Systems and methods of additive manufacturing

Abstract

An additive manufacturing apparatus includes a resin support configured to support a first resin and a second resin. A support plate includes a window. A platform is configured to hold one or more cured layers of resin to form a part positioned opposite the support plate. A radiant energy device is positioned on an opposite side of the resin support from the platform and is operable to generate radiant energy and project the radiant energy through the window in a patterned image. An actuator assembly is configured to move the platform in a Z-axis direction and a Y-axis direction.

Description

Technical Field

[0001] This topic generally relates to additive manufacturing equipment, and more specifically to components used to change the position of various parts of additive manufacturing equipment. Background Technology

[0002] Additive manufacturing is the process of building materials layer by layer to form a part. Stereolithography (SLA) is an additive manufacturing process that uses a box of radiation-curable photopolymer "resin" and a curing energy source, such as a laser. Similarly, digital light processing (DLP) 3D printing uses a 2D image projector to build a part one layer at a time. For each layer, the energy source draws or flashes a radiation image of the part's cross-section onto the resin surface. Exposure to radiation cures and solidifies the pattern in the resin, bonding it to the previously cured layer.

[0003] In some cases, additive manufacturing can be accomplished through a “casting” process. In this process, resin is deposited onto a flexible, radiotransparent resin support, such as a tape or foil, which is fed from a supply reel into a build zone. Radiation energy is generated by a radiation energy device and directed through a window to cure the resin into a part supported by a platform in the build zone. Once the first layer has cured, the platform and the resin support separate from each other. The resin support is then advanced, and fresh resin is supplied to the build zone. Next, the first layer of cured resin is placed on top of the fresh resin and cured by an energy device to form an additional layer of the part. Subsequent layers are added to each previous layer until the part is complete. The casting process can be used to form a wide variety of parts. Attached Figure Description

[0004] The complete and enabling disclosure of this disclosure, including its best mode, is set forth in the description with reference to the accompanying drawings and is intended for use by those skilled in the art.

[0005] Figure 1A This is a schematic side view of an additive manufacturing apparatus according to various aspects of this disclosure;

[0006] Figure 1B This is a schematic side view of an additive manufacturing apparatus according to various aspects of this disclosure;

[0007] Figure 2 This is a front perspective view of an additive manufacturing apparatus according to various aspects of this disclosure;

[0008] Figure 3 This is a side perspective view of an additive manufacturing apparatus according to various aspects of this disclosure;

[0009] Figure 4 This is a side perspective view of an additive manufacturing apparatus according to various aspects of this disclosure;

[0010] Figure 5 Methods of operating additive manufacturing equipment according to various aspects of this disclosure;

[0011] Figure 6-24 A schematic diagram of an additive manufacturing apparatus during equipment operation is shown according to various aspects of this disclosure;

[0012] Figure 25 This is a side perspective view of an additive manufacturing apparatus according to various aspects of this disclosure;

[0013] Figure 26 This is a side perspective view of the frame of an additive manufacturing apparatus according to various aspects of this disclosure;

[0014] Figure 27 This is a rear perspective view of the frame of an additive manufacturing apparatus according to various aspects of this disclosure;

[0015] Figure 28 This is a side perspective view of the printhead of an additive manufacturing apparatus according to various aspects of this disclosure;

[0016] Figure 29 It is in accordance with all aspects of this disclosure. Figure 25 A cross-sectional view of the printhead of the additive manufacturing equipment taken from line XXIX-XXIX;

[0017] Figure 30 This is a top view of the first sliding assembly of the additive manufacturing apparatus according to various aspects of this disclosure;

[0018] Figure 31 This is a top view of the second sliding assembly of the additive manufacturing apparatus according to various aspects of this disclosure;

[0019] Figure 32 It is a side perspective view of an additive manufacturing apparatus according to various aspects of this disclosure, wherein the platform is in a first position and the radiation energy device is in a first projection position;

[0020] Figure 33 It is a side perspective view of an additive manufacturing apparatus according to various aspects of this disclosure, wherein the platform is in a first position and the radiation energy device is in a second projection position;

[0021] Figure 34 It is a side perspective view of an additive manufacturing apparatus according to various aspects of this disclosure, wherein the platform is in the second position and the radiation energy device is in the third projection position;

[0022] Figure 35 It is a side perspective view of an additive manufacturing apparatus according to various aspects of this disclosure, wherein the platform is in the second position and the radiation energy device is in the fourth projection position;

[0023] Figure 36 This is a side perspective view of an additive manufacturing apparatus according to various aspects of this disclosure;

[0024] Figure 37 Methods of operating additive manufacturing equipment according to various aspects of this disclosure; and

[0025] Figure 38 An exemplary computing system for additive manufacturing equipment according to various aspects of this disclosure is described.

[0026] Reference characters are used repeatedly in this specification and drawings to indicate the same or similar features or elements of this disclosure. Detailed Implementation

[0027] Reference will now be made in detail to the present embodiments of this disclosure, one or more examples of which are illustrated in the accompanying drawings. Detailed description uses numerals and letter designations to refer to features in the drawings. Similar or analogous reference numerals in the drawings and description have been used to refer to similar or analogous portions of this disclosure.

[0028] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of individual components. Unless otherwise specified herein, the terms “connection,” “fixed,” “attached,” etc., refer to direct connection, fixation, or attachment, as well as indirect connection, fixation, or attachment via one or more intermediate components or features. The terms “upstream” and “downstream” refer to the relative directions of movement of the resin support along the manufacturing equipment. For example, “upstream” refers to the direction in which the resin support moves from it, and “downstream” refers to the direction in which the resin support moves toward it. The term “selectivity” refers to the ability of a component to operate in various states (e.g., ON and OFF states) based on manual and / or automatic control of the component.

[0029] Unless the context clearly indicates otherwise, the singular forms “a,” “one,” and “the” include plural references.

[0030] The approximate language used throughout the specification and claims is applied to modify any quantitative expression that allows for variation without altering its underlying function. Therefore, values ​​modified by one or more terms such as “about,” “approximately,” and “substantially” are not limited to specified exact values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value, or the precision of the method or machine used to construct or manufacture the component and / or system. For example, approximate language may refer to a margin of ten percent.

[0031] Furthermore, the techniques of this application will be described in conjunction with exemplary embodiments. The term "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as superior to or advantageous to other implementations. Moreover, unless explicitly stated otherwise, all embodiments described herein should be considered exemplary.

[0032] Throughout this specification and claims, scope limitations are combined and interchanged, and unless the context or language otherwise indicates otherwise, such scopes are identified and include all subscopes contained herein. For example, all scopes disclosed herein include endpoints, and endpoints may be combined independently of each other.

[0033] As used herein, when the term “and / or” is used in a list of two or more items, it means that any one of the listed items may be used alone, or any combination of two or more of the listed items may be used. For example, if a composition or component is described as containing components A, B, and / or C, then the composition or component may contain only A; only B; only C; a combination of A and B; a combination of A and C; a combination of B and C; or a combination of A, B, and C.

[0034] This disclosure generally relates to an additive manufacturing apparatus that enables various manufacturing processes such that successive layers of material are provided on top of each other to “build” a three-dimensional part layer by layer. The successive layers are typically cured together to form a monolithic part that may have multiple integral sub-parts. Although additive manufacturing technology is described herein as capable of manufacturing complex objects by building them point by point, layer by layer, variations of the described additive manufacturing apparatus and technology are possible and within the scope of this subject matter.

[0035] Additive manufacturing equipment may include a support plate, a window supported by the support plate, and a platform movable relative to the window. The additive manufacturing equipment may further include a first resin and a second resin, both deposited as layers of desired thickness on a resin support (e.g., foil, tape, barrel, plate, etc.) fed in the X-axis direction from a supply reel or a pair of supply reels. In various cases, the first resin may be laterally offset from the second resin in the Y-axis direction.

[0036] The platform descends onto the resin, positioning a working surface, defined by the platform's surface or one of the surfaces of the workpiece, such that the working surface just contacts the resin or compresses it between the resin support and the platform, defining the layer thickness. Radiative energy is used to cure the resin through the resin support. Once the first layer has cured, the platform retracts, and the cured material moves with the platform. The resin support is then advanced to expose new, clean sections, ready for the deposition of additional resin in subsequent cycles.

[0037] In some cases, the additive manufacturing apparatus further includes an actuator assembly comprising a first actuator configured to move the platform in the Z-axis direction and a second actuator configured to move the platform in the Y-axis direction. Movement of the platform in the Y-axis direction allows layers of the part to be selectively formed from a first resin and / or a second resin. Therefore, the part can be formed from one or more resins.

[0038] Referring to the accompanying drawings, the same reference numerals denote similar elements in the various views. Figure 1A and 1B An example of a suitable device 10 of one type is schematically shown for forming a component 12 produced by one or more layers of at least one cured resin R. The device 10 may include one or more of a support plate 14, a window 16, a platform 18 movable relative to the window 16, and a radiation energy device 20, the combination of which can be used to form any number (e.g., one or more) of additively manufactured components 12.

[0039] exist Figure 1A In the example shown, device 10 includes a feed module 22 and a take-up module 24. Feed module 22 may include a first roller 22A, and take-up module 24 may include a second roller 24A. Feed module 22 and take-up module 24 are spaced apart by a resin support 26 extending therebetween. A portion of the resin support 26 may be supported from below by a support plate 14. Suitable mechanical supports (frames, brackets, etc.) and / or alignment devices may be provided for rollers 22A, 24A, and support plate 14. The first roller 22A and / or the second roller 24A may be configured to control the speed and direction of the resin support 26 such that a desired tension and speed are maintained in the resin support 26 by a drive system 28. By way of example and not limitation, drive system 28 may be configured as a separate motor associated with the first roller 22A and / or the second roller 24A. In addition, various components, such as motors, actuators, feedback sensors and / or controllers, can be provided to drive rollers 22A and 24A, thereby keeping the resin support 26 taut between the aligned rollers 22A and 24A, and winding the resin support 26 from the first roller 22A to the second roller 24A.

