An additive manufacturing device that hardens photocurable resin to create three-dimensional objects.

Abstract

The present invention relates to an additive manufacturing apparatus that additively manufactures a three-dimensional object by curing a photocurable resin, and more particularly to a bottom-up additive manufacturing apparatus.

Description

[Technical Field]

[0001] The present invention relates to an additive manufacturing apparatus that cures a photocurable resin to additively manufacture a three-dimensional object. [Background technology]

[0002] Various additive manufacturing devices are commonly known in the art and are configured to (photo)cure a photocurable resin to additively manufacture a three-dimensional object. Each device typically includes a bath device defining a receiving volume for receiving the photocurable resin, a build table device, and a build table positioned above a film, for example, and supported so as to be movable relative to the film with at least one degree of freedom. The build table device also includes an irradiation device, for example, a digital light irradiation device. The at least one irradiation device is configured to irradiate electromagnetic waves to selectively and sequentially cure the photocurable resin supplied to the receiving volume and additively manufacture a three-dimensional object in the build direction. The basic operation of each device is well known and does not require further explanation.

[0003] Although these devices are continually being improved to provide satisfactory quality of printed 3D objects, process-related issues remain that can affect the quality of the manufacturing process and / or the quality of the resulting 3D objects, particularly the so-called suction (cupping) effect that can occur between the bottom wall of the vat device and the cured resin layer when the build stage moves, for example, upward relative to the vat device.

[0004] Therefore, there is a need for a further improved additive manufacturing device that (photo) cures a photocurable resin to additively manufacture a three-dimensional object. Summary of the Invention [Problem to be solved by the invention]

[0005] Therefore, an object of the present invention is to provide an improved layered manufacturing device that layer-by-layer manufactures a three-dimensional object by (photo) curing a photocurable resin. [Means for solving the problem]

[0006] This object is specifically achieved by the subject matter of the appended claims.

[0007] A first aspect of the present invention relates to an additive manufacturing apparatus (hereinafter referred to as "apparatus") that additively manufactures a three-dimensional object by (photo) curing a photocurable resin. Therefore, the apparatus is generally configured to additively manufacture a three-dimensional object by (photo) curing a photocurable resin. Curing the photocurable resin typically involves selectively irradiating the photocurable resin in layers with electromagnetic energy (light) emitted from at least one irradiation device to sequentially generate cured resin layers of the three-dimensional object to be additively manufactured, with each cured resin layer representing a cross-section of the three-dimensional object to be additively manufactured.

[0008] The apparatus includes a vat apparatus. The vat apparatus defines a receiving volume for receiving a photocurable resin. Each photocurable resin may be, for example, a polyamide resin. The vat apparatus may include one or more vat apparatus elements. The one or more vat apparatus elements form one or more walls of the vat apparatus arranged and / or oriented to define a receiving volume for receiving the photocurable resin. A bottom of the receiving volume is defined by a membrane. As will be further apparent below, the membrane is typically attachable to or attached to one or more vat apparatus elements of the vat apparatus. The membrane is typically transparent to electromagnetic waves (light) emitted from at least one irradiation device of the apparatus. Thus, the membrane is transparent to at least the electromagnetic waves emitted from at least one irradiation device of the apparatus. Thus, the membrane may be transparent (to at least a characteristic, e.g., wavelength, of the electromagnetic waves emitted from at least one irradiation device of the apparatus). The membrane typically has a planar base shape. The membrane is typically elastic and / or flexible. The membrane may therefore exhibit reversible deflection and / or deformation behavior upon the action of forces, such as compressive forces, that occur during operation of the apparatus. The forces may arise directly or indirectly from the movement of the build stage of the apparatus relative to the membrane, particularly in the direction of the membrane. The membrane may therefore reversibly deflect and / or deform relative to a null state upon the action of the forces. The membrane may therefore be composed of elastic and / or flexible materials or elastic and / or flexible material structures that enable the reversible deflection and / or deformation behavior. As will be apparent further below, the elastic and / or flexible materials may be polymeric materials, and the elastic and / or flexible material structures may be, for example, polymeric material structures.

[0009] The apparatus further includes a build table device. The build table device includes a build table. The build table forms a build surface on which a three-dimensional object can be additively manufactured. The build surface typically includes a flat surface facing the membrane. The build table is movably supported with at least one degree of freedom of movement relative to the membrane. The at least one degree of freedom of movement is typically a free movement of movement along a movement axis. The movement axis is typically located and oriented perpendicular to the base surface of the membrane (in a non-flexed and non-deformed state). The build table device may include one or more actuators, such as one or more electric motors, configured to move the build table relative to the membrane along the movement axis. The one or more actuators may be configured, in particular, to reciprocate the build table along the movement axis, so that the build table can be moved in two directions along the movement axis, for example, upward and downward. The build table is typically positioned above the membrane. Thus, the apparatus may have a so-called bottom-up configuration. However, at least some of the aspects or features of the apparatus identified below may be implemented in a so-called top-down configuration. Thus the device can also have a so-called top-down configuration.

[0010] The device typically includes a transparent member disposed below the membrane. The transparent member is at least transparent to electromagnetic waves (light) emitted from at least one irradiation device of the device. Therefore, the transparent member is transparent to at least electromagnetic waves emitted from at least one irradiation device of the device. Therefore, the transparent member may be transparent to at least electromagnetic waves emitted from at least one irradiation device of the device. The transparent member is typically rigid. Therefore, the transparent member typically does not exhibit reversible bending and / or deformation behavior even when a force is applied during operation of the device. Therefore, the transparent member is made of a rigid material or rigid material structure and does not exhibit reversible bending and / or deformation behavior during operation of the device. Each rigid material can be, for example, a glass material or a polymer material, and each rigid material structure can be, for example, a glass structure or a polymer material structure. In a specific, but non-limiting example, the transparent member is made of glass, particularly borosilicate glass, which exhibits both rigidity and the necessary transparency to at least electromagnetic waves emitted from at least one irradiation device of the device.

[0011] The transmission element typically has a plate-like configuration. The plate-like configuration of the transmission element comprises at least one flat upper surface. The flat upper surface of the transmission element is typically parallel to the basal plane of the membrane when the membrane is in an undeflected and undeformed state.

