a build cycle for a full-sized part, no tray insert 170 can be installed within the tray and the system 100 can execute the build cycle - with resin loaded into a total volume of the standard tray - accordingly to generate the full-sized part.

[0058] For example, in the preceding example, the projection system 116 is configured to, in the material development configuration with the first tray insert 170 transiently affixed to the separation membrane 160, project radiation toward the first volume of the first resin, transiently contained within the first secondary resin reservoir 172, according to a first set of print parameters to form a first set of layers of the first test coupon within the first secondary resin reservoir 172. The projection system 116 is further configured to, in a production with the first tray insert 170 removed from the separationmembrane 160, project radiation toward a volume of the first resin, transiently contained within the primary resin reservoir 152, according to the first set of print parameters to form a second set of layers of a final build within the primary resin reservoir 152.

[0059] Therefore, the system 100 can be configured to print test coupons - via installation of the tray insert 170 on the separation membrane 160 - and full-size parts (e.g., absent the tray insert 170) on the same print machine. By printing a test coupon formed of a new test resin on the same print machine as a final (larger) part formed of the new test resin, the system 100 can enable mapping of machine parameters and / or controls - implemented during printing of the test coupon - to actual production parameters and / or controls implemented by the print machine during printing of the final part (e.g., absent the tray insert 170).4.4 Tray Insert Flexibility

[0060] Generally, the tray insert 170 can be formed of a flexible material, such that the tray insert 170 exhibits a target flexibility. For example, the tray insert 170 can be formed of a rubber material.

[0061] As shown in FIGURE 2B, the tray insert 170 can define a target flexibility exceeding a lower threshold flexibility, such that - when affixed to the separation membrane 160 in the affixed configuration - the tray insert 170 can expand and retract with the separation membrane 160 during separation of the separation membrane 160 from the build window 112 (or “delamination”) in response to injection of fluid into the interstitial region 164 and during lamination of the separation membrane 160 to the build window 112 in response to evacuation of fluid from the interstitial region 164. By expanding and contracting in tandem with the separation membrane 160, the tray insert 170 can prevent deformation (e.g., wrinkling) of the separation membrane 160 (e.g., maintaining a flat, taut membrane) during lamination and delamination of the separation membrane 160 from the build window 112. For example, the tray insert 170 may be formed of a rubber material having a shore value of more than 20.

[0062] Furthermore, the tray insert 170 can define the target flexibility less than an upper threshold flexibility, such that the tray insert 170 is sufficiently rigid to: bond (e.g., via adhesion) to the separation membrane 160 without separation during lamination and delamination of the separation membrane 160 from the build window 112; and prevent resin spills from the inner tray volume - defined by the continuous wall 176 of the tray insert 170 and the separation membrane 160 - into the outer tray volume. For example,the tray insert 170 may be formed of a rubber material having a shore A value of less than 90.4.5 Contact Area

[0063] In one implementation, the base flange 178 of the tray insert 170 and the separation membrane 160 define a contact area - between the bottom surface of the base flange 178 and the separation membrane 160 in the affixed configuration - less than a maximum contact area.

[0064] In particular, in order to maintain bonding (e.g., via the adhesive layer) between the bottom surface of the base flange 178 of the tray insert 170 and the separation membrane 160 - without peeling of the bottom surface away from the separation membrane 160, breaking of the tray insert 170, and / or tearing of the separation membrane 160 - the contact area between the bottom surface of the base flange 178 and the separation membrane 160 can be less than the maximum contact area. The base flange 178 can, therefore, define a relatively short width extending between the inner perimeter and the outer perimeter, thereby minimizing the contact area.

[0065] However, in order to maintain sufficient bonding between the bottom surface of the base flange 178 and the separation membrane 160 during delamination and / or lamination of the separation membrane 160 to the build window 112, the base flange 178 and the separation membrane 160 can define a contact area exceeding a minimum contact area. The base flange 178 can, therefore, be configured to define a contact area falling between the minimum contact area and the maximum contact area.4.6 Adhesive Layer

[0066] The tray insert 170 can include an adhesive layer applied to the bottom surface of the base flange 178. Generally, the adhesive layer can define a target thickness less than a threshold thickness, the adhesive layer interposed between the separation membrane 160 and the bottom surface of the base flange 178 in the affixed configuration. For example, the adhesive layer can define a thickness of approximately (e.g., within five percent) 0.2 millimeters.