[0040] In various embodiments, window 16 is transparent and can be operatively supported by support plate 14. Furthermore, window 16 and support plate 14 can be integrally formed such that one or more windows 16 are integrated within support plate 14. Similarly, resin support 26 is also transparent or includes transparent portions. As used herein, the terms "transparent" and "ray-transmissive" refer to materials that allow at least a portion of radiant energy of a selected wavelength to pass through. For example, the radiant energy passing through window 16 and resin support 26 can be ultraviolet, infrared, visible, or any other feasible radiant energy. Non-limiting examples of transparent materials include polymers, glasses, and crystalline minerals such as sapphire or quartz.

[0041] The resin support 26 extends between the feed module 22 and the take-up module 24 and defines a “build surface” 30, which may appear planar but can also be arcuate (depending on the shape of the support plate 14). In some cases, the build surface 30 may be defined by the resin support 26 and positioned facing the platform 18, with the window 16 on the side of the resin support 26 opposite to the platform 18. For ease of description, the build surface 30 may be considered to be oriented parallel to the XY plane of the device 10, and the direction perpendicular to the XY plane is represented by the Z-axis direction (X, Y, and Z are three mutually perpendicular directions). As used herein, the X-axis refers to the machine direction along the length of the resin support 26. As used herein, the Y-axis refers to the lateral direction across the width of the resin support 26 and is generally perpendicular to the machine direction. As used herein, the Z-axis refers to the platform direction, which can be defined as the direction of movement of the platform 18 relative to the window 16.

[0042] The build surface 30 can be configured to be "non-stick," i.e., resistant to adhesion to the cured resin R. The non-stick property can be manifested through a combination of variables, such as the chemical properties of the resin support 26, its surface finish, and / or the applied coating. For example, a permanent or semi-permanent non-stick coating can be applied. A non-limiting example of a suitable coating is polytetrafluoroethylene (“PTFE”). In some examples, all or part of the build surface 30 may contain controlled roughness or surface texture (e.g., protrusions, pits, grooves, ridges, etc.) with non-stick properties. Additionally or alternatively, the resin support 26 may be made wholly or partially of an oxygen-permeable material.

[0043] For reference purposes, the area or volume immediately surrounding the location of the resin support 26 and the window 16 or the permeable portion defined by the support plate 14 can be defined as the “construction area” denoted as 32.

[0044] In some cases, the material depositor 34 may be positioned along the resin support 26. The material depositor 34 may be any means or combination of means operable to apply a layer of resin R onto the resin support 26. The material depositor 34 may optionally include means or combination of means for defining the height of the resin R on the resin support 26 and / or leveling the resin R on the resin support 26. Non-limiting examples of suitable material depositing means include chutes, rollers, hoppers, pumps, nozzles, spray bars, or printheads (e.g., inkjet printers). In some examples, a scraper may be used to control the thickness of the resin R applied to the resin support 26 as the resin support 26 passes through the material depositor 34.

[0045] exist Figure 1B In the example shown, the resin support 26 may be in the form of a bucket 36, configured to isolate potentially contaminated build debris from the available resin R. The bucket 36 may include a base plate 38 and a peripheral wall 40. The peripheral wall 40 extends from the base plate 38. The inner surfaces of the base plate 38 and the peripheral wall 40 define a container 42 for receiving the resin R.

[0046] Drive system 28 (available) Figure 1A The resin support 26 is used to move the barrel 36 relative to the platform 18 in the X direction between the build area 32 and a location at least partially outside the build area 32. However, it should be understood that in other embodiments, the resin support 26 may be stationary without departing from the scope of this disclosure.

[0047] In some cases, the resin support 26 may be positioned to receive resin R from the material depositor 34, which is operable to introduce a layer of resin R into the resin support 26. The material depositor 34 may optionally include means or combinations of means for defining the height of the resin and / or leveling the resin R. Non-limiting examples of suitable material depositing devices include chutes, hoppers, pumps, nozzles, spray bars, or printheads (e.g., inkjet printers).

[0048] Return to reference Figure 1A and 1B Resin R includes any radiation-curable material capable of adhering or binding fillers (if used) together in a cured state. As used herein, the term "radiation-curable" refers to any material that solidifies or partially solidifies in response to the application of radiation energy of a specific frequency and energy level. For example, resin R may include a photopolymer resin containing a photoinitiator compound that initiates a polymerization reaction, causing resin R to change from a liquid (or powder) state to a solid state. Alternatively, resin R may include a material containing a solvent that can be evaporated by the application of radiation energy. Uncured resin R may be provided in solid (e.g., granular) or liquid form, including pastes or slurries.

[0049] Furthermore, resin R can be a relatively high-viscosity resin that will not "collapse" or run off during the construction process. The composition of resin R can be selected as needed to suit specific applications. Mixtures of different compositions can be used. Resin R can be selected to have the ability to vent gases or burn off during further processing (e.g., sintering processes).

[0050] Additionally or alternatively, resin R may be selected as a component with a reduced viscosity. The viscosity of these components decreases when shear stress is applied or when heated. For example, resin R may be selected to be shear-thinned, such that resin R exhibits a reduced viscosity as the stress applied to resin R increases. Additionally or alternatively, resin R may be selected to reduce its viscosity as resin R is heated.

[0051] Resin R may contain filler. The filler may be premixed with resin R and then loaded into material depositor 34. Alternatively, the filler may be mixed with resin R on device 10. The filler comprises particles, which are generally defined as “very small substances.” The filler may comprise any material that is chemically and physically compatible with the selected resin R. The shape of the particles may be regular or irregular, the size may be uniform or non-uniform, and they may have a variable aspect ratio. For example, the particles may take the form of powder, spheres, or granules, or may be in the form of rods or fibers.

[0052] The composition of the filler can be selected as needed, including its chemical properties and microstructure to suit a specific application. For example, fillers can be metallic, ceramic, polymeric, and / or organic. Other examples of potential fillers include diamond, silicon, and graphite. Mixtures of different components can be used. In some examples, the filler composition can be selected based on its electrical or electromagnetic properties; for example, it can be specifically an electrical insulator, dielectric material, electrical conductor, and / or magnetic.

[0053] The filler can be "fusible," meaning it can solidify into a mass when sufficient energy is applied. Fusibility is a characteristic of many available powders, including but not limited to polymers, ceramics, glass, and metals. The filler-to-resin R ratio can be selected to suit a specific application. Generally, any amount of filler can be used, as long as the combined material is flowable and can be leveled, and there is sufficient resin R to hold the filler particles in a cured state.

[0054] Platform 18 is a structure defining a flat surface 44, which can be oriented parallel to the building surface 30 or the XY plane. Various means can be provided to move platform 18 relative to window 16. For example, Figure 1A and 1BAs shown, movement can be provided by actuator assembly 46, which can be coupled to static support 48. In some embodiments, actuator assembly 46 may include a first actuator 50 between platform 18 and static support 48, which allows movement of platform 18 in a first vertical direction (e.g., along the Z-axis). Actuator assembly 46 may additionally or alternatively include a second actuator 52 between platform 18 and the first actuator 50 and / or static support 48, which allows movement in the X-axis and / or Y-axis directions. Actuator assembly 46 may additionally or alternatively include a third actuator 54 between platform 18 and the second actuator 52 and / or platform 18, which allows movement in the X-axis and / or Y-axis directions. Actuator assembly 46 may include any feasible means for moving platform 18 in any direction, such as a ball screw electric actuator, linear electric actuator, pneumatic cylinder, hydraulic cylinder, delta drive, conveyor belt system, or any other feasible means. It should be understood that in other examples, the resin support may additionally or alternatively translate in the Y-axis direction (or any other direction).

[0055] The radiation energy device 20 can be configured as any device or combination of devices operable to generate and project radiation energy onto the resin R during the construction process in a suitable pattern, at a suitable energy level, and with other operating characteristics to cure the resin R. For example, as... Figure 1A and 1B As shown, the radiant energy device 20 may include a projector 56, which generally refers to any device operable to generate radiant energy with appropriate energy levels and other operating characteristics to cure resin R. As used herein, the term "patterned image" refers to the projection of radiant energy comprising an array of one or more individual pixels. Non-limiting examples of patterned image devices include DLP projectors or other digital micromirror devices, two-dimensional LED arrays, two-dimensional laser arrays, and / or optically addressed light valves. In the illustrated example, the projector 56 includes a radiant energy source 58 such as a UV lamp, an image forming apparatus 60, and optional focusing optics 66 (e.g., one or more lenses) operable to receive a source beam 62 from the radiant energy source 58 and generate a patterned image 64 to be projected onto the surface of resin R.

[0056] Image forming apparatus 60 may include one or more mirrors, prisms, and / or lenses, and is equipped with suitable actuators, and is arranged such that a source beam 62 from radiant energy 58 can be converted into a pixelated image 64 in an XY plane coinciding with the surface of resin R. In the illustrated example, image forming apparatus 60 may be a digital micromirror device.

[0057] The projector 56 may include additional components, such as actuators, mirrors, etc., configured to selectively move the image forming apparatus 60 or other parts of the projector 56, having the effect of rasterizing or moving the patterned image 64 to a position on the build surface 30. In other words, the patterned image 64 can be moved away from its nominal or starting position.

[0058] In addition to other types of radiant energy devices 20, the radiant energy device 20 may also include, as used herein, a “scanning beam apparatus,” which generally refers to any apparatus operable to generate a radiant energy beam with appropriate energy levels and other operating characteristics to cure resin R and scan the beam on the surface of resin R in a desired pattern. For example, a scanning beam apparatus may include a radiant energy source 58 and a beam steering device. The radiant energy source 58 may include any apparatus operable to generate a beam with appropriate power and other operating characteristics to cure resin R. Non-limiting examples of suitable radiant energy sources 58 include lasers or electron beam guns.

[0059] In some cases, the device 10 may include a material holding assembly 68 configured to hold the resin support 26 at a predetermined position along the support plate 14. In some cases, the material holding assembly 68 may include one or more pneumatically actuated zones 70, each configured to selectively interact with the resin support 20 by generating forces on the surface of the resin support 26 opposite to the resin R.

[0060] One or more pneumatic actuation zones 70 may apply negative pressure to a first surface of the resin support 26 opposite to the resin R or to a second side of the resin support 26 to create suction or vacuum on the resin support 26. Negative pressure can hold the resin support 26 in a desired position along the support plate 14. One or more pneumatic actuation zones 70 may also apply positive pressure to a first surface of the resin support 26 opposite to the resin R or to a second side of the resin support 26 to create thrust on the resin support 26. Positive pressure can release the resin support 26 from components of the device 10 (e.g., window 16, material holding assembly 68, etc.). As used herein, “negative” pressure is any pressure less than the ambient pressure near one or more pneumatic actuation zones 70, allowing fluid to be drawn into one or more pneumatic actuation zones 70. Conversely, “positive” pressure is any pressure greater than the ambient pressure near one or more pneumatic actuation zones 70, allowing fluid to be discharged from one or more pneumatic actuation zones 70. Furthermore, “medium” pressure is any pressure substantially equal to the ambient pressure near one or more pneumatic actuation zones 70.