[0012] The transparent member is typically supported movably within a horizontal operating plane. In this manner, the transparent member is movable between at least one operating position and at least one non-operating position. Both the at least one operating position and the at least one non-operating position are typically located within the horizontal operating plane of the transparent member. The horizontal operating plane of the transparent member can be a plane parallel to the (horizontal) base surface of the vat device. In particular, the horizontal operating plane of the transparent member can be a plane parallel to the (undeflected and undeformed) base surface of the membrane or a plane parallel to the build surface of the build platform.

[0013] In at least one operating position, the transparent member is generally positioned above or below the membrane so as to provide mechanical support to the membrane, particularly in a deflected and / or deformed state. Thus, in at least one operating position, the transparent member is typically positioned adjacent (vertically) above or below the membrane, such that the space above or below the membrane is at least partially occupied by the transparent member. In at least one operating position, the transparent member is positioned below the membrane so that deflections or deformations of the membrane, such as bending, buckling, curvature, etc., that occur during operation of the device, particularly resulting directly or indirectly from movement of the build platform toward the membrane and associated pressure generation on the membrane, can be compensated for or at least reduced by the transparent member. Thus, the transparent member is configured, through its rigidity, to compensate for and at least reduce, respectively, deflections or deformations of the membrane that occur during operation of the device. In particular, deflections or deformations of the membrane relative to the transparent member result in the deflections or deformations of the membrane being compensated for or at least reduced by the plate-like form and rigidity of the transparent member. In particular, mechanical contact between the membrane and the transparent member causes deflected or deformed portions of the membrane to be pressed against the flat upper surface of the transparent member, thereby eliminating or reducing deflection or deformation of the membrane. More specifically, due to the plate-like shape of the transparent member, including the flat upper surface, any deflection or deformation of the membrane pressed against the upper surface of the transparent member, particularly due to movement of the build table in the direction of the membrane, conforms to the planar shape of the upper surface of the transparent member. Thus, in at least one operating position, the transparent member ensures a (substantially) planar shape of at least a portion of the membrane, allowing for the formation and maintenance of a constant gap between the membrane and the build table during operation of the apparatus, and further allowing for the formation and maintenance of a constant resin layer thickness during operation of the apparatus. Thus, when the membrane deflects or deforms during operation of the apparatus, the transparent member provides mechanical support to the membrane, particularly to each of the deflected or deformed portions of the membrane, and is therefore considered a support member.

[0014] In at least one non-operating position, the transparent member is generally not positioned above or below the membrane and therefore cannot provide mechanical support for the membrane, particularly in deflected and / or deformed states of the membrane. Therefore, in at least one non-operating position, the transparent member is typically not positioned adjacent (vertically) above or below the membrane, so that the space above or below the membrane is not occupied by the transparent member. Therefore, in at least one non-operating position, the transparent member is not positioned below the membrane, so that deflections or deformations of the membrane, particularly those resulting directly or indirectly from movement of the build platform toward the membrane, are not compensated for or at least reduced by the transparent member.

[0015] Furthermore, moving the transparent element from at least one operating position to at least one non-operating position is an effective way to eliminate or at least reduce the suction (cupping) effect between the (previously) cured resin layer, the film, and the transparent element, which means that after moving the transparent element to at least one non-operating position after the resin layer has cured, the build platform with each deposited cured resin layer can be moved (substantially) away from the film with no or only a small mechanical load on the cured resin layer that would occur if the suction (cupping) effect was not eliminated or reduced.

[0016] Movement of the permeable member between at least one operative position and at least one non-operative position may be performed by one or more actuators, such as one or more electric motors, configured to move the permeable member relative to the membrane in a horizontal plane of motion. The one or more actuators may be configured, in particular, for reciprocating movement of the permeable member in the horizontal plane of motion, thereby moving the permeable member in two directions in the horizontal plane of motion. As will be more apparent below, movement of the permeable member in the horizontal plane may be or include lateral movement along an axis of movement or rotational movement about an axis of rotation.

[0017] The apparatus further includes at least one irradiation device, such as a digital light irradiation device, arranged above or below the transparent member. The at least one irradiation device is configured to irradiate electromagnetic waves to selectively and sequentially cure the photocurable resin contained in the receiving volume of the bath apparatus, thereby additively manufacturing a three-dimensional object. In an exemplary embodiment, the apparatus may include at least two different irradiation devices. In an exemplary configuration of the apparatus having at least two different irradiation devices, the first irradiation device may be a digital light irradiation device, and the second irradiation device may be or include a laser device. The at least two different irradiation sources may be configured to irradiate electromagnetic waves of (substantially) the same wavelength or similar wavelengths. Similar wavelengths mean that the wavelengths of the electromagnetic waves differ from each other by 10% or less, particularly 5% or less. The apparatus may include one or more optical devices assigned to one or more irradiation devices. Each optical device may be arranged in an optical path between one or more irradiation devices and the film. Each optical device may include at least one of a beam combining device, a collimating device, an expanding device, a focusing device, a polarizing device, a beam splitting device, etc.

[0018] The configuration of the present device allows for significant improvements over existing devices, in particular by effectively eliminating or at least significantly reducing the suction (cup) effect, thereby improving the quality of the additive manufacturing process and the resulting three-dimensional objects.

[0019] As mentioned above, the membrane generally has a planar base shape in its undeflected and undeformed states, respectively. The undeflected and undeformed states of the membrane can be considered or denoted as the "zero state." In the membrane's zero state, a gap may exist between the membrane, i.e., the surface of the membrane that faces the permeable element, particularly in at least one operating position, and the upper surface of the permeable element, i.e., the upper surface of the permeable element that faces the membrane, particularly in at least one operating position. Therefore, in the membrane's zero state, there is no mechanical contact between the membrane and the permeable element. Therefore, movement of the permeable element from at least one undeflected position to at least one operating position is not adversely affected by mechanical contact and associated frictional and / or sticking effects between the permeable element and the membrane. This means that the base surface of the membrane (in the zero state) and the horizontal operating surface of the permeable element may be displaced (vertically) relative to each other. The gap between the membrane (in the zero state) and the transparent element can be in the range of 25 to 200 μm, in particular in the range of 25 to 175 μm, more particularly in the range of 25 to 150 μm, more particularly in the range of 25 to 125 μm, more particularly in the range of 25 to 100 μm, more particularly in the range of 25 to 75 μm, and even more particularly in the range of 25 to 50 μm. Preferably, the gap between the membrane (in the zero state) and the transparent element can correspond to the layer thickness to be implemented in the additive manufacturing process when the device is operated. The layer thickness can be selected, for example, based on the properties of the photocurable resin. An exemplary layer thickness is 1 in the above range.