[0067] The adhesive layer can be formed of a material configured to be inert (e.g. no substantial chemical interaction) with the tested materials, withstand operating parameters (e.g., temperature, pressure) of the print machine and retain the bottom surface of the base flange 178 against the separation membrane 160, such as during the lamination, pressurization, retraction, and relamination phases of the build cycle.

[0068] For example, the adhesive layer can be formed of an acrylic adhesive defining a maximum temperature rating exceeding the maximum resin temperature and / or maximum membrane temperature throughout execution of the build cycle (e.g., exceeding 60 degrees Celsius, exceeding 80 degrees Celsius). In one example, the adhesive layer can be rated to a maximum temperature of approximately (e.g., within five percent) 90 degrees Celsius.

[0069] In one implementation, the adhesive layer can be pre-applied to the bottom surface of the base flange 178 of the tray insert 170. In this implementation, the tray insert 170 can further include a backing (or “cover”) applied across the adhesive layer to preserve the adhesive layer and prevent sticking of this layer to other surfaces prior to installation within the tray. To install the tray insert 170 within the tray base 150, the backing can be removed from the adhesive layer and the bottom surface of the base flange 178 of the tray insert 170 can be affixed to the separation membrane 160 via bonding of the adhesive layer to the separation membrane 160. For example, a layer of an acrylic adhesive - defining a target thickness (e.g., 0.2 millimeters) - can be applied to the bottom surface of the base flange 178. Then, a paper or film backing can be applied across the layer of the acrylic adhesive. This backing can then be removed to expose the layer of the acrylic adhesive and affix the bottom surface of the base flange 178 to the separation membrane 160. In this implementation, the tray insert 170 - including the adhesive layer - can be replaced prior to each build cycle.

[0070] Alternatively, in another implementation, the adhesive layer can be removably coupled to the bottom surface of the tray insert 170, such that a new adhesive layer can be applied to the bottom surface of the tray insert 170 between build cycles and this single tray insert 170 can therefore be implemented across multiple build cycles, without reduced bonding between the tray insert 170 and the separation membrane 160.5. Build Platform Adapter

[0071] The system 100 can also include a build platform adapter 180 - configured to transiently install within the print machine - defining a cross-sectional area corresponding to a cross-sectional area of the insert aperture 174 of the tray insert 170 and less than a cross-sectional area of the standard build platform 120.

[0072] Generally, the build platform adapter 180 can: be configured to couple to a build platform 120 actuator configured to transiently drive the build platform adapter 180 (vertically) toward and away from the build window 112 during execution of the buildcycle; and define a planar surface configured to seat opposite and substantially parallel to the build window 112 when coupled to the build platform 120 actuator.

[0073] In one implementation, the build platform adapter 180 can be configured to transiently couple to the build platform 120 over a target region on the separation membrane 160 circumscribed by the continuous wall 176 of the tray insert 170. In this implementation, the continuous wall 176 of the tray insert 170 defines the insert aperture 174 of a first width. Furthermore, the build platform adapter 180 defines a second width less than the first width. In particular, the build platform adapter 180 can be configured to nest within the tray insert 170 - by inserting into the insert aperture 174 of the tray insert 170 - during actuation of the build platform adapter 180 during execution of a build cycle, with the planar surface parallel the build window 112 throughout the build cycle. The build platform adapter 180 can therefore define an adapter cross-section configured to nest within a cross-section of the tray insert 170, such that when the build platform adapter 180 is inserted into the tray insert 170 (e.g., toward the separation membrane 160), the tray insert 170 and the build platform adapter 180 cooperate to define a gap 179 between an outer perimeter of the build platform adapter 180 and an inner perimeter of the tray insert 170. More specifically, the build platform adapter 180 is configured to insert into the insert aperture 174 to form the gap 179, arranged between the continuous wall 176 and an outer wall of the build platform adapter 180, corresponding to a target depth defined for a layer of a test coupon. For example, the build platform adapter 180 and the tray insert 170 can define an approximately (e.g., within ten percent) five- millimeter gap 179 between the build platform adapter 180 and the inner perimeter of the tray insert 170.

[0074] The print machine can, therefore, execute the methods and techniques described above to advance and retract this build platform adapter 180 toward and / or away from the separation membrane 160 during execution of the build cycle.