[0061] In some examples, the pneumatic actuation zone 70 may be fluidly connected to the pneumatic assembly 72 via various hoses and one or more ports. The pneumatic assembly 72 may include any means capable of providing vacuum / suction and / or propelling fluid (e.g., air or process gas (e.g., nitrogen or argon)) through one or more pneumatic actuation zones 70. For example, the pneumatic assembly 72 may include a pressurized fluid source comprising a compressor and / or a blower. The pneumatic assembly 72 may additionally or alternatively include any component capable of changing pressure, such as a venturi vacuum pump. In some embodiments, one or more valves and / or switches may be coupled to the pneumatic assembly 72 and one or more pneumatic actuation zones 70. The one or more valves and / or switches are configured to regulate the pressure in each of the one or more pneumatic actuation zones 70.

[0062] In some embodiments, the pneumatically actuated region 70 includes one or more holes 74 of arbitrary size and shape for interacting with the resin support 26. For example, the holes 74 can be any number of holes, slits, or other geometries defined by any component of the additive manufacturing apparatus 10 (e.g., a portion of the support plate 14), and any combination of holes, slits, or other geometries. Additionally or alternatively, the holes 74 can be defined by a portion of the support plate 14 formed of a porous material, or by any other component, wherein fluid can move from a first side of the support plate 14 to a second side of the support plate 14 to interact with the resin support 26.

[0063] In some examples, the pneumatic actuation zone 70 may be defined by an air chamber 76. The air chamber 76 may be of any size and may be similar in shape to or different from any other air chamber 76. In some cases, a gasket may be positioned around the edge of the air chamber 76. Additionally or alternatively, the material holding assembly 68 may include one or more clamps that compressively hold the resin support 26 along the support plate 14.

[0064] Further reference Figure 1A and 1B The viscosity changing component 78 may be integrated within the support plate 14 and / or otherwise operatively coupled to the resin support 26. The viscosity changing component 78 may be configured to apply shear stress to the resin R to change (e.g., reduce) the viscosity of the resin R. Additionally or alternatively, the viscosity changing component 78 may be configured to heat the resin R to change its viscosity. It should be understood that in embodiments where the resin R is heated to change its viscosity, the heat provided may be within a predetermined range sufficient to change the viscosity of the resin R without causing any crosslinking in the polymer.

[0065] In some embodiments, the viscosity changing component 78 may be configured to mechanically vibrate a portion of the support plate 14 to generate shear stress on the resin R. For example, the viscosity changing component 78 may include a moving device 80 (e.g., a transducer) operatively coupled to the support plate 14. The moving device 80 may be configured to vibrate at least a portion of the support plate 14 or any other module of the device 10 and then transmit the vibration to the resin R. Additionally and / or alternatively, the moving device 80 may be configured to convert electrical energy into ultrasonic mechanical pressure waves transmitted to the resin R. For example, the moving device 80 may be in the form of an ultrasonic vibration device, such as an ultrasonic vibration device utilizing a piezoelectric transducer. In other embodiments, in addition to a transducer or an alternative transducer, the viscosity changing component 78 may include, alone or in combination with one or another, a fluid, acoustic, motor (e.g., an eccentric cam), reciprocating piston, or any other moving device 80.

[0066] Mobile device 80 may be operatively coupled to computing system 84. Computing system 84 may include a signal generator that provides electrical pulses to mobile device 80, the voltage of which may vary at different frequencies and with different waveforms. For example, the signal may be a pure sine wave, or it may be modulated with one or more other frequencies. Alternatively, the signal may be a step pulse or a spike pulse. In some embodiments, the signal generator transmits a signal between 20 and 80 kHz. For example, the signal is at approximately 60 kHz. The signal generator may, for example, transmit a constant amplitude signal at a constant frequency, or alternate one or both of these parameters. The power level may be selected as a percentage of maximum power.

[0067] In other embodiments, the viscosity-changing component 78 may be configured to generate shear stress on the resin R through other configurations without departing from the scope of this disclosure. For example, the viscosity-changing component 78 may be configured as a probe that is adjacent to and in physical contact with the resin support 26 and / or any other module of the device 10 that may transfer shear stress to the resin support 26. Additionally or alternatively, the viscosity-changing component 78 may be configured as an ultrasonic or vibrating plate that may be operatively coupled to the resin support 26 and / or any other module of the device 10 that may provide shear stress to the resin R on the resin support 26.

[0068] Further reference Figure 1A and 1BIn various embodiments, the gasket 82 may be positioned between the window 16 and the support plate 14 to isolate the movement of each of the window 16 and the support plate 14 from each other. By isolating the movement of the window 16 from the support plate 14, degradation problems of the device 10 caused by the operation of the viscosity-changing component 78 can be mitigated. In various examples, the gasket 82 may be formed of a motion-damping material, such as any of a variety of elastic elastomers, including but not limited to materials containing natural rubber and silicone.

[0069] As provided herein, in some cases, the viscosity changing component 78 may additionally or alternatively generate heat to change the viscosity of the resin R. For example, rapid heating processes, such as dielectric or microwave heating, may be used to avoid exposing the resin R to prolonged heating cycles before reaching the operating temperature.

[0070] Figure 1A and 1B The computing system 84 is a general representation of the hardware and software that can be implemented to control the operation of device 10 (including platform 18, drive system 28, radiant energy device 20, actuator assembly 46, material holding assembly 68, viscosity changing assembly 78, moving device 80, actuators, and some or all of the various parts of device 10 described herein). For example, the computing system 84 can be implemented by software running on one or more processors, which are implemented in one or more devices such as programmable logic controllers (“PLCs”) or microcomputers. Such processors can be coupled to process sensors and operating components, for example, via wired or wireless connections. The same one or more processors can be used to retrieve and analyze sensor data, for statistical analysis, and for feedback control. Multiple aspects of device 10 can be subject to closed-loop control.

[0071] Optionally, components of device 10 may be enclosed by housing 86, which may be used to provide a shielding or inert gas (e.g., "process gas") atmosphere using gas port 88. Optionally, the pressure within housing 86 may be maintained at a desired level greater than or less than atmospheric pressure. Optionally, housing 86 may be temperature and / or humidity controlled. Optionally, ventilation of housing 86 may be controlled based on factors such as time intervals, temperature, humidity, and / or chemical concentrations. In some embodiments, housing 86 may be maintained at a pressure different from atmospheric pressure.

[0072] refer to Figure 2-4Various perspective views of an additive manufacturing apparatus 10 including an actuator assembly 46 according to exemplary embodiments of the present disclosure are provided. The exemplary apparatus 10 may include a base structure 90 and a static support 48 extending from the base structure 90. In the illustrated embodiment, the actuator assembly 46 is operatively coupled to the static support 48 and configured to change the position of the platform 18. However, it should be understood that the actuator assembly 46 may be operatively coupled to any other component without departing from the scope of the present disclosure.

[0073] As shown, actuator assembly 46 includes a first actuator 50 operably coupled to a static support 48. A second actuator 52 is operably coupled to the first actuator 50 and is movable along the first actuator 50. Additionally, a third actuator 54 is operably coupled to the second actuator 52 and is movable together with a second brake 52. Platform 18 is operably coupled to the third actuator 54 and is movable along the third actuator 54. In various embodiments, when platform 18 is moved along the Z-axis using the first actuator 50, the second actuator 52, the third actuator 54, and platform 18 move along the first actuator 50. When platform 18 is moved along the X-axis using the second actuator 52, the third actuator 54 and platform 18 move along the second actuator 52. When platform 18 is moved along the Y-axis, platform 18 moves along the third actuator 54. Although in Figure 2 The first actuator 50 is shown translating in the Z direction, the second actuator 52 is shown translating in the X-axis direction, and the third actuator 54 is shown translating in the Y direction. However, it should be understood that each actuator can be coupled to any other actuator and / or platform 18 and can move with any other actuator or platform 18 without departing from the scope of this disclosure. It should be understood that, for clarity, the terms "first actuator," "second actuator," and "third actuator" are used herein. It should be understood that, without departing from the scope of this disclosure, the additive manufacturing apparatus may include any one or more actuators.

[0074] Further reference Figure 2-4 The resin support 26 can be configured to hold a first material and a second material thereon. For example, the first material can be a first resin R1, and the second material can be a second resin R2. As shown, the first resin R1 can be positioned adjacent to the second resin R2 in the Y-axis direction. Thus, in some cases, as the resin support 26 translates across the window 16, the first resin R1 can be positioned on a first segment of the window 16. Similarly, as the resin support 26 translates across the window 16, the second resin R2 can be positioned on a second segment of the window 16, which is offset from the first segment.

[0075] In various embodiments, such as Figure 2-4 In the embodiment shown, the resin support 26 can be in the form of a first resin support 26A and a second resin support 26B, with the first resin support 26A configured to deposit a first resin R1 thereon, and the second resin support 26B configured to deposit a second resin R2 thereon. Each of the first resin support 26A and the second resin support 26B can be connected to the feed module 22 ( Figure 1A ) and winding module 24 ( Figure 1B Operablely connected. In some cases, each of the first resin support 26A and the second resin support 26-B can be operably connected to a common first roller 22A within the feed module 22 and / or a common second roller 24A within the take-up module 24. In this case, the translational travel length of the first resin support 26A can be approximately equal to the translational travel length of the second resin support 26. However, it should be understood that the first resin support 26A can be operably connected to rollers in the feed module 22 and take-up module 24 that are different from the second resin support 26, such that each resin support 26A, 26B can translate independently of each other in the X direction.

[0076] Further reference Figure 2-4 The material depositor 34 may include a first reservoir 92 configured to hold a first resin R1 and a second reservoir 94 configured to hold a second resin R2. As shown, the first reservoir 92 may be configured to hold the first resin R1 and the second reservoir 94 may be configured to hold the second resin R2.