[0020] The at least one degree of freedom of movement of the permeable member can be a lateral movement of the permeable member along a horizontal axis of movement, particularly a horizontal axis of movement parallel to the base plane of the membrane. In this way, the permeable member can be moved to at least one operating position and / or at least one non-operating position by lateral movement in a horizontal plane of movement. The lateral movement can be effective, for example, to achieve specific spatial requirements necessary for the implementation of each movable support of the permeable member. Alternatively or additionally, the at least one degree of freedom of movement of the permeable member can be a rotational movement of the permeable member about a vertical axis of rotation, particularly a rotational axis perpendicular to the base plane of the membrane. In this way, the permeable member can be moved to at least one operating position and / or at least one non-operating position by rotational movement in a horizontal plane of movement. The rotational movement can also be effective to achieve specific spatial requirements necessary for the implementation of each movable support of the permeable member. In either case, the device comprises one or more guide elements enabling each guided movement of the permeable member along the horizontal axis of movement or about the vertical axis of movement.

[0021] The apparatus further includes at least one actuator device coupleable or coupled to the transparent member to provide a driving force to the transparent member, thereby moving the transparent member from at least one operative position to at least one inoperative position and vice versa. Each actuator device may include one or more actuators as described above. Each actuator may generally be or include an electric actuator, a mechanical actuator, an electromechanical actuator, a hydraulic actuator, a pneumatic actuator, or the like.

[0022] The apparatus may further include a hardware and / or software-based controller configured to control movement of the transparent member between the operative position and the non-operative position and vice versa. The controller may be in communication with at least one actuator device and generate control signals to control operation of the at least one actuator device to move the transparent member between the at least one operative position and the at least one non-operative position, respectively. The controller may be connected to one or more other controllers of the apparatus, such as a controller controlling operation of the build table and / or a controller controlling application of electromagnetic waves by the at least one application device. The controller may further be configured to utilize information, such as operational information, status information, etc., from one or more other controllers of the apparatus to generate control signals to control movement of the transparent member between the at least one operative position and the at least one non-operative position.

[0023] The apparatus may further include a responsive suspension device. The responsive suspension device is configured to suspend the transparent member and / or the build platform. In particular, the responsive suspension device is configured to suspend the transparent member and / or the build platform in a responsive manner. The responsive suspension of the transparent member and / or the build platform typically means that when a force acts directly or indirectly on the transparent member, for example, due to relative movement of the build platform with respect to the membrane, causing the transparent member and / or the build platform to be displaced from its initial (vertical) position, the suspension device is configured to return the transparent member and / or the build platform to its initial (vertical) position. Each initial (vertical) position of the transparent member and / or the build platform may correspond to a zero vertical position of the transparent member and / or the build platform with respect to the membrane. At each zero vertical position of the transparent member and / or the build platform, a gap may exist between the transparent member and / or the build platform and the membrane. The gap may also be the gap specified above.

[0024] The zero vertical position of the transparent member and / or the build platform may be formed by one or more stop elements provided on the apparatus. Each stop element may be provided, in particular, on a frame structure of the apparatus. Each stop element may be configured to limit further upward or downward movement of the transparent member and / or the build platform beyond the respective zero vertical position. As an example, each stop element may be a mechanical stop element, such as a mechanical engagement element with a protrusion, that limits further upward or downward movement of the transparent member and / or the build platform beyond the zero vertical position, for example, by direct or indirect mechanical engagement with the transparent member. Similarly, other stop elements, such as electrical stop elements, magnetic stop elements, etc., are also contemplated.

[0025] The responsive suspension device may include one or more suspension elements. The one or more suspension elements may be adjustable relative to a suspension direction of the responsive suspension device. The suspension direction may correspond to a build direction of the device. The one or more suspension elements may therefore have a variable spatial extension relative to the build direction of the device, i.e., in particular a variable longitudinal extension. The one or more suspension elements may therefore be reversibly transitionable from an initial state having a first spatial extension to at least one compressed state and / or at least one extended state having a second spatial extension different from the first spatial extension. Thus, by virtue of the extension and / or compression of the one or more suspension elements, the transparent member and / or the build platform may be moved to different vertical positions relative to the membrane.

[0026] The one or more suspension elements are typically configured to automatically return to an initial state corresponding to the zero vertical position of the transparent member and / or the build platform, such that the transparent member and / or the build platform can also automatically return to the zero vertical position. The time required for the transparent member and / or the build platform to automatically return to the zero vertical position can be the blank time of the device, during which no irradiation occurs. The blank time can vary depending on various parameters, such as the viscosity of the photocurable resin, the layer thickness, the cross-section to be irradiated, etc. Thus, there is no "default blank" time, and the device adjusts the blank time accordingly, enabling a faster additive manufacturing process.

[0027] Therefore, the effect of compensating for or at least reducing the deflection or deformation of the membrane can be improved when one or more suspension elements return to their initial state and when the transparent member suspended by the responsive suspension device makes a corresponding movement towards the membrane or the build platform, respectively. In particular, each movement of the transparent member towards the membrane or the build platform can increase the mechanical contact area between the transparent member and the membrane, resulting in an improved effect of compensating for or at least reducing the deflection or deformation of the membrane.

[0028] The suspension element(s) may be configured as or comprise, for example, a spring element, in particular a compression spring element. The use of a spring element is a reliable and cost-effective way to implement the respective suspension element. However, other active or passive suspension elements, such as hydraulic cylinders, pneumatic cylinders, piezo elements, etc., may also be generally considered.

[0029] The responsive suspension system may comprise a frame structure. One or more suspension elements may be attached to the frame structure of the responsive suspension system. The frame structure of the responsive suspension system may comprise one or more frame structural elements providing at least one attachment point for each suspension element. In particular, the frame structure may comprise at least one upper frame structural element and at least one lower frame structural element, and one or more suspension elements may be arranged between the at least one upper frame structural element and the at least one lower frame structural element. Thus, the at least one upper frame structural element and the at least one lower frame structural element may be connected via one or more suspension elements.