[0075] In one implementation, the build platform adapter 180 can be configured to install within the print machine in replacement of the standard build platform 120, such that the standard build platform 120 can be removed prior to installation of the build platform adapter 180. In particular, the platform actuator is configured to locate the build platform adapter 180: in a first vertical position over the separation membrane 160 at the target region, the build platform adapter 180 circumscribed by the continuous wall 176 of the tray insert 170 in the first vertical position; and, in a second vertical position over the separation membrane 160 over the target region, the build platform adapter 180 elevated above the tray insert 170 in the second vertical position.

[0076] In one example with the build platform adapter 180 transiently coupled to the platform actuator in replacement of the build platform 120: the platform actuator is configured to locate the build platform 120 actuator over a range of positions over the build window 112 and locate the build platform adapter 180 within the insert aperture 174; the projection system 116 is configured to project radiation toward the volume of the resin, transiently contained within the secondary resin reservoir 172, to form a layer of the test coupon at the target depth, the layer coupled to the planar surface of the build platform adapter 180, opposite the separation membrane 160; and the platform actuator is further configured to retract the build platform adapter 180 away from the build window 112 to separate the layer of the test coupon from the separation membrane 160.

[0077] In this implementation, an operator may: remove the standard build platform 120 from the print machine, such as via a quick release mechanism integrated into the print machine; and couple the build platform adapter 180 to the platform actuator to couple the build platform adapter 180 to the print machine in replacement of the standard build platform 120. For example, the build platform 120 actuator can define a set of three connection locations at which the build platform 120 actuator can actuate the standard build platform 120 and / or build platform adapter 180 to raise and lower these build platforms 120 accordingly. The build platform adapter 180 can be configured to kinematically mount to the build platform 120 actuator by coupling (e.g., via clamps, via magnets) the build platform adapter 180 to the build platform 120 actuator at the set of three connection locations, thereby enabling accurate and repeatable positioning of the build platform adapter 180 relative the build window 112, such that the build platform adapter 180 can nest within the boundary wall of the tray insert 170 during actuation.

[0078] Alternatively, in another implementation, the build platform adapter 180 can be configured to couple to the standard build platform 120, such that the build platform adapter 180 extends from the standard build platform 120. In particular, in this implementation, an operator may similarly couple the build platform adapter 180 to the standard build platform 120 - such as via kinematically mounting the build platform adapter 180 to the standard build platform 120 - to locate the planar surface of the build platform adapter 180 vertically above the build window 112 and in alignment with the insert aperture 174 of the tray insert 170.

[0079] In each of these implementations, the print machine can be configured to: receive the build platform adapter 180, such as in replacement of the standard build platform 120 and / or coupled to the standard build platform 120; preserve parallelism between the build window 112 and the build platform adapter 180; and accurately positionthe planar surface of the build platform adapter 180 at a target depth within the tray insert 170 corresponding to a target layer depth defined for the build cycle.6. Tray Insert Installation: Centering Tool

[0080] In one implementation, the system 100 can also include a centering tool 190 configured to enable accurate placement of the tray insert 170 in a target position within the tray base 150, such that the insert aperture 174 of the tray insert 170 seats over a target region (e.g., a center region) of the tray. In particular, the centering tool 190 can be configured to transiently install (i.e., seat) within the tray to guide placement of the tray insert 170 within the tray during installation of the tray insert 170, such that the insert aperture 174 of the tray insert 170 is vertically aligned with the build platform adapter 180 and the build platform adapter 180 can nest within the insert aperture 174 during actuation of the build platform adapter 180 toward and / or away from the separation membrane 160.

[0081] In one implementation, the centering tool 190 defines an annular frame defining an aperture of a geometry corresponding to a geometry of the base flange 178 of the tray insert 170, such that the base flange 178 nests within the aperture of the annular frame.

[0082] In particular, the centering tool 190 can define: an outer wall configured to abut walls of the tray to rigidly locate the centering tool 190 within the tray base 150; an inner wall defining an aperture of a cross-section (e.g., size, shape) matched to (e.g., approximating) a cross-section of the base flange 178 of the tray insert 170. More specifically, the aperture is configured to expose the target region of the separation membrane to receive the tray insert.