[0077] In some examples, the material depositor 34 may further include a first container 96 fluidly connected to a first reservoir 92. A first conduit 98 extends from the first container 96 to guide a first resin R1 from the first container 96 to the first reservoir 92. Similarly, the material depositor 34 may also include a second container 100 fluidly connected to a second reservoir 94. A second conduit 102 extends from the second container 100 to guide a second resin R2 from the second container 100 to the second reservoir 94.

[0078] In various embodiments, the material depositor 34 may further include a first volume sensor 104 and / or a second volume sensor 106. The first volume sensor 104 may be configured to provide a signal to a computing system 84 relating to the volume of a first resin R1 within a first reservoir 92. The computing system 84 is configured to receive the monitoring signals and process them using a predetermined algorithm to generate a control signal for controlling a first regulator 108, which may allow or restrict the flow of the first resin R1 from the first container 96 to the first reservoir 92. Similarly, the second volume sensor 106 may be configured to provide a signal to the computing system 84 relating to the volume of a second resin R2 within a second reservoir 94. The computing system 84 is configured to receive the monitoring signals and process them using a predetermined algorithm to generate a control signal for controlling a second regulator 110, which may allow or restrict the flow of the second resin R2 from the second container 100 to the first reservoir 92. In this way, closed-loop control of the volumes of the first resin R1 and the second resin R2 can be achieved. The first volume sensor 104 and the second volume sensor 106 can each be implemented as one or more imaging sensors or any other vision-based device. The first volume sensor 104 and the second volume sensor 106 can be additionally and / or alternatively configured as any other feasible proximity sensor, such as, but not limited to, ultrasonic sensors, radar sensors, lidar sensors, etc.

[0079] Further reference Figure 2-4 As the first resin R1 is deposited on the resin support 26, the first thickness component 112 can be used to control the thickness of the resin R applied to the resin support 26. As the second resin R2 is deposited on the resin support 26, the second thickness component 114 can be used to control the thickness of the second resin R2 applied to the resin support 26. In the illustrated embodiment, the thickness of the first resin R1 can be defined using a doctor blade, and the thickness of the second resin R2 can be defined using a doctor blade. In various embodiments, other material deposition equipment can be used alone or in combination with the first and second doctor blades, such as, but not limited to, gravure rollers, metering rollers, weir-based cascades, direct die casting, and combinations thereof.

[0080] In some embodiments, a common thickness component may be used additionally or alternatively with the first thickness component 112 and the second thickness component 114. For example, a common material deposition apparatus may be used for each of the first resin R1 and the second resin R2. In some cases, the common material deposition apparatus may be configured to serve as overall control of the thickness of the initial deposited layers of the first resin R1 and the second resin R2. Furthermore, the first thickness component 112 may further define the thickness of the first resin R1, and the second thickness component 114 may further define the thickness of the second resin R2.

[0081] Still referencing Figure 2-4 The radiant energy device 20 can be positioned within the base structure 90. Alternatively, the radiant energy device 20 can be coupled to the image moving device 116 via a bracket 118. The moving device 80 may include actuators, mirrors, etc., configured to selectively move the radiant energy device 20 or another portion of the radiant energy device 20, having the effect of rasterizing or moving the patterned image 64 relative to the window 16. In other words, the patterned image 64 can be moved away from its nominal or starting position. For example, this allows a single radiant energy device 20 to cover a larger build area. This type of image projection may be referred to herein as a “tiled image.”

[0082] Additionally or alternatively, device 10 may include a plurality of radiant energy devices 20 operatively coupled to build area 32. Each of the plurality of radiant energy devices 20 may be configured, or may not be configured, to translate below window 16 and / or support plate 14. Furthermore, each of the plurality of radiant energy devices 20 may generate an image 64 that at least partially overlaps with an image 64 of an additional radiant energy device to form a stitched image on resin R. In various embodiments, the images 64 from each of the plurality of radiant energy devices 20 may have a degree of overlap, wherein the overlap is a single pixel, less than one pixel (e.g., half a pixel), or more than one pixel. Additionally, in some embodiments, optics 66 may be optically coupled to one or more radiant energy devices 20. In this case, at least one of the one or more radiant energy devices 20 and / or optics 66 may be translated along the Y-axis and / or otherwise moved by moving device 80 to generate patterned images 64 on various portions of resin support 26.

[0083] Furthermore, in some embodiments, device 10 may include one or more sensors 120 configured to detect information relating to the position of platform 18, resin support 26, and / or radiant energy device 20. For example, one or more sensors 120 may verify the position of platform 18 and / or resin support 26 whenever it is moved by actuator assembly 46. Similarly, one or more sensors 120 may verify the position of radiant energy device 20 whenever it is translated by moving device 80. In various embodiments, one or more sensors 120 may be any combination of devices configured to provide information indicating the position of platform 18 and / or resin support 26 or the position of radiant energy device 20. For example, one or more sensors 120 may include gyroscopes, accelerometers, proximity sensors, image sensors, and / or any other feasible sensors.

[0084] During operation, the radiant energy device 20 and / or moving components may generate heat. Therefore, one or more vents and / or fans 122 may be positioned within the base structure 90 to remove heat from the base structure 90. The one or more fans 122 may be configured to draw heated air from the base structure 90 to any fluid moving device 80 in the area adjacent to the base structure 90.

[0085] Now for reference Figure 5 According to various aspects of this disclosure, a method 200 for operating additive manufacturing equipment 10 is provided. The various steps of method 200 are as follows: Figure 5-24 The method 200 is illustrated schematically. It can be used to operate additive manufacturing equipment 10 or any other suitable additive manufacturing equipment 10. It should be understood that the exemplary method 200 discussed herein is for illustrative purposes only and is not intended to be limiting. Details may be omitted without departing from the scope of this disclosure. Figure 5 Any step in it.

[0086] Now for reference Figure 5 and Figure 6 Method 200 may include, at step 202, depositing a layer of first uncured resin and a layer of second uncured resin onto the resin support 26. In various embodiments, the first resin R1 may be laterally offset from the second resin R2 in the Y direction on the resin support 26. Furthermore, a gap 124 may be defined between the laterally offset first resin R1 and second resin R2.

[0087] Furthermore, the resin support 26 can be in the form of a first resin support 26A and a second resin support 26B, with the first resin support 26A configured to deposit a first resin R1 thereon and the second resin support 26B configured to deposit a second resin R2 thereon. Each of the first resin support 26A and the second resin support 26B can be operatively coupled to the feed module 22 and the take-up module 24. Conversely, the first resin R1 and the second resin R2 can be deposited on a common resin support 26.

[0088] When the first resin R1 and / or the second resin R2 are deposited on the resin support 26 and / or after the first resin R1 or the second polymer R2 is deposited on the resin support 26, the resin support 26 can be translated into the build area 32 in the X-axis direction.

[0089] like Figure 5 and Figure 7As shown, at step 204, method 200 may include placing platform 18 in a first curing position by moving platform 18 such that the working surface of platform 18 and / or the component 12 held by platform 18 contact the first resin R1. As platform 18 moves to the first curing position, the working surface of platform 18 and / or the component 12 held by platform 18 contact the first resin R1.

[0090] like Figure 5 and 8 As shown, at step 206, method 200 may include curing a portion of the first resin R1 by applying radiant energy from the radiant energy device 20 through the window 16 and the resin support 26 while the platform 18 is in a first curing position relative to the window 16. As provided herein, the radiant energy may be in the form of a first patterned image 64 transmitted through at least a portion of the window 16. The cured portion of the first resin R1 forms a layer of the component 12 held by the platform 18. Figure 8 In an exemplary embodiment, the patterned image 64 is typically equal to the width of the first resin R1 in the Y-axis direction. However, the first portion may have any width (variable or constant) in the Y-axis direction.

[0091] like Figure 5 and 9 As shown, at step 208, method 200 may include changing the position of platform 18 via actuator assembly 46 to separate component 12 from resin support 26. It should be understood that platform 18 may move in the X-axis, Y-axis, and / or Z-axis directions.

[0092] like Figure 5 and 10 As shown, at step 210, method 200 may include placing platform 18 in a second curing position by moving platform 18 such that the working surface of component 12 held by platform 18 contacts the second resin R2. As platform 18 moves to the second curing position, the working surface of component 12 held by platform 18 contacts the second resin R2.

[0093] like Figure 5 and 11 As shown, at step 212, method 200 may include curing a portion of the second resin R2 by applying radiant energy from the radiant energy device 20 through the window 16 and the resin support 26 while the platform 18 is in a second curing position relative to the window 16. As provided herein, the radiant energy may be in the form of a patterned image 64 transmitted through at least a portion of the window 16. The cured portion of the second resin R2 forms a layer of the component 12 held by the platform 18. Figure 11In an exemplary embodiment, the patterned image 64 is typically equal to the width of the second resin R2 in the Y-axis direction. However, the second portion may have any width (variable or constant) in the Y-axis direction.

[0094] like Figure 5 and Figure 12 As shown, at step 214, method 200 may include changing the position of platform 18 via actuator assembly 46 to separate component 12 from resin support 26. It should be understood that platform 18 can move in the X-axis, Y-axis, and / or Z-axis directions.

[0095] like Figure 5 and 13 As shown, at step 216, after component 12 separates from resin support 26, method 200 may include translating resin support 26 such that fresh first resin R1 and second resin R2 are positioned between window 16 and platform 18. However, it should be understood that in various embodiments, resin support 26 supporting the respective resin can be translated after a portion of either resin has cured. Additionally or alternatively, resin support 26 can be translated whenever fresh resin is needed for the next layer to be formed. For example, if first resin R1 forms a first layer and second resin R2 forms a second layer, resin support 26 can be translated after the second layer. If first resin R1 forms both a first and a second layer, resin support 26 can be translated between the first and second layers, even if second resin R2 remains unused between the first and second layers.

[0096] As the resin support 26 translates, the platform 18 and the component 12 attached to the platform 18 can move based on the next layer to be formed. For example, in the illustrated embodiment, the third layer will include the first resin R1. Thus, the platform 18 can move in the Y-axis direction to a position above the first resin R1.

[0097] like Figure 5 and 14 As shown, at step 218, method 200 may include placing platform 18 in a third curing position by moving platform 18 such that the working surface of component 12 held by platform 18 contacts the first resin R1. As platform 18 moves to the third curing position, the working surface of component 12 held by platform 18 contacts the first resin R1.