[0030] The transparent member or the modeling platform may also be attached to the frame structure of the responsive suspension system via one or more attachment locations. Accordingly, the frame structure may include a receiving portion for receiving the transparent member or the modeling platform. The dimensions and / or shape of the receiving portion may correspond to the dimensions and / or shape of the transparent member or the modeling platform. As a specific, but non-limiting example, the receiving portion may each be provided as a recess in the frame structure or at least one frame structural element. The dimensions and / or shape of the recess may correspond to the dimensions and / or shape of the transparent member and / or the modeling platform to be received therein. Furthermore, one or more mounting elements may be provided for stably mounting the transparent member or the modeling platform to the frame structure or at least one frame structural element. Each mounting element may include a mechanical mounting element, such as a bolt element, a clamp element, a rivet element, or other chemical and / or physical mounting element, such as adhesive, solder, or welding.

[0031] The responsive suspension system is supported for movement relative to the membrane in at least one degree of freedom in a horizontal plane of movement, such that the permeable member suspended by the responsive suspension system is movable between at least one first position in at least one operative position and at least one second position in which the permeable member suspended by the responsive suspension system is in at least one non-operative position. Thus, movement of the permeable member to the at least one operative position and / or the at least one non-operative position may be effected via movement of the responsive suspension system to the first and second positions. Thus, the responsive suspension system may comprise one or more actuators for moving the responsive suspension system in at least one degree of freedom of movement.

[0032] The apparatus may further include a sensor device configured to determine the lateral and / or horizontal position of the transparent element and / or the build platform, particularly relative to the membrane. The sensor device may be configured to generate sensor information indicative of the position of the transparent element and / or the build platform. Each piece of sensor information may directly or indirectly indicate the position of the transparent element and / or the build platform corresponding to a respective zero vertical position. Thus, the sensor device may be configured to determine whether the transparent element and / or the build platform is in and / or is not in the zero vertical position. Alternatively or additionally, each piece of sensor information may directly or indirectly indicate the position of the transparent element corresponding to at least one operating position and / or at least one non-operating position. Thus, the sensor device may be configured to determine, for example, whether the transparent element is in or is not in at least one operating position and / or at least one non-operating position.

[0033] Each sensor device may comprise one or more sensor elements. Each sensor element may comprise, for example, at least one of an acoustic sensor element, an electromechanical sensor element, a magnetic sensor element, an electromagnetic sensor element, and an optical sensor element. Each sensor element may, for example, be provided together with and / or adjacent to a frame structure of the adaptive suspension device. The corresponding sensor elements may be arranged in one or more planes, in particular in one or more horizontal and / or vertical planes. The sensor elements may, in particular, be arranged to form a sensor element array, for example to increase the (total) detection area of ​​the sensor device.

[0034] Returning to the configuration of the bat device, the following exemplary configurations are possible. The bat device can comprise a plurality of frame-shaped bat device elements connectable or connected to each other to form the bat device. Each frame-shaped bat device element can form the respective bat device element. In particular, the bat device can comprise a first frame-shaped bat device element and a second frame-shaped bat device element. The first frame-shaped bat device element has at least one first mating surface, and the second frame-shaped bat device element has at least one second mating surface, where the at least one first mating surface and the at least one second mating surface are configured to cooperatively grip the membrane between the first frame-shaped bat device element and the second frame-shaped bat device element. The first mating surface and the second mating surface can be configured as, for example, engaging elements. In particular, the first mating surface, which can be configured as or comprise a receiving portion, is configured to receive the second connecting element, and the second connecting element can be a protrusion configured to engage with the receiving portion. The reverse configuration is also possible. This allows for a highly stable attachment of the membrane and the bat device, which has a positive effect on the quality of the manufacturing process and the resulting three-dimensional object.

[0035] At least one of the first and second frame-shaped vat device elements can include or form a deformation compensator configured to compensate for the deformation effect of the membrane, which results from the gripping of the membrane between at least one of the first and second frame-shaped vat device elements, resulting in a non-uniform shape of the membrane and therefore a non-uniform bottom of the receiving volume of the vat device. Thus, a substantially flat bottom shape of the membrane is ensured, at least when no forces resulting from movement of the build platform in the direction of the membrane act on the membrane, thereby achieving the zero state of the membrane.

[0036] The deformation compensation portion of the first or second frame-shaped bat device element may include at least first, second, and third auxiliary portions. The at least three auxiliary portions may form separate parts of the single-structure first or second frame-shaped bat device element. The second auxiliary portion may be disposed or formed between and connect the first and third auxiliary portions. The first auxiliary portion may extend at an angle relative to the membrane, the third auxiliary portion may extend parallel to the membrane, and the second auxiliary portion may extend curvedly. In this way, a so-called Poisson compensation profile may be constructed.

[0037] The membrane may comprise a plurality of membrane elements that are connectable or connected to one another. The membrane elements that form the membrane are typically arranged vertically in a stacked manner, i.e., the membrane elements may be provided as stacked membrane layers. Forming the membrane from a plurality of membrane elements or membrane layers is advantageous for achieving the desired non-stick behavior of the membrane with respect to various materials, such as (cured) photocurable resins and materials that form the transparent member.

[0038] The membrane elements or layers may be bonded to one another by at least one bonding agent, such as an adhesive and / or a cohesive bonding agent. Generally, the bonding of each of the at least two laminated membrane elements or layers may be provided or supported by a bonding agent, such as an adhesive. Alternatively or additionally, mechanical bonding of each of the at least two laminated membrane elements or layers, for example by force and / or press-fitting, is also conceivable.

[0039] The membrane may include a first membrane element or membrane layer having an anti-sticking surface or material that exhibits an anti-sticking effect against the photocurable resin, particularly against the resin layer formed by curing the photocurable resin, and a second membrane element or membrane layer having an anti-sticking surface or material that exhibits an anti-sticking effect against the transparent member, particularly against the upper surface of the transparent member. These anti-sticking effects allow the resin layer formed by curing the photocurable resin to be easily removed from the membrane, and also allow the transparent member to be easily moved relative to the membrane, for example, from at least one operating position to at least one non-operating position, even when there is mechanical contact between the transparent member and the membrane. In other words, the frictional effect caused by the relative movement of the transparent member relative to the membrane can be significantly reduced.