[0083] For example, the base flange 178 of the tray insert 170 can be configured to nest within the aperture of the centering tool 190 to locate the tray insert 170 on the separation membrane 160 within the tray. Thus, the centering tool 190 is configured to receive the tray insert 170 within the aperture to locate the insert aperture 174 over the target region of the separation membrane 160 within the tray base 150.

[0084] Generally, once the tray insert 170 is installed within the tray and affixed to the separation membrane 160 at the target position, the centering tool 190 can be removed from the tray prior to initiation of the build cycle.7. Build Cycle: Test Resin

[0085] Generally, once the tray insert 170 is affixed to the separation membrane 160 and the build platform adapter 180 is installed (e.g., in replacement of the standard build platform 120), the print machine can execute a build cycle as described above.

[0086] For example, an operator may: install a separation membrane 160 into the tray and then install the tray base 150 onto the tray seat of the base assembly no, which repeatably locates the tray relative to the build window 112 and tensions the separation membrane 160 across the build window 112. The operator may then: remove the standard build platform 120 via the quick-release mechanism as described above; and rigidly couple the build platform adapter 180 to the build platform 120 actuator, such as by kinematically mounting the build platform adapter 180 to the build platform 120 actuator. Then, to install the tray insert 170, the operator may: insert the centering tool 190 into the tray base 150; remove a backing from a bottom surface of a base flange 178 of a tray insert 170 to expose an adhesive layer applied across the bottom surface; and seat the tray insert 170 within an aperture of the centering tool 190 to affix the tray insert 170 to the separation membrane 160 and form a reduced tray volume bounded by a region of the separation membrane 160 - vertically aligned to the build platform adapter 180- and the continuous wall 176 of the tray insert 170.

[0087] Then, during execution of a build cycle, the print machine can: evacuate fluid from the interstitial region 164, between the separation membrane 160 and the build window 112, to laminate the separation membrane 160 - affixed to the tray insert 170- against the build window 112 (e.g., a substantially planar build window 112); actuate the build platform adapter 180 downward toward the build window 112 - such that the build platform adapter 180 nests within the continuous wall 176 of the tray insert 170 - to a target depth, forming a gap between the planar surface of the build platform adapter 180 and the separation membrane 160; fill the tray insert 170 with a volume of test resin, which fills the gap between the planar surface of the build platform adapter 180 and the separation membrane 160 and forms a first resin layer; and project light through the build window 112 and the separation membrane 160 - via the projection system 116 - to polymerize the first resin layer which then bonds to the build platform adapter 180, the separation membrane 160, and the tray insert 170.

[0088] The system 100 can then: actuate the build platform adapter 180 to slowly retract the build platform adapter 180 from the tray insert 170 and away from the build window 112; and inject fluid (e.g., air) into the interstitial region 164 to separate the separation membrane 160 from the build window 112. As the separation membrane 160 expands and separates from the build window 112, the flexible tray insert 170 can similarlyexpand with the separation membrane 160 and remain affixed (e.g., via adhesion) to the separation membrane 160. The tray insert 170 can thus expand with the separation membrane 160 responsive to injection of fluid into the interstitial region 164.

[0089] The system 100 can then evacuate fluid from the interstitial region 164 to retract the separation membrane 160 and relaminate the separation membrane 160 - affixed to the tray insert 170 - against the build window 112 (e.g., a substantially planar build window 112), while peeling the separation membrane 160 from the first layer of newly cured resin. As the separation membrane 160 retracts and thus separates from the first layer, the flexible tray insert 170 can similarly retract with the separation membrane 160 - without wrinkling and / or deforming the separation membrane 160 - and remain affixed to the separation membrane 160. The tray insert 170 can thus retract with the separation membrane 160 responsive to evacuation of fluid from the interstitial region 164.