[0098] like Figure 5 and 15As shown, at step 220, method 200 may include curing a portion of the first resin R1 by applying radiant energy from the radiant energy device 20 through the window 16 and the resin support 26 when the platform 18 is in a third curing position relative to the window 16. As provided herein, the radiant energy may be in the form of a patterned image 64 transmitted through at least a portion of the window 16. The cured portion of the first resin R1 forms a layer of the component 12 held by the platform 18. Figure 15 In an exemplary embodiment, the patterned image 64 is smaller than the width of the first resin R1 in the Y-axis direction. However, the cured portion can have any width (variable or constant) in the Y-axis direction.

[0099] like Figure 5 , 16 As shown in Figure 17, at step 222, method 200 may include changing the position of platform 18 via actuator assembly 46 to separate component 12 from resin support 26. It should be understood that platform 18 may be movable in the X-axis direction, Y-axis direction, and / or Z-axis direction.

[0100] like Figure 5 and 18 As shown, at step 224, method 200 may include placing platform 18 in a fourth curing position by moving platform 18 such that the working surface of component 12 held by platform 18 contacts the second resin R2. As platform 18 moves to the fourth curing position, the working surface of component 12 held by platform 18 contacts the second resin R2.

[0101] like Figure 5 and 19 As shown, at step 226, method 200 may include curing a portion of the second resin R2 by applying radiant energy from the radiant energy device 20 through the window 16 and the resin support 26 when the platform 18 is in a fourth curing position relative to the window 16. As provided herein, the radiant energy may be in the form of a patterned image 64 transmitted through at least a portion of the window 16. The cured portion of the second resin R2 forms a layer of the component 12 held by the platform 18. Figure 19 In an exemplary embodiment, the patterned image 64 is smaller than the width of the second resin R2 in the Y-axis direction. However, the cured portion can have any width (variable or constant) in the Y-axis direction.

[0102] like Figure 5 and 20 As shown, at step 230, method 200 may include changing the position of platform 18 via actuator assembly 46 to separate component 12 from resin support 26. It should be understood that platform 18 can move in the X-axis, Y-axis, and / or Z-axis directions.

[0103] like Figure 5 and 21 As shown, at step 232, after the component 12 is separated from the resin support 26, method 200 may include translating the resin support 26 such that fresh first resin R1 and second resin R2 are positioned within the build area 32.

[0104] like Figure 5 and 22 As shown, at step 234, method 200 may include placing platform 18 in a fifth curing position by moving platform 18 in the X-axis, Y-axis and / or Z-axis directions, such that the working surface of component 12 is held in contact with the first resin R1 and the second resin R2 by platform 18. As platform 18 moves to the fifth curing position, the working surface of component 12 held by platform 18 contacts the first resin R1 and the second resin R2.

[0105] like Figure 5 and 23 As shown, at step 236, method 200 may include curing a portion of the first resin R1 and the second resin R2 by applying radiant energy from the radiant energy device 20 through the window 16 and the resin support 26 when the platform 18 is in the fifth curing position relative to the window 16. As provided herein, the radiant energy may be in the form of a patterned image 64 transmitted through at least a portion of the window 16.

[0106] like Figure 5 and 24 As shown, at step 238, method 200 may include changing the position of platform 18 via actuator assembly 46 to separate component 12 from resin support 26. It should be understood that platform 18 and resin support 26 can be moved to any number (one or more) of curing locations to form each layer of component 12 based on component design.

[0107] Now for reference Figure 25-34 Various views of the additive manufacturing apparatus 10 according to various aspects of this disclosure are shown. Although for clarity, Figure 25-34 Only some components of the additive manufacturing equipment are shown in this disclosure; however, it should be understood that the additive manufacturing equipment may include any features described herein. Furthermore, it should be understood that the additive manufacturing equipment can perform… Figure 5-24 Method 200 and / or any other method described herein, such as Figure 36 The method described in 400.

[0108] exist Figure 25-34In the illustrated embodiments, the additive manufacturing apparatus may include a frame 126 and an actuator assembly 46 configured to allow various components of the additive manufacturing apparatus to move relative to each other. In some cases, the frame 126 may include a frame structure 128 and may be operatively coupled to and / or operatively support various components of the additive manufacturing apparatus. As shown, the frame 126 may support a build plate 130, a support plate 14, and / or a substrate 132.

[0109] The build plate 130 may support the first actuator 50. In some embodiments, the first actuator 50 may allow the platform 18 to move in a first vertical direction (e.g., along the Z-axis). The first actuator 50 may include any device capable of moving the platform 18 in the Z-axis direction, such as a ball screw electric actuator, a linear electric actuator, a pneumatic cylinder, a hydraulic cylinder, a delta drive, a conveyor system, or any other feasible device.

[0110] The printhead 134 may be operatively coupled to the first actuator 50. In this configuration, the printhead 134 may be configured to translate by actuation of the first actuator 50 or otherwise. The printhead 134 may be further operatively coupled to the platform 18. In some cases, the printhead 134 may include a clamp 136 and / or any other features for holding the platform 18 on the printhead 134.

[0111] The frame 126 can be further operatively connected to the support plate 14. In various embodiments, the window 16 can be operatively supported by the support plate 14. Furthermore, the window 16 and the support plate 14 can be integrally formed, such that one or more windows 16 are integrated within the support plate 14.

[0112] Further reference Figure 25-34 The substrate 132 can be fixed to the bottom portion of the frame structure 128. A first sliding assembly 138 can be operatively coupled to the substrate 132. The first sliding assembly 138 can be configured to guide movement of the substrate 132 relative to a mounting plate 140, which can be held in a generally static position within the additive manufacturing apparatus. However, it should be understood that the mounting plate 140 can be movable.

[0113] exist Figure 25-34In the illustrated embodiment, one or more guides 142 may be operatively coupled to the substrate 132. The guides 142 may move along a track 144 operatively coupled to the mounting plate 140. As will be described in more detail below, a first sliding assembly 138 may allow the frame 126, and thus the platform 18, to translate along the track 144 in the Y-axis direction, such that the platform 18 may descend onto a first resin R1 and / or a second resin R2. As provided herein, the first resin R1 may be separated from the second resin R2 by a gap 124. Thus, the platform 18 may be moved to various resins to form various portions of the component 12. It should be understood that in other embodiments, the track 144 may be operatively coupled to the substrate 132, and the guides 142 may be operatively coupled to the mounting plate 140, without departing from the scope of this disclosure. Furthermore, it should be understood that the first sliding assembly 138 may include any components that allow the substrate 132 to move relative to the mounting plate 140 without departing from the teachings provided herein.

[0114] In various embodiments, the second actuator 52 may be operatively coupled to the base plate 132 and the mounting plate 140. The second actuator 52 may be configured to move the base plate 132 relative to the mounting plate 140 in the Y-axis direction. The second actuator 52 may include any feasible device, such as a ball screw electric actuator, a linear electric actuator, a pneumatic cylinder, a hydraulic cylinder, a delta driver, a conveyor belt system, or any other feasible device.

[0115] Still referencing Figure 25-34 In various embodiments, the radiant energy device 20 may be operatively coupled to the frame 126 and positioned in the Z direction on the side of the window opposite the platform 18. In the illustrated embodiment, the radiant energy device 20 may include a pair of projectors 56. However, it should be understood that the radiant energy device 20 may be configured as any device or combination of devices operable to generate and project radiant energy at the resin R in a suitable pattern, at a suitable energy level, and with other operating characteristics during the build process to cure the resin R.

[0116] In some embodiments, the radiant energy device 20 may be operatively coupled to the support plate 146. In some cases, the radiant energy device 20 may include one or more support rails 148 coupled to the support plate 146 for holding the radiant energy device 20 relative to the support plate 146.

[0117] In several embodiments, the radiant energy device 20 may be movably coupled to the frame 126. For example, a second sliding assembly 150 may be positioned between the support plate 146 and the substrate 132. The second sliding assembly 150 may be configured to guide movement of the support plate 146 relative to the substrate 132. Thus, in some examples, the platform 18 and the radiant energy device 20 may be moved relative to each other relative to the mounting panel using a first sliding assembly 138, and the radiant energy device 20 may be moved relative to the platform 18 using the second sliding assembly 150.

[0118] exist Figure 25-34 In the illustrated embodiment, one or more guides 152 may be operatively coupled to the carrier plate 146. The guides 152 may move along a guide rail 154 operatively coupled to the substrate 132. As will be described in more detail below, a second sliding assembly 150 may allow the radiant energy device 20 to translate along the second sliding assembly 150 in the Y-axis direction, such that the radiant energy device 20 may be aligned with various portions of the resin support 26. It should be understood that in other embodiments, without departing from the scope of this disclosure, the guide rail 154 may be operatively coupled to the carrier plate 146, and the guides 152 may be operatively coupled to the substrate 132. Furthermore, it should be understood that without departing from the scope of this disclosure, the second sliding assembly 150 may be operatively coupled to any other component (e.g., the frame 126 or the mounting plate 140).

[0119] In various embodiments, the third actuator 54 may be operatively coupled to the carrier plate 146 and the base plate 132. The third actuator 54 may be configured to move the carrier plate 146 relative to the base plate 132 in the Y-axis direction. The third actuator 54 may include any feasible means, such as a ball screw electric actuator, a linear electric actuator, a pneumatic cylinder, a hydraulic cylinder, a delta driver, a conveyor belt system, or any other feasible means.

[0120] like Figure 25 As shown, cover 156 is operatively coupled to frame 126 and configured to shield the area between lens and support plate 14 of radiant energy device 20. In various embodiments, the shield can be configured to prevent the passage of light across a variety of spectra and / or all light.

[0121] Further reference Figure 28 and 29 The printhead 134 may include a printhead mounting plate 158, one or more printhead arms 160 extending from the printhead mounting plate 158, and an attachment assembly 162. The printhead 134 may be configured to selectively hold the platform 18.

[0122] In some embodiments, for example Figure 29In the embodiment shown, platform 18 is a structure defining a flat surface 44 that can be oriented parallel to build surface 30 or the XY plane. Platform 18 may further include one or more platform rails 164 configured to interact with printhead 134. One or more references 166 may also be positioned on and / or integrally formed with platform 18. In some cases, platform 18 may further include one or more handles 168.