[0040] Therefore, the first membrane element or membrane layer can generally be composed of any anti-stick or anti-friction material or structure that reduces the sticking or friction effect between the first membrane element and the resin layer formed by curing the photocurable resin. As an example, the first membrane element or membrane layer can be derived from or comprise at least one fluoropolymer, in particular (poly)tetrafluoroethylene or a (poly)tetrafluoroethylene compound. Similarly, the first membrane element or membrane layer can be derived from or comprise one or more (viscous) lubricants, such as silicone. Each lubricant can comprise one or more anti-stick or anti-friction materials.

[0041] Furthermore, the second membrane element or layer may generally be composed of any anti-stick or anti-friction material or structure that reduces sticking or friction effects between the second membrane element and the permeable member. By way of example, the second membrane element or layer may be derived from or comprise at least one polyester-based polymer, in particular poly(ethylene terephthalate) or a poly(ethylene terephthalate) compound. Similarly, the second membrane element or layer may be derived from or comprise one or more (viscous) lubricants, such as silicone. Each lubricant may comprise one or more anti-stick or anti-friction materials.

[0042] In either case, the manufacturing process may use each membrane element facing the build platform as a so-called zero reference.

[0043] Additionally or alternatively, the transparent member may be provided, in particular on its upper surface, with an anti-stick surface or material, respectively, that provides an anti-stick effect to the membrane, in particular to the lower surface of the membrane facing the transparent member in its operating position. Similarly, the transparent member may be at least partially coated with one or more (viscous) lubricants, such as or including silicone. Each lubricant may comprise one or more anti-stick or anti-friction materials.

[0044] A second aspect of the present invention relates to a method for additive manufacturing of a three-dimensional object by selectively and continuously curing a photocurable resin supplied into a receiving volume of a vat device using electromagnetic waves emitted from at least one irradiation device. The method is performed by an additive manufacturing device, particularly the additive manufacturing device according to the first aspect of the present invention.

[0045] The method includes at least one step of moving the transparent member in a horizontal operating plane in at least one operating position that provides mechanical support to the membrane of the batt device of the additive manufacturing device, and / or moving the transparent member in a horizontal operating plane in at least one non-operating position that does not provide mechanical support to the membrane of the batt device of the additive manufacturing device.

[0046] All discussion relating to the apparatus of the first aspect of the invention also applies to the method of the second aspect of the invention, and vice versa.

[0047] When implemented by an additive manufacturing apparatus with a bottom-up configuration, the method includes, inter alia, the steps of: (i) moving the build platform downwards in the direction of the membrane of a butt device of the additive manufacturing apparatus, thereby exerting a force on the membrane that causes a temporary deflection or deformation of the membrane relative to its zero state; (ii) causing a transparent member arranged in an operating position below the membrane to move downwards due to the deflection or deformation of the membrane, thereby moving one or more suspension elements of a responsive suspension device that suspends the transparent member from an initial state in compression; (iii) returning the one or more suspension elements to their initial state, thereby moving the transparent member upwards to a zero vertical position; and (iv') optionally detecting, for example via a sensor device, that the transparent member is in the zero vertical position. (iv) when the transparent member is returned to the zero vertical position and placed at the zero vertical position, the irradiation device irradiates electromagnetic waves to generate a cured resin layer; (v) when the transparent member is moved to at least one non-operating position and the modeling table on which the cured resin layer is attached is moved upward (because the transparent member is not present below the cured resin layer in the at least one non-operating position), the suction effect between the cured resin layer and the transparent member is particularly removed or reduced; (vi) when the modeling table is moved upward to form a space for a new resin layer between the cured resin layer and the film; and (vii) repeating steps (i) to (vi) one or more times until a three-dimensional object of the desired configuration is formed.

[0048] The effect of compensating for or at least reducing the deflected or deformed portions of the membrane can be improved by each upward movement of the transparent member towards the build platform, in particular by the upward movement of the transparent member increasing the mechanical contact area between the transparent member and the membrane, thereby improving the effect of compensating for or at least reducing the deflected or deformed portions of the membrane.

[0049] The steps (i) to (vii) can also be carried out in a similar manner in an additive manufacturing apparatus having a top-down configuration.

[0050] The present disclosure will also be readily understood from the following description of exemplary embodiments taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0051] [Figure 1] FIG. 1 is a principle diagram illustrating an additive manufacturing apparatus according to an exemplary embodiment; [Figure 2] FIG. 1 is a principle diagram illustrating an additive manufacturing apparatus according to an exemplary embodiment; [Figure 3] FIG. 1 is a principle diagram illustrating an additive manufacturing apparatus according to an exemplary embodiment; [Figure 4] FIG. 1 is a principle diagram illustrating an additive manufacturing apparatus according to an exemplary embodiment; [Figure 5] FIG. 1 is a principle diagram illustrating an additive manufacturing apparatus according to an exemplary embodiment; [Figure 6] FIG. 1 is a principle diagram illustrating an additive manufacturing apparatus according to an exemplary embodiment; [Figure 7] FIG. 1 is a principle diagram illustrating an additive manufacturing apparatus according to an exemplary embodiment; [Figure 8] 1 is an enlarged principle diagram showing a bat device and membrane according to an exemplary embodiment; [Figure 9] FIG. 1 is a principle diagram illustrating an additive manufacturing apparatus according to another exemplary embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0052] 1 to 7 each show a principle diagram of an additive manufacturing apparatus 1 ("apparatus") according to an exemplary embodiment. The apparatus 1 is generally configured to (photo) cure a photocurable resin 3 to additively manufacture a three-dimensional object 2 (the three-dimensional object 2 is shown in the figure only by cured resin layers 2.1-2.n). Curing of the photocurable resin 3 by the apparatus 1 typically involves sequentially and selectively irradiating the photocurable resin 3 in layers with electromagnetic energy 4 (light) (see FIG. 4) emitted from at least one irradiation device 5, thereby sequentially producing each of the cured resin layers 2.1-2.n of the three-dimensional object 2 to be additively manufactured, and each of the cured resin layers 2.1-2.n represents a cross section of the three-dimensional object 2 to be additively manufactured.