[0090] The print machine can then repeat this process to cure a next layer of the resin until all layers are complete and a final coupon of cured test resin is generated. The tray insert 170 can therefore be implemented - without replacement - during curing of each layer of resin forming the coupon, without spilling of resin from the reduced tray volume and / or deformation of the tray insert 170 or separation membrane 160.8. Variation: Pour Adapter

[0091] The system 100 can include a resin collection subsystem, substantially as described in US Patent Publication No. US20240165880A1 by the same Applicant, and shown in FIGURE 4, configured to enable collection of resin remaining in the tray after completion of the build cycle. In particular, in this variation, the resin collection subsystem 100 can include: a chassis 192 defining a set of platform mounts 194, arranged coaxial along a pivot axis, and a slot extending downward from the pivot axis between the set of platform mounts 194; a filter receptacle (not shown) - configured to receive and retain a resin filter (not shown)- transiently arranged within the slot below the pivot axis; a tray platform 196 - pivotably coupled to the set of platform mounts 194 - configured to transiently receive the tray base 150 on a surface of the tray platform 196 and kinematically locate and retain a fluid release point (e.g., a spout) of the tray in a fixed pivot location coaxial the pivot axis and vertically above the filter receptacle within the slot; and a handle 197 configured to enable a user to rapidly pivot the tray platform 196, about the pivot axis, from a retracted position (e.g., approximately at horizontal) to a deployed position - defining a range of tray orientations (e.g., between o -degrees fromhorizontal and 100-degrees from horizontal) - to release or pour resin from the tray at the fluid release point and into the filter arranged in the filter receptacle for filtering and collection of filtered resin in a collection vessel arranged below the filter receptacle.

[0092] As shown in FIGURE 4, to enable pouring of any remaining resin contained by the tray insert 170 within the tray base 150, the system 100 can further include an adapter vessel 198 configured to: transiently affix to the tray base 150; and receive and retain a volume of resin - released from the tray insert 170 at a secondary fluid release point 200 defined by the tray insert 170 - responsive to rotation of the handle and pivoting of the tray platform 196 about the pivot axis.

[0093] For example, the adapter vessel 198 can: define an inner volume configured to receive and retain a target volume of resin; define an inlet configured to seat vertically below the secondary fluid release point defined by the tray insert 170 in the deployed position; and define a set of retention features configured to engage features of the tray - such as at the fluid release point - to locate the inlet of the adapter vessel 198 at a target position aligned to the secondary fluid release point. Once any remaining resin is collected in the adapter vessel 198, the adapter vessel 198 can be decoupled from the tray, and the resin may be stored and / or poured into the tray insert 170 for execution of a next build cycle.9. Conclusion

[0094] The systems and methods described herein can be embodied and / or implemented at least in part as a machine configured to receive a computer-readable medium storing computer-readable instructions. The instructions can be executed by computer-executable components integrated with the application, applet, host, server, network, website, communication service, communication interface, hardware / firm ware / soft ware elements of a user computer or mobile device, wristband, smartphone, or any suitable combination thereof. Other systems and methods of the embodiment can be embodied and / or implemented at least in part as a machine configured to receive a computer-readable medium storing computer -readable instructions. The instructions can be executed by computer -executable components integrated by computer-executable components integrated with apparatuses and networks of the type described above. The computer-readable medium can be stored on any suitable computer readable media such as RAMs, ROMs, flash memory, EEPROMs, optical devices (CD or DVD), hard drives, floppy drives, or any suitable device. Thecomputer-executable component can be a processor but any suitable dedicated hardware device can (alternatively or additionally) execute the instructions.

[0095] As a person skilled in the art will recognize from the previous detailed description and from the figures and claims, modifications and changes can be made to the embodiments of the invention without departing from the scope of this invention as defined in the following claims.

Claims

CLAIMSI Claim:

1. An additive manufacturing system comprising:• a build window arranged above a projection system and configured to pass radiation emitted by the projection system;• a build platform facing the build window opposite the projection system and operable over a range of positions above the build window;• a tray assembly: o comprising a tray base defining a tray aperture; o comprising a separation membrane:■ tensioned across the tray aperture; and■ cooperating with the tray base to define a primary resin reservoir of a first reservoir volume; and o configured to locate adjacent the build window:■ with the tray aperture arranged about the build window; and■ with the separation membrane extending over the build window;• a first tray insert comprising: o a base flange configured to bond to the separation membrane; and o a continuous wall:■ extending upwardly from the base flange; and■ cooperating with the separation membrane to define a first secondary resin reservoir of a second reservoir volume less than the first reservoir volume; and• the projection system configured to project radiation toward a first volume of a test resin, stored in the first secondary resin reservoir, to form a first layer of a first test coupon over the separation membrane.