[0123] Return to reference Figure 28 and 29 The clamp 136 of the attachment assembly 162 can selectively hold the platform 18 relative to the printhead 134. Furthermore, the attachment assembly 162 may further include an anchor plate 170 and a clamping plate 172. In operation, the anchor plate 170 can remain in a common position when the clamp 136 is in the unlocked and locked positions. The clamping plate 172 can be operatively coupled to the clamping arm 174. When the clamp 136 moves from the unlocked position to the locked position, the clamping plate 172 and the clamping arm 174 can move in an engaging manner, and vice versa.

[0124] The gripping arm 174 may include one or more protrusions 176 configured to be positioned within one or more guide rails 154 of the platform 18. In some cases, the one or more protrusions 176 may define a notch 178 to aid in positioning the platform 18 relative to the protrusions 176. In the case of one or more protrusions 176 within one or more guide rails 154 of the platform 18, one or more references 166 of the platform 18 may be aligned with a locator 180 within the attachment assembly 162. In various embodiments, as the gripper 136 moves to the locked position, the distance between the bottom portion of the locator 180 and the top portion of the gripping arm 174 increases in the Z-axis direction. This increased distance generates an expansion force on the guide rails 154 and one or more references 166 of the platform 18, thereby holding the platform 18 in place relative to the printhead 134.

[0125] Further reference Figure 30 and 31 As described herein, mounting plate 140 may have a pair of tracks 144 operably coupled thereto. A plurality of guides 142 are coupled to substrate 132 and may be configured to move along a first sliding assembly 138. As shown, a second actuator 52 may be operably coupled to substrate 132 and mounting plate 140 to move substrate 132 relative to mounting plate 140. In some cases, the second actuator 52 may be configured to move substrate 132 between a first position and a second position.

[0126] In the first position, the platform 18 can be activated by the first actuator 50 ( Figure 25The platform 18 descends to a position on at least a portion of the first resin R1. In the first position, the guide 142 can contact the first pair of stops 182. In the second position, the platform 18 can be lowered by the first actuator 50 (…). Figure 25 The guide 142 descends to a position on at least a portion of the second resin R2. When in the second position, the guide 142 can contact the second pair of stops 184. It should be understood that, without departing from the scope of this disclosure, the first sliding assembly 138 may include a single first stop and / or a single second stop.

[0127] In various embodiments, each of the first pair of stops 182 and the second pair of stops 184 can be adjustable. For example, the first pair of stops 182 and the second pair of stops 184 can be in the form of fine-threaded (e.g., 100 threads per inch (TPI)) adjustable end stops, which allows for precise positioning of each pair of corresponding end stops 182, 184. In some embodiments, one or more guides 142 may include a hardened support 186 configured to engage with the end stops 182, 184. The support 186 can be removable and replaceable, thereby allowing easy replacement of the support 186 in use when it wears down due to use and / or any other reason.

[0128] Further reference Figure 31 As provided herein, the second sliding assembly 150 may include a pair of guide rails 154 operatively coupled to the substrate 132. The second sliding assembly 150 may also include one or more guides 152 coupled to the carrier plate 146. The guides 152 may be configured to move along the pair of guide rails 154. As shown, a third actuator 54 may be operatively coupled to the substrate 132 and the carrier plate 146 to move the carrier plate 146 relative to the substrate 132. In some cases, the third actuator 54 may be configured to move the carrier plate 146 between a first position and a second position.

[0129] In a first position, the radiant energy device 20 can be positioned relative to the window 16 and / or the substrate 132. When in the first position, the guide 152 can contact the first stop 188. In a second position, the radiant energy device 20 can be positioned relative to the window 16 and / or the substrate 132 in a second position offset from the first position in the Y-axis direction. When in the second position, the guide 152 can contact the second stop 190.

[0130] exist Figure 31In the illustrated embodiment, a first stop 188 is operatively coupled to a substrate 132. A second stop 190 is operatively coupled to a flange 192 of the substrate 132. In various embodiments, each of the first and second end stops can be adjustable. For example, the first and second end stops can be in the form of fine-threaded (e.g., 100 TPI) adjustable end stops that allow precise positioning of each of the first and second end stops. In some embodiments, a first support 186 can be supported by a carrier plate 146 and configured to align with the first end stop. The second support 186 can be operatively coupled to the opposite end of the carrier plate 146 and / or the guide 152 of the second sliding assembly 150. Each of the first and second supports 186 can be removable and replaceable, thereby allowing easy replacement of the support 186 in use when it wears due to use and / or any other reason.

[0131] Now for reference Figures 32-34 Various perspective views of an additive manufacturing apparatus having an actuator assembly 46 are provided according to various aspects of this disclosure. As provided herein, the additive manufacturing apparatus can be configured to deposit a first resin R1 and a second resin R2 onto a resin support 26. The first resin R1 can be laterally offset from the second resin R2 in the Y direction on the resin support 26. Furthermore, a gap 124 can be defined between the laterally offset first resin R1 and second resin R2.

[0132] Actuator assembly 46 may include a first actuator 50 configured to move platform 18 at multiple locations along the Z-axis. Actuator assembly 46 may also include a second actuator 52 that can be associated with a first sliding assembly 138. The first sliding assembly 138 may be configured to move platform 18 relative to mounting plate 140. Furthermore, actuator assembly 46 may include a third actuator 54 that can be associated with a second sliding assembly 150. The second sliding assembly 150 may be configured to move radiant energy device 20 relative to frame 126 and / or window 16.

[0133] During operation, the resin support 26 can be held in a generally consistent position. Conversely, the platform 18 and / or the radiant energy device 20 can be moved relative to the resin support 26, allowing the first resin R1 (or portions of the first resin R1) and / or the second resin R2 (or portions of the second resin R2) to be selectively cured.

[0134] For example, such as Figure 32As shown, the first sliding assembly 138 can be positioned in a first position relative to the mounting plate 140. In the first position, the guide 142 of the first sliding assembly 138 can contact and / or approach the first pair of stops 182. In the first position, the platform 18 can be substantially aligned with the first resin R1 in the Y-axis direction.

[0135] For example Figure 32 As shown, the second sliding assembly 150 can be in a first position. In the first position, the guide 152 of the second sliding assembly 150 can contact and / or approach the first stop 188 of the second sliding assembly 150. In the first position, the radiant energy device 20 can be in a first position relative to the window 16. In this way, the radiant energy device 20 can be guided toward a first portion of the first resin R1.

[0136] like Figure 33 As shown, when the first sliding assembly 138 is in the first position, the second sliding assembly 150 may alternatively be in the second position. In the second position, the guide 152 of the second sliding assembly 150 may contact and / or approach the second stop 190 of the second sliding assembly 150. In the second position, the radiant energy device 20 may be in a second position relative to the window 16. In this way, the radiant energy device 20 may be guided toward the second portion of the first resin R1.

[0137] like Figure 34 As shown, the first sliding assembly 138 can also be positioned in a second position relative to the mounting plate 140. In the second position, the guide 142 of the first sliding assembly 138 can contact and / or approach the second pair of stops 184. In the second position, the platform 18 can be substantially aligned with the second resin R2 in the Y-axis direction.

[0138] For example Figure 34 As shown, the second sliding assembly 150 can be in a first position. In the first position, the guide 152 of the second sliding assembly 150 can contact and / or approach the first stop 188 of the second sliding assembly 150. In the first position, the radiant energy device 20 can be in a third position relative to the window 16. In this way, the radiant energy device 20 can be guided toward the first portion of the second resin R2.

[0139] like Figure 35 As shown, when the first sliding assembly 138 is in the second position, the second sliding assembly 150 may alternatively be in the second position. In the second position, the guide 152 of the second sliding assembly 150 may contact and / or approach the second stop 190 of the second sliding assembly 150. In the second position, the radiant energy device 20 may be in a fourth position relative to the window 16. In this way, the radiant energy device 20 may be guided toward the second portion of the second resin R2.

[0140] During operation, each sliding component can be operated in any order to form part 12 formed from one or both of the first resin R1 and the second resin R2. In some cases, the radiant energy device 20 can be configured as any device or combination of devices operable to generate and project radiant energy at the resin R in a suitable pattern, at a suitable energy level, and with other operating characteristics during the construction process to cure the first resin R1 and / or the second resin R2. Furthermore, the radiant energy device 20 can be configured, or may not be configured, to translate below the window 16 and / or the support plate 14. For example, as... Figures 31-34 As shown, the radiant energy device 20 may include a first projector 56 and a second projector 56. Each of the first and second projectors 56 can generate an image 64 that at least partially overlaps with an image 64 from an additional radiant energy device to form a stitched image 64 on a first resin R1 and / or a second resin R2. In various embodiments, the images 64 from each of the plurality of radiant energy devices 20 may have a degree of overlap, wherein the overlap is a single pixel, less than a pixel (e.g., half a pixel), or greater than a pixel. Additionally or alternatively, the radiant energy device 20 is capable of performing a scanning process in which a series of patterned images 64 are emitted from the radiant energy device 20 as the radiant energy device 20 translates along the moving device 80. Thus, in some embodiments, the images 64 from the first projector 56 and the images 64 from the second projector 56 may be stitched together statically or mechanically. Additionally or alternatively, as the third actuator 54 changes the position of the first projector 56, the plurality of images 64 from the first projector 56 may be stitched together with each other. Similarly, as the third actuator 54 changes the position of the second projector 56, multiple images 64 from the second projector 56 can be stitched together.

[0141] Furthermore, in some embodiments, device 10 may include one or more sensors 194 configured to detect information relating to the position of the printhead, frame 126, and / or radiant energy device 20. For example, one or more sensors 194 may verify the position of platform 18 whenever platform 18 is moved. Additionally or alternatively, one or more sensors 194 may verify the position of frame 126 whenever frame 126 is translated. Additionally or alternatively, one or more sensors 194 may verify the position of radiant energy device 20 whenever radiant energy device 20 is translated by moving device 80. In various embodiments, one or more sensors 194 may be any combination of devices configured to provide information indicating the position of printhead, frame 126, and / or radiant energy device 20. For example, one or more sensors 194 may include a gyroscope, accelerometer, proximity sensor, image sensor, and / or any other feasible sensor.