[0053] The apparatus 1 includes a vat apparatus 6. The vat apparatus 6 defines a receiving volume 6.1 for receiving the photocurable resin 3. The vat apparatus 6 can include one or more vat apparatus elements 6.2, 6.3, with at least one vat apparatus element 6.1 forming a wall of the vat apparatus 6 arranged and / or oriented to define the receiving volume 6.1 for receiving the photocurable resin 3. The bottom of the receiving volume 6.1 is defined by a membrane 7. As can be seen from the figure, the membrane 7 is typically attachable to or attached to one or more of the vat apparatus elements 6.2, 6.3 of the vat apparatus 6. The membrane 7 is typically transparent to electromagnetic waves (light) emitted from the irradiation device 5 of the apparatus 1. Thus, the membrane 7 is transparent to at least the electromagnetic waves emitted from the irradiation device 5 of the apparatus 1. Thus, the membrane 7 can be transparent (to at least the characteristics, e.g., wavelengths, of the electromagnetic waves emitted from at least one irradiation device of the apparatus).

[0054] The membrane 7 is typically elastic and / or flexible and typically has a flat-bottom shape. Therefore, the membrane 7 can exhibit reversible deflection and / or deformation behavior when subjected to a force, such as a compressive force (shown by arrow F in FIG. 2 ), during operation of the apparatus 1. As shown in FIG. 2 , the forces can result directly or indirectly from the movement of the build stage 8.1 of the apparatus 1 relative to the membrane 7. Thus, upon application of the forces, the membrane 7 can reversibly deflect and / or deform relative to its null state (see FIG. 1 ). Therefore, the membrane 7 can be made of an elastic and / or flexible material or an elastic and / or flexible material structure that enables the reversible deflection and / or deformation behavior. As will be apparent further below, the elastic and / or flexible material can be a polymer material, and the elastic and / or flexible material structure can be, for example, a polymer material structure.

[0055] As described above, the apparatus 1 further comprises a build table device 8 constituting a build table 8.1. The build table 8.1 defines a build surface 8.2 on which a three-dimensional object 2 can be additively manufactured. The build surface 8.2 typically comprises a planar surface facing the membrane 7. As indicated by the double-headed arrow P1 in FIG. 1, the build table 8.1 is movably supported with at least one degree of freedom of movement relative to the membrane 7. In the illustrated exemplary embodiment, the at least one degree of freedom of movement is along a movement axis A1. The movement axis A1 is located and oriented perpendicular to the base surface of the membrane 7 (in its undeflected and undeformed state). The build table device 8 may comprise one or more actuators (not shown), e.g., one or more electric motors, configured to move the build table 8.1 relative to the membrane 7 along the movement axis A1. The actuator(s) may be configured to provide a reciprocating movement of the build platform 8.1, particularly along the axis of movement A1, so that the build platform 8.1 can move in two directions along the axis of movement A1, for example upwards and downwards.

[0056] In the illustrated exemplary embodiment, the build platform 8.1 is arranged above the membrane 7. The apparatus 1 therefore has a so-called bottom-up configuration, in which the build platform 8.1 is arranged above the membrane 7 and the irradiation device 5 is arranged below the membrane 7. However, the apparatus 1 may also generally have a so-called top-down configuration.

[0057] The device 1 further includes a transparent member 9 disposed below the film 7. The transparent member 9 is transparent to at least the electromagnetic waves (light) emitted from the irradiation device 5 of the device 1. Therefore, the transparent member 9 is transparent to at least the electromagnetic waves emitted from the irradiation device 5 of the device 1. Therefore, the transparent member 9 is transparent to at least the electromagnetic waves emitted from the irradiation device 5 of the device 1. The transparent member 9 is (substantially) rigid. Therefore, the transparent member 9 typically does not exhibit reversible bending and / or deformation behavior even when a force F is applied during operation of the device 1. Therefore, the transparent member 9 is made of a rigid material or rigid material structure, which enables the transparent member 9 not to exhibit reversible bending and / or deformation behavior during operation of the device 1. Each rigid material may be, for example, a glass material or a polymer material, and each rigid material structure may be, for example, a glass structure or a polymer material structure. According to a non-limiting example, the transparent member 9 can be made of glass, in particular borosilicate glass, which has both rigidity and the necessary transparency at least for the electromagnetic waves emitted by the irradiation device 5 of the device 1.

[0058] In the illustrated exemplary embodiment, the transmission member 9 has a plate-like configuration. The plate-like configuration of the transmission member 9 comprises a flat upper surface 9.1. The flat upper surface 9.1 of the transmission member 9 is typically parallel to the underlying surface of the membrane 7 when the membrane 7 is in an undeflected and undeformed state, as illustrated in FIG.

[0059] As shown by the double-headed arrow P2 in Figure 1, the transparent member 9 is supported so as to be movable within a horizontal operating plane MP. In this manner, the transparent member 9 is movable between an operating position (shown in Figures 1-4 and 7) and a non-operating position (shown in Figures 5 and 6). Both the operating and non-operating positions are typically located within the horizontal operating plane MP. The horizontal operating plane MP may be a plane parallel to the (horizontal) base surface of the vat device 6. In particular, the horizontal operating plane MP may be a plane parallel to the (undeflected and undeformed) base surface of the membrane 7 or a plane parallel to the build surface 8.2 of the build platform 8.1.