2. The additive manufacturing system of Claim 1:• wherein the base flange of the first tray insert is: o configured to bond to the separation membrane in a material development configuration; and o separated from the separation membrane in a production configuration; and• wherein the projection system is configured to:o project radiation toward the first volume of the test resin, stored in the first secondary resin reservoir, to form the first layer of the first test coupon over the separation membrane in the material development configuration; and o project radiation toward a second volume of a second resin, stored in the primary resin reservoir, to form a second layer of a second part over the separation membrane in the production configuration, the second volume of the second resin greater than the first volume of the test resin.

3. The additive manufacturing system of Claim 2, wherein the projection system is configured to:• project radiation toward the first volume of the test resin over a first area bounded by the first tray insert to form the first layer of the first test coupon over the separation membrane in the material development configuration; and• project radiation toward the second volume of the second resin over a second area bounded by the build window to form the second layer of the second part over the separation membrane in the production configuration, the second area greater than the first area.

4. The additive manufacturing system of Claim 1:• wherein the tray base of the tray assembly defines the tray aperture of a first width;• wherein the continuous wall of the first tray insert encloses an insert aperture of a second width less than the first width;• wherein the build window defines a third width greater than the first width and less than the second width;• wherein the base flange of the first tray insert is configured to bond to the separation membrane in a material development configuration; and• wherein the projection system is configured to: o project radiation toward through the build window to form the first layer of the first test coupon over the separation membrane in the material development configuration, the first layer of the first test coupon spanning a fourth width less than the second width; and o project radiation toward through the build window to form a second layer of a second part over the separation membrane in a production configuration, the base flange separated from the separation membrane in the productionconfiguration, the first layer of the first test coupon spanning a fifth width less than the third width and greater than the second width.

5. The additive manufacturing system of Claim 1, wherein the first tray insert further comprises an adhesive layer:• arranged across the base flange opposite the continuous wall; and• configured to transiently adhere the base flange of the first tray insert to the separation membrane.

6. The additive manufacturing system of Claim 1:• further comprising a second tray insert comprising: o a second base flange configured to bond to the separation membrane adjacent the first tray insert; and o a second continuous wall:■ extending upwardly from the second base flange; and■ cooperating with the separation membrane to define a second secondary resin reservoir of a third reservoir volume less than the first volume; and• wherein the projection system is configured to: o project radiation toward the first volume of the test resin, stored in the first secondary resin reservoir, to form the first layer of the first test coupon over the separation membrane during a build cycle; and o project radiation toward a second volume of a second resin, stored in the second secondary resin reservoir, to form a second layer of a second test coupon over the separation membrane during the build cycle.

7. The additive manufacturing system of Claim 1:• further comprising a platform actuator configured to locate the build platform over the range of positions above the build window;• further comprising a build platform adapter configured to: o transiently couple to the platform actuator in replacement of the build platform; and o locate on the platform actuator over a target region on the separation membrane circumscribed by the continuous wall of the first tray insert; and• wherein the platform actuator is further configured to locate the build platform adapter:o in a first vertical position over the separation membrane at the target region, the build platform adapter circumscribed by the continuous wall of the first tray insert in the first vertical position; and o in a second vertical position over the separation membrane over the target region, the build platform adapter elevated above the first tray insert in the second vertical position.

8. The additive manufacturing system of Claim 1:• wherein the continuous wall of the first tray insert defines a second aperture of a first width; and• further comprising a build platform adapter configured to: o transiently couple to the build platform over a target region on the separation membrane circumscribed by the continuous wall of the first tray insert; and o defining a second width less than the first width.

9. The additive manufacturing system of Claim 1:• wherein the tray assembly further comprises a tray wall: o extending upwardly from the tray base; and o cooperating with the tray base, the separation membrane, and the continuous wall of the first tray insert to define an outer reservoir of a third reservoir volume less than the first volume; and• wherein the first secondary resin reservoir is configured to transiently contain the first volume of the test resin within the first secondary resin reservoir and prevent flow of the test resin into the outer reservoir.