[0142] Now for reference Figure 36 According to various aspects of this disclosure, a perspective view of an additive manufacturing apparatus is provided. As provided herein, the additive manufacturing apparatus can be configured to deposit a first resin R1 and a second resin R2 onto a resin support 26. The first resin R1 can be laterally offset from the second resin R2 in the Y direction on the resin support 26. Furthermore, a gap can be defined between the laterally offset first resin R1 and second resin R2.

[0143] As shown in the figures, in various embodiments, the frame 126 is movable relative to the support plate 14 and the window 16. Therefore, in some cases, there may be almost no relative movement between the resin support 26 and the support plate 14 and the window 16 in the Y-axis direction.

[0144] In some embodiments, the opening 196 may be defined between the support plate 14 and the frame 126 to accommodate movement of the frame 126 relative to the support plate 14. The length of the opening 196 in the Y-axis direction may be at least equal to the travel length of the construction plate 130 when the frame 126 moves from a first position to a second position.

[0145] Now for reference Figure 37 A method 400 for operating an additive manufacturing apparatus 10 is provided. Method 400 can be used to operate the additive manufacturing apparatus 10 or any other suitable additive manufacturing apparatus 10. It should be understood that the exemplary method 400 discussed herein is only for describing exemplary aspects of the subject matter and is not intended to be limiting. Details may be omitted without departing from the scope of this disclosure. Figure 36 Any step in it.

[0146] At 402, method 400 may include depositing a layer of first uncured resin and a layer of second uncured resin onto a resin support. In various embodiments, the first resin may be laterally offset from the second resin R2 in the Y direction on the resin support. Furthermore, a gap may be defined between the laterally offset first resin R1 and second resin R2.

[0147] Furthermore, the resin support can be in the form of a first resin support and a second resin support, with the first resin support configured to deposit a first resin thereon and the second resin support configured to deposit a second resin thereon. Each of the first and second resin supports can be operatively coupled to the feed module and the take-up module. Conversely, the first and second resins can be deposited on a common resin support.

[0148] At 404, method 400 may include translating the resin support in the X-axis direction into the build area while the first resin and / or the second resin are deposited onto the resin support and / or after the first resin and / or the second resin are deposited onto the resin support. As provided herein, the resin support can be translated by a drive assembly.

[0149] At 406, method 400 may include placing the platform in a first curing position by moving the platform, such that the working surface of the platform and / or the components held by the platform contact the first resin. As provided herein, additive manufacturing equipment includes a frame. The frame may include a frame structure, a building plate, a support plate, and / or a substrate.

[0150] A build plate can support a first actuator. In some embodiments, the first actuator can allow the platform to move in a first vertical direction (e.g., along the Z-axis). A printhead can be operatively coupled to the first actuator. In this case, the printhead can be configured to translate or otherwise move in the Z-axis direction via the actuator. The printhead can be further operatively coupled to the platform.

[0151] The substrate can be fixed to the bottom portion of the frame structure. A first sliding assembly can be operatively coupled to the substrate. The first sliding assembly can guide movement of the substrate relative to the mounting plate in the Y-axis direction. The mounting plate can be held in a generally static position within the additive manufacturing apparatus. In various embodiments, a second actuator can be operatively coupled to both the substrate and the mounting plate. The second actuator can be configured to move the substrate relative to the mounting plate in the Y-axis direction.

[0152] At 408, method 400 may include positioning the radiant energy device at a first projected position. In various embodiments, the radiant energy device may be operatively coupled to the frame and positioned in the Z direction on the side of the window opposite the platform. In several embodiments, the radiant energy device may be movably coupled to the frame. For example, a second sliding assembly may be positioned between a support plate and a substrate. The second sliding assembly may guide movement of the support plate relative to the substrate. Thus, in some examples, by using the first sliding assembly, the platform and the radiant energy device can be moved relative to each other relative to the mounting panel, and by using the second sliding assembly, the radiant energy device can be moved relative to the platform.

[0153] At 410, method 400 may include curing a portion of a first resin by applying radiant energy from the radiant energy device through a window of the support plate and a resin support, when the platform is in a first curing position and the radiant energy device is in a first projection position. As provided herein, the radiant energy may be in the form of a patterned image transmitted through at least a portion of the window.

[0154] At 412, method 400 may include positioning the radiant energy device at a second projected position. The second projected position is offset from the first cured position in the Y-axis direction. In various embodiments, the radiant energy device is moved from the first projected position to the second projected position by translating along a second sliding assembly. A third actuator may be operatively coupled to the base plate and carrier plate of the frame, the carrier plate being operatively coupled to the radiant energy device, to move the radiant energy device relative to the platform and / or resin support.

[0155] At 414, method 400 may include curing a portion of the first resin by applying radiant energy from the radiant energy device through a window of the support plate and a resin support when the platform is in a first curing position and the radiant energy device is in a second projection position. As provided herein, the radiant energy may be in the form of a patterned image transmitted through at least a portion of the window.

[0156] At 416, method 400 may include placing a platform in a second curing position by moving the platform, such that the working surface of the platform and / or the components held by the platform contact the first resin and / or the second resin. The second curing position is offset from the first curing position in the Y-axis direction.

[0157] At 418, method 400 may include positioning the radiant energy device at a first projection position. Furthermore, at 420, method 400 may include curing a portion of the second resin by applying radiant energy from the radiant energy device through a window in the support plate and a resin support when the platform is in a second curing position and the radiant energy device is in the first projection position. As provided herein, the radiant energy may be in the form of a patterned image transmitted through at least a portion of the window.

[0158] At 422, method 400 may include positioning the radiant energy device at a second projected position. The second projected position is offset from the first curing position in the Y-axis direction. In various embodiments, the radiant energy device is moved from the first projected position to the second projected position by translating along a second sliding assembly.

[0159] At 424, method 400 may include curing a portion of the second resin by applying radiant energy from the radiant energy device through a window of the support plate and a resin support when the platform is in the second curing position and the radiant energy device is in the second projection position.

[0160] Figure 38Certain components of a computing system 84 according to an exemplary embodiment of the present disclosure are depicted. The computing system 84 may include one or more computing devices 84A that can be used to implement the methods 200, 400 described herein. The computing device 84A may include one or more processors 84B and one or more memory devices 84C. The one or more processors 84B may include any suitable processing device, such as a microprocessor, microcontroller, integrated circuit, application-specific integrated circuit (ASIC), digital signal processor (DSP), field-programmable gate array (FPGA), logic device, one or more central processing units (CPUs), graphics processing units (GPUs) (e.g., dedicated to efficiently rendering images), processing units performing other specialized calculations, etc. The memory device 84C may include one or more non-transitory computer-readable storage media, such as RAM, ROM, EEPROM, EPROM, flash memory devices, disks, etc., and / or combinations thereof.

[0161] Memory device 84C may include one or more computer-readable media and may store information accessible by one or more processors 84B, including instructions 84D executable by one or more processors 84B. Instructions 84D may include one or more steps of methods 200, 400 described above, for example, performed at the additive manufacturing apparatus 10 described herein. Memory device 84C may store instructions 84D for running one or more software applications, displaying a user interface, receiving user input, processing user input, etc. In some implementations, instructions 84D may be executed by one or more processors 84B to cause one or more processors 84A to perform operations, for example, one or more portions of methods 200, 400 described herein. Instructions 84D may be software written in any suitable programming language or may be implemented in hardware. Additionally and / or alternatively, instructions 84D may be executed in logically and / or virtually separate threads on processor 84B.

[0162] One or more memory devices 84C may also store data 84E, which may be retrieved, manipulated, created, or stored by one or more processors 84B. Data 84E may include, for example, data that facilitates the execution of the methods 200, 400 described herein. Data 84E may be stored in one or more databases. The one or more databases may be connected to the computing system 84 via a high-bandwidth LAN or WAN, or via a network. The one or more databases may be split so that they are located in multiple regions. In some implementations, data 84E may be received from another device.

[0163] The computing device 84A may also include a communication module or interface 84F for communicating with one or more other components of the computing system 84 or the additive manufacturing apparatus 10 via a network. The communication interface 84F may include any suitable component for interfacing with one or more networks, including, for example, a transmitter, receiver, port, controller, antenna, or other suitable component.

[0164] It should be understood that the additive manufacturing equipment described herein is for illustrative purposes only. In other exemplary embodiments, the additive manufacturing equipment may have any other suitable configuration and may use any other suitable additive manufacturing technology. Furthermore, the additive manufacturing equipment and processes or methods 200, 400 described herein can be used to form parts using any suitable material. For example, the material may be plastic, metal, concrete, ceramic, polymer, epoxy resin, photopolymer resin, or any other suitable material, which may be contained in layers of slurry, resin, or any other suitable form of sheet material having any suitable consistency, viscosity, or material properties. For example, according to various embodiments of this subject matter, the additively manufactured parts described herein may be formed from a portion of the material, all of the material, or a combination of materials, including but not limited to pure metals, nickel alloys, chromium alloys, titanium, titanium alloys, magnesium, magnesium alloys, aluminum, aluminum alloys, iron, ferroalloys, stainless steel, and nickel-based or cobalt-based superalloys (e.g., available from Special Metals Corporation). (Products under the name). These materials are examples of materials suitable for the additive manufacturing process described herein and are generally referred to as "additive materials".

[0165] The various aspects of this invention are provided by the subject matter of the following clauses, which are intended to cover all suitable combinations unless otherwise specified based on the logic or context of the clauses and / or the related drawings and descriptions:

[0166] An additive manufacturing apparatus includes: a resin support configured to support a first resin and a second resin; a support plate including a window; a platform configured to hold one or more cured layers of the first resin or the second resin to form a component positioned relative to the support plate; a radiation energy device positioned on a side of the resin support opposite to the platform and operable to generate radiation energy and project the radiation energy through the window in the form of a patterned image; and an actuator assembly configured to move the platform in a Z-axis direction and a Y-axis direction.

[0167] The additive manufacturing apparatus according to one or more of these clauses, wherein the first resin is laterally offset from the second resin in the Y-axis direction.

[0168] The additive manufacturing apparatus according to one or more of these clauses, wherein a gap is defined between the first resin and the second resin.

[0169] The additive manufacturing apparatus according to one or more of these clauses, wherein the resin support comprises a first resin support and a second resin support, the first resin support being configured to deposit the first resin thereon, and the second resin support being configured to deposit the second resin thereon.