[0060] As shown in FIGS. 1-4 and 7 , the permeable member 9 is generally disposed below the membrane 7 in the operating position (see FIGS. 2 and 3 ) so as to provide or be able to provide mechanical support to the membrane 7, particularly in a deflected and / or deformed state of the membrane 7. Thus, in the operating position, the permeable member 9 is disposed vertically below and adjacent to the membrane 7, such that the space below the membrane 7 is at least partially occupied by the permeable member 9. In the operating position, the permeable member 9 is disposed particularly below the membrane 7 so that deflections or deformations of the membrane 7 (shown in FIG. 2 ), such as bending, buckling, curvature, etc., that occur during operation of the apparatus 1, i.e., deflections or deformations of the membrane 7 that occur directly or indirectly due to movement of the build platform 8.1 in the direction of the membrane 7 and the associated generation of pressure on the membrane 7, can be compensated for or at least reduced by the permeable member 9. The permeable member 9 is thus configured, through its stiffness, to compensate for or at least reduce each deflection or deformation of the membrane 7 that occurs during operation of the apparatus 1. In particular, deflection or deformation of the membrane 7 relative to the transparent member 9 is compensated for or at least reduced by the plate-like form and rigidity of the transparent member 9. In particular, mechanical contact between the membrane 7 and the transparent member 9 causes the deflected or deformed portion of the membrane 7 to be pressed against the flat upper surface 9.1 of the transparent member 9 (as shown in FIGS. 2 and 3), thereby eliminating or reducing the deflection or deformation of the membrane 7. More specifically, with the plate-like form of the transparent member 9 including the flat upper surface 9.1, deflected or deformed portions of the membrane 7, particularly due to movement of the build platform 8.1 toward the membrane 7, are pressed against the upper surface 9.1 of the transparent member 9 and conform to the planar shape of the upper surface 9.1 of the transparent member 9. Thus, in the operating position, the transparent member 9 ensures a (substantially) planar shape of at least a portion of the membrane 7, which allows for the formation and maintenance of a constant gap 10 between the membrane 7 and the build platform 8.1 during operation of the apparatus 1, and further allows for the formation and maintenance of a constant resin layer thickness during operation of the apparatus 1. In this way, when the membrane 7 is deflected or deformed during operation of the device 1, the permeable member 9 can be considered a support member since it provides mechanical support to the membrane 7, i.e., in particular to each deflected or deformed portion of the membrane 7.

[0061] 5 and 6, the transparent member 9 is generally not positioned below the membrane 7 and is therefore unable to provide mechanical support to the membrane 7, particularly in a deflected and / or deformed state of the membrane 7. Therefore, in the non-operating position, the transparent member 9 is typically not positioned adjacent and vertically below the membrane 7, so that the space below the membrane 7 is not occupied by the transparent member 9. Therefore, in the non-operating position, the transparent member 9 is not positioned specifically below the membrane 7, so that deflections or deformations of the membrane 7 that occur during operation of the apparatus 1, i.e., deflections or deformations of the membrane 7 that result directly or indirectly from movement of the build platform 8.1, particularly in the direction of the membrane 7, are not compensated for or at least reduced by the transparent member 9.

[0062] Furthermore, moving the transparent member 9 from the operating position to the non-operating position is an effective way to eliminate or at least reduce the suction (cupping) effect between the previously cured resin layer 2.1, the membrane 7, and the transparent member 9. This means that the mechanical load on the cured resin layer 2.1 (indicated by arrow P3 in FIG. 6 ) that would occur if the suction (cupping) effect were not eliminated or reduced is (substantially) or almost not generated after the transparent member 9 is moved to the non-operating position (see FIG. 5 ) after the resin layer 2.1 has hardened, and the build platform 8.1 with each cured resin layer 2.1 attached can be moved away from the membrane 7.

[0063] Movement of the transmission member 9 between the operative and non-operative positions may be effected by one or more actuators (not shown), e.g., one or more electromagnetic motors, configured to move the transmission member 9 relative to the membrane 7 in the horizontal motion plane MP. The one or more actuators may be configured, in particular, to reciprocate the transmission member 9 in the horizontal motion plane MP, thereby moving the transmission member 9 in two directions in the horizontal motion plane MP. As will be apparent further below, movement of the transmission member 9 in the horizontal motion plane MP may be or include lateral movement along a movement axis A2 or rotational movement about a rotation axis.

[0064] In the illustrated exemplary embodiment, at least one degree of freedom of movement of the permeable member 9 is lateral movement of the permeable member along a horizontal axis of movement A2 parallel to the base plane of the membrane 7. Thus, the permeable member 9 can be moved to an operative position and / or a non-operative position by lateral movement in the horizontal plane of movement MP. The lateral movement can be useful, for example, to achieve specific spatial requirements necessary to implement each movable support of the permeable member 9.

[0065] Alternatively or additionally, the movement of at least one degree of freedom of the permeable member 9 allows for rotational movement of the permeable member about a vertical axis of rotation (e.g., an axis parallel to axis A1), in particular a rotational axis perpendicular to the base plane of the membrane 7. In this way, the permeable member 9 can be moved to an operative position and / or a non-operative position via a rotational movement in the horizontal plane of movement MP. The rotational movement is also useful for achieving specific spatial requirements necessary for implementing each movable support of the permeable member 9.

[0066] In either case, the device 1 comprises one or more guide elements (not shown) allowing a guided movement of the transmission member 9 along a horizontal movement axis A2 or about a vertical movement axis, respectively.

[0067] The device 1 further includes at least one actuator device (not shown) coupleable to or coupled to the transparent member 9 to apply a driving force to the transparent member 9 to move the transparent member 9 from the operative position to the inoperative position and vice versa. Each actuator device may include one or more actuators, as described above. Each actuator may generally be or include an electric actuator, a mechanical actuator, an electromechanical actuator, a hydraulic actuator, a pneumatic actuator, etc.

[0068] The apparatus 1 may further include a hardware and / or software-based controller (not shown) configured at least to control movement of the transparent member 9 between the operative and non-operative positions. The controller may be in communication with at least one actuator device and generate control signals to control operation of the at least one actuator device to move the transparent member 9 to the operative and non-operative positions, respectively. The controller may be connected to one or more other controllers of the apparatus 1, such as a controller controlling operation of the build platform 8.1 and / or a controller controlling the application of electromagnetic waves by the application device 5. The controller may further be configured to utilize information, such as operational information, status information, etc., from one or more other controllers of the apparatus 1 to generate control signals to control movement of the transparent member 9 between the operative and non-operative positions.

[0069] As described above, in the exemplary embodiment, the apparatus 1 further includes an irradiation device 5, such as a digital light irradiation device, disposed below the transparent member 9. The irradiation device 5 is configured to irradiate electromagnetic waves to selectively and continuously cure the photocurable resin 43 supplied into the receiving volume 6.1 of the vat device 6, thereby enabling additive manufacturing of the three-dimensional object 2.

[0070] The configuration of the present device 1 allows for significant improvements over existing devices, in particular by effectively eliminating or at least significantly reducing the suction (cup) effect, thereby improving the quality of the additive manufacturing process and the quality of the resulting three-dimensional object 2.

[0071] As mentioned above, the membrane 7 has a planar base configuration, generally shown in FIG. 1 , in its undeflected and undeformed states, respectively. The undeflected and undeformed states of the membrane 7 may be considered or labeled as the "zero state." FIG. 1 further shows that in the zero state of the membrane 7, a gap 11 exists between the membrane 7, i.e., the surface of the membrane 7 that faces the permeable member 9, particularly in the actuated position, and the upper surface 9.1 of the permeable member 9 that faces the membrane 7, particularly in the actuated position. Thus, in the zero state of the membrane 7, there is no mechanical contact between the membrane 7 and the permeable member 9. Therefore, movement of the permeable member 9 from the unactuated position to the actuated position is not adversely affected by mechanical contact between the permeable member 9 and the membrane 7 and the associated frictional and / or sticking effects. This means that the base surface of the membrane 7 (in the zero state) and the horizontal actuated surface MP of the permeable member 9 are offset (vertically) relative to each other. The gap 11 between the membrane 7 (in the zero state) and the transparent member 9 can be, for example, in the range of 25 to 200 μm, specifically in the range of 25 to 175 μm, more specifically in the range of 25 to 150 μm, more specifically in the range of 25 to 125 μm, more specifically in the range of 25 to 100 μm, more specifically in the range of 25 to 75 μm, and even more specifically in the range of 25 to 50 μm. Preferably, the gap 11 between the membrane 7 (in the zero state) and the transparent member 9 corresponds to a layer thickness to be implemented in an additive manufacturing process when the apparatus 1 is operated. The layer thickness can be selected, for example, based on the properties of the photocurable resin. An exemplary layer thickness is one of the above ranges.

[0072] In the illustrated exemplary embodiment, the apparatus 1 further comprises a responsive suspension device 12. The responsive suspension device 12 is configured to responsively suspend the permeable member 9. Responsive suspension of the permeable member 9 typically means that the responsive suspension device 12 is configured to return the permeable member 9 to its initial (vertical) position, as shown in FIG. 1, when a force F acts directly or indirectly on the permeable member 9, causing the permeable member 9 to be displaced from its initial (vertical) position, for example, due to movement of the build platform 8.1 relative to the membrane 7. FIG. 2 illustrates the permeable member 9 displaced from its initial (vertical) position (as indicated by arrow P3), particularly due to hydrostatic pressure on the permeable member 9, and FIG. 3 illustrates the permeable member 9 returned to its initial (vertical) position (as indicated by arrow P4).

[0073] Each initial (vertical) position of the permeable member 9 may correspond to a zero vertical position of the permeable member 9 relative to the membrane 7. Figure 1 shows that at each zero vertical position of the permeable member 9, a gap 11 exists between the permeable member 9 and the membrane 7.

[0074] 1 shows schematically that the zero vertical position of the transparent member 9 can be determined by one or more stop elements 13 provided on the device 1. Each stop element 13 can be provided, in particular, on a frame structure (not shown) of the device 1. Each stop element 13 can be configured to limit further upward or downward movement of the transparent member 9 beyond the respective zero vertical position. By way of example, each stop element 13 is a mechanical stop element, such as a mechanical engagement element with a protrusion, which can limit further upward movement of the transparent member 9 beyond the zero vertical position, for example, by direct or indirect mechanical engagement with the transparent member 9. Similarly, other stop elements, such as electrical stop elements, magnetic stop elements, etc., are also contemplated.

[0075] The responsive suspension system 12 may comprise one or more suspension elements 12.1. The one or more suspension elements 12.1 are adjustable in a suspension direction of the responsive suspension system 12. The suspension direction may correspond to the construction direction of the device 1. The one or more suspension elements 12.1 may therefore have a variable spatial extension, i.e., in particular a variable longitudinal extension, relative to the construction direction of the device 1. The one or more suspension elements 12.1 may therefore be reversibly operated from an initial state having a first spatial extension (as shown in FIG. 1 ) to at least one compressed state having a second spatial extension (as shown in FIG. 2 ) different from the first spatial extension. The compressibility of the one or more suspension elements 12.1 may therefore operate the permeable member 9 to different vertical positions relative to the membrane 7.

[0076] The one or more suspension elements 12.1 are typically configured to automatically return to an initial state corresponding to the zero vertical position of the transparent member 9, so that the transparent member 9 can also be automatically returned to the zero vertical position. The time required for the transparent member 9 to automatically return to the zero vertical position is the blanking time of the apparatus 1, during which no irradiation occurs. The blanking time may vary depending on various parameters, such as the viscosity of the photocurable resin, the layer thickness, the cross-section to be irradiated, etc. Thus, the apparatus 1 may enable faster additive manufacturing processes, since there is no "default blanking" time, and the apparatus 1 adjusts the blanking time accordingly via the responsive suspension device 12.

[0077] As shown, the one or more suspension elements 12.1 may be configured as or comprise spring elements, in particular compression spring elements, for example. The use of spring elements is a reliable and cost-effective way of implementing each suspension element. However, other active or passive suspension elements 12.1, such as hydraulic cylinders, pneumatic cylinders, piezo elements, etc., are also generally contemplated.

[0078] As further shown, the responsive suspension system 12 may include a frame structure. One or more suspension elements 12.1 may be attached to the frame structure. The frame structure may include one or more frame structural elements 12.2, 12.3, each providing at least one attachment point for each suspension element 12.1. In particular, the frame structure may include at least one upper frame structural element 12.2 and at least one lower frame structural element 12.3, and one or more suspension elements 12.1 may be disposed between the at least one upper frame structural element 12.2 and the at least one lower frame structural element 12.3. Thus, the at least one upper frame structural element 12.2 and the at least one lower frame structural element 12.3 may be connected via one or more suspension elements 12.1.

[0079] As further shown, the transparent member 9 can be attached to the frame structure of the responsive suspension system 12 via one or more attachment locations. Accordingly, the frame structure can include receiving portions 12.4 for receiving the transparent member 9. The dimensions and / or shape of the receiving portions 12.4 can correspond to the dimensions and / or shape of the transparent member 9. In the illustrated non-limiting example, the receiving portions 12.4 can be provided as recesses in the frame structure or at least one frame structural element 12.2. The dimensions and / or shape of the receiving portions 12.4 can correspond to the dimensions and / or shape of the transparent member 9 to be received therein. Furthermore, one or more attachment elements (not shown) can be provided to enable stable attachment of the transparent member