10. The additive manufacturing system of Claim 1:• wherein the separation membrane is configured to: o laminate across an upper surface of the build window responsive to evacuation of fluid from an interstitial region between the separation membrane and the upper surface of the build window; and o delaminate from the build window responsive to injection of fluid into the interstitial region; and• wherein the first tray insert is configured to: o retract with the separation membrane responsive to evacuation of fluid from the interstitial region; ando expand with the separation membrane responsive to injection of fluid into the interstitial region. n. The additive manufacturing system of Claim 1, further comprising a centering tool:• configured to transiently install into the tray assembly during installation of the first tray insert;• defining an aperture of a second cross-sectional area corresponding to a first cross- sectional area of the first tray insert, the aperture configured to expose a first target region of the separation membrane; and• configured to receive the first tray insert within the aperture to locate the first tray insert over the first target region of the separation membrane within the tray assembly.

12. A system comprising:• a tray assembly: o comprising a tray base defining a tray aperture; o comprising a separation membrane:■ tensioned across the tray aperture; and■ cooperating with the tray base to define a primary resin reservoir of a first reservoir volume; and o configured to locate adjacent a build window of an additive manufacturing system:■ with the tray aperture arranged about the build window; and■ with the separation membrane extending over the build window; and• a first tray insert comprising: o a base flange configured to bond to the separation membrane; and o a continuous wall:■ extending upwardly from the base flange; and■ cooperating with the separation membrane to define a first secondary resin reservoir of a second reservoir volume less than the first reservoir volume.

13. The system of Claim 12, further comprising a second tray insert comprising:• a second base flange configured to bond to the separation membrane in replacement of the first tray insert; anda second continuous wall: o extending upwardly from the second base flange; and o cooperating with the separation membrane to define a second secondary resin reservoir of a third reservoir volume less than the first reservoir volume and different from the second reservoir volume.

14. The system of Claim 12:• wherein the separation membrane is configured to: o laminate across an upper surface of the build window responsive to evacuation of fluid from an interstitial region between the separation membrane and the upper surface of the build window; and o delaminate from the build window responsive to injection of fluid into the interstitial region; and• wherein the first tray insert is configured to: o retract with the separation membrane responsive to evacuation of fluid from the interstitial region; and o expand with the separation membrane responsive to injection of fluid into the interstitial region.

15. A system comprising:• a tray insert comprising: o a base flange; o an adhesive layer:■ arranged across a side of the base flange; and■ configured to bond the base flange to a separation membrane arranged over a build window of an additive manufacturing system; and o a continuous wall:■ extending upwardly from the base flange opposite the adhesive layer; and■ cooperating with the separation membrane to define a resin reservoir configured to store a first volume of resin over the separation membrane.

16. The system of Claim 15, further comprising a tray assembly:• comprising:o a tray base defining a tray aperture; and o the separation membrane:■ tensioned across the tray aperture; and■ cooperating with the tray base to define a primary resin reservoir configured to store a second volume of resin over the separation membrane, the second volume greater than the first volume; and• configured to locate adjacent the build window of the additive manufacturing system: o with the tray aperture arranged about the build window; and o with the separation membrane extending over the build window.

17. The system of Claim 16:• wherein the base flange is configured to bond to the separation membrane;• wherein the separation membrane is configured to: o laminate across an upper surface of the build window responsive to evacuation of fluid from an interstitial region between the separation membrane and the upper surface of the build window; and o delaminate from the build window responsive to injection of fluid into the interstitial region; and• wherein the tray insert is configured to: o retract with the separation membrane responsive to evacuation of fluid from the interstitial region; and o expand with the separation membrane responsive to injection of fluid into the interstitial region.

18. The system of Claim 16, further comprising:• the build window arranged above a projection system;• a build platform facing the build window opposite the projection system and operable over a range of positions above the build window; and• the projection system configured to project radiation toward resin, stored in the resin reservoir, to form a layer of a test coupon over the separation membrane.

19. The system of Claim 18:• wherein the base flange of the tray insert is:o configured to bond to the separation membrane in a material development configuration; and o separated from the separation membrane in a production configuration; and• wherein the projection system configured to: o project radiation toward the first volume of a test resin, stored in the resin reservoir, to form the layer of the test coupon over the separation membrane in the material development configuration; and o project radiation toward the second volume of a second resin, stored in the primary resin reservoir, to form a second layer of a second part over the separation membrane in the production configuration, the second volume of the second resin greater than the first volume of the test resin.

20. The system of Claim 15, further comprising:• a platform actuator operable over a range of positions above the build window; and• a build platform adapter configured to: o transiently couple to the platform actuator; and o locate on the platform actuator over a target region on the separation membrane circumscribed by the continuous wall of the tray insert.