[0170] According to one or more of these clauses, in the additive manufacturing apparatus, the actuator assembly is further configured to move the radiant energy device relative to the resin support along the Y-axis direction.

[0171] The additive manufacturing apparatus according to one or more of these clauses further includes: a material depositor configured to deposit the first resin and the second resin onto the resin support, the material depositor including a first reservoir for holding the first resin and a second reservoir for holding the second resin.

[0172] The additive manufacturing apparatus according to one or more of these clauses further includes: a frame operatively coupled to the platform, the radiant energy device, and the support plate, the frame being further coupled to a mounting plate; and a first sliding assembly, wherein the frame, the platform, the radiant energy device, and the support plate are movable relative to the mounting plate along the first sliding assembly.

[0173] The additive manufacturing apparatus according to one or more of these clauses, wherein the actuator of the actuator assembly is operatively coupled to the frame and the mounting plate, and wherein the actuator is configured to move the frame between a first position and a second position along the first sliding assembly.

[0174] The additive manufacturing apparatus according to one or more of these clauses further includes: a second sliding assembly operatively coupled to the radiation energy device and the frame, wherein the radiation energy device is movable relative to the frame along the second sliding assembly.

[0175] The additive manufacturing apparatus according to one or more of these clauses further includes: a third actuator operatively coupled to the frame and the radiation energy device, wherein the third actuator is configured to move the radiation energy device between a first position and a second position along the second sliding assembly.

[0176] The additive manufacturing apparatus according to one or more of these clauses further includes: a frame operatively coupled to the platform, the radiant energy device, and the actuator assembly, wherein the frame, the platform, and the radiant energy device are movable relative to the support plate along a first sliding assembly.

[0177] A method of operating an additive manufacturing apparatus, the method comprising: depositing a first resin and a second resin onto a resin support; translating the resin support in an X-axis direction; placing a platform in a first curing position such that a working surface contacts the first resin; curing a portion of the first resin while the platform is in the first curing position; placing the platform in a second curing position, wherein the second curing position is offset from the first curing position in a Y-axis direction; and curing a portion of the second resin while the platform is in the second curing position.

[0178] The method according to one or more of these clauses, wherein when the platform is in the first curing position, the portion of the first resin is cured to form a first layer of the component, and when the platform is in the second curing position, the portion of the second resin is cured to form a second layer of the component.

[0179] The method according to one or more of these clauses, wherein when the platform is in the first curing position, the portion of the first resin is cured to form a first portion of the layer of the component, and when the platform is in the second curing position, the portion of the second resin is cured to form a second portion of the layer of the component.

[0180] The method according to one or more of these clauses further includes: positioning the radiant energy device at a first projection position, wherein the portion of the first resin is cured when the radiant energy device is at the first projection position.

[0181] The method according to one or more of these clauses further includes: positioning the radiant energy device at a second projection position, wherein the second projection curing position is offset from the first projection position in the Y-axis direction, and wherein the portion of the first resin is cured when the radiant energy device is at the second projection position.

[0182] An additive manufacturing apparatus includes: a frame including a frame structure having a build plate, a support plate, and a substrate respectively connected to the frame structure, wherein the support plate includes a window therein; a first actuator operatively coupled to the build plate; a printhead operatively coupled to the first actuator, wherein the actuator is configured to move the printhead relative to a Z-axis direction; a platform operatively coupled to the printhead; a radiation energy device operatively coupled to the frame and positioned in the Z-axis direction on a side of the window opposite to the platform; and a first sliding assembly operatively coupled to the substrate and a mounting plate of the frame, the first sliding assembly being configured to guide movement of the frame relative to the mounting plate in a Y-axis direction.

[0183] According to the method described in one or more of these clauses, the first sliding assembly includes a track operatively coupled to the mounting plate and one or more guides operatively coupled to the substrate, the one or more guides being slidable along the track.

[0184] The method according to one or more of these clauses further includes: a second sliding assembly positioned between the radiant energy device and the frame structure, the second sliding assembly being configured to guide movement of the radiant energy device relative to the window.

[0185] According to the method described in one or more of these clauses, the second sliding component includes a guide rail and one or more guides, the guide rail being operatively coupled to the frame structure, and the one or more guides being slidable along the guide rail.

[0186] This written description uses examples to disclose the invention, including the best mode, and also enables any person skilled in the art to practice the invention, including making and using any device or system and performing any combination of methods. The patentable scope of the invention is defined by the claims, but may include other examples that would occur to a person skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. An additive manufacturing apparatus, characterized in that, include: A common resin support member is configured to support a first resin and a second resin, wherein the first resin is laterally offset from the second resin in the Y-axis direction, and a gap is defined between the first resin and the second resin. Support plate, the support plate including a window; A platform configured to hold one or more cured layers of the first resin or the second resin to form a component positioned relative to the support plate; A radiant energy device, positioned on the side of the common resin support opposite to the platform, and operable to generate radiant energy and project radiant energy through the window in the form of a patterned image. An actuator assembly configured to move the platform in the Z-axis direction and the Y-axis direction; A frame, operably connected to the platform, the radiant energy device, and the support plate, the frame being further connected to a mounting plate; and A first sliding assembly, wherein the frame, the platform, the radiant energy device, and the support plate are movable relative to the mounting plate along the first sliding assembly.

2. The additive manufacturing equipment according to claim 1, characterized in that, The common resin support includes a first resin support and a second resin support, wherein the first resin support is configured to deposit the first resin thereon, and the second resin support is configured to deposit the second resin thereon.

3. The additive manufacturing equipment according to claim 1, characterized in that, The actuator assembly is further configured to move the radiant energy device relative to the common resin support along the Y-axis direction.

4. The additive manufacturing equipment according to claim 1, characterized in that, Further includes: A material depositor configured to deposit a first resin and a second resin onto a common resin support, the material depositor including a first reservoir for holding the first resin and a second reservoir for holding the second resin.

5. The additive manufacturing equipment according to claim 1, characterized in that, The actuator of the actuator assembly is operatively coupled to the frame and the mounting plate, and the actuator is configured to move the frame between a first position and a second position along the first sliding assembly.

6. The additive manufacturing equipment according to claim 1, characterized in that, Further includes: A second sliding assembly is operatively connected to the radiant energy device and the frame, wherein the radiant energy device is movable relative to the frame along the second sliding assembly.

7. The additive manufacturing equipment according to claim 6, characterized in that, Further includes: A third actuator, operatively coupled to the frame and the radiant energy device, wherein the third actuator is configured to move the radiant energy device between a first position and a second position along the second sliding assembly.

8. The additive manufacturing equipment according to claim 1, characterized in that, Further includes: A frame operatively connected to the platform, the radiant energy device, and the actuator assembly, wherein the frame, the platform, and the radiant energy device are movable relative to the support plate along a first sliding assembly.

9. A method of operating the additive manufacturing equipment according to claim 1, characterized in that, The method includes: A first resin and a second resin are deposited onto the common resin support; Place the platform in the first curing position so that the working surface contacts the first resin; A portion of the first resin is cured when the platform is in the first curing position; The platform is placed at a second curing position, wherein the second curing position is offset from the first curing position in the Y-axis direction; and A portion of the second resin is cured when the platform is in the second curing position.

10. The method according to claim 9, characterized in that, When the platform is in the first curing position, the portion of the first resin is cured to form the first layer of the component, and when the platform is in the second curing position, the portion of the second resin is cured to form the second layer of the component.

11. The method according to claim 9, characterized in that, When the platform is in the first curing position, the portion of the first resin is cured to form a first portion of the layer of the component, and when the platform is in the second curing position, the portion of the second resin is cured to form a second portion of the layer of the component.

12. The method according to claim 9, characterized in that, Further includes: The radiant energy device is positioned at a first projection position, wherein when the radiant energy device is at the first projection position, the portion of the first resin is cured.

13. The method according to claim 12, characterized in that, Further includes: The radiant energy device is positioned at a second projection position, wherein the second projection position is offset from the first projection position in the Y-axis direction, and wherein when the radiant energy device is at the second projection position, the portion of the first resin is cured.

14. An additive manufacturing apparatus, characterized in that, include: A frame, the frame including a frame structure having a building plate, a support plate and a base plate respectively connected to the frame structure, wherein the support plate includes a window therein; A first actuator, which is operatively coupled to the building plate; A printhead operatively coupled to a first actuator, wherein the first actuator is configured to move the printhead relative to a Z-axis direction; A platform, which is operatively connected to the printhead; A radiation energy device, which is operably connected to the frame and positioned in the Z-axis direction on the side of the window opposite to the platform; A resin support member, wherein the resin support member includes a first resin support member and a second resin support member; and A first sliding assembly, operably coupled to the base plate and mounting plate of the frame, is configured to guide movement of the frame relative to the mounting plate in the Y-axis direction between a first curing position and a second curing position, wherein the platform is configured to be aligned with a first resin support in the first curing position and with a second resin support in the second curing position, the first curing position being offset from the second curing position in the Y-axis direction.

15. The additive manufacturing equipment according to claim 14, characterized in that, The first sliding assembly includes a track operably coupled to the mounting plate and one or more guides operably coupled to the substrate, the one or more guides being capable of sliding along the track.

16. The additive manufacturing equipment according to claim 14, characterized in that, Further includes: A second sliding assembly is positioned between the radiant energy device and the frame structure, and is configured to guide the movement of the radiant energy device relative to the window.

17. The additive manufacturing equipment according to claim 16, characterized in that, The second sliding component includes a guide rail and one or more guide members, the guide rail being operably connected to the frame structure, and the one or more guide members being capable of sliding along the guide rail.

18. An additive manufacturing apparatus, characterized in that, include: A common resin support member, which is configured to support a first resin and a second resin; Support plate, the support plate including a window; A platform configured to hold one or more cured layers of the first resin or the second resin to form a component positioned relative to the support plate, wherein a working surface is defined by one of the surfaces of the platform or the component, and wherein the working surface is configured to simultaneously contact the first resin and the second resin. A radiant energy device, positioned on the side of the common resin support opposite to the platform, and operable to generate radiant energy and project radiant energy through the window in the form of a patterned image. An actuator assembly configured to move the platform in the Z-axis and Y-axis directions; A frame, which is operatively connected to the platform, the radiant energy device, and the actuator assembly; and A first sliding assembly, wherein the frame, the platform, and the radiant energy device are movable relative to the support plate along the first sliding assembly.

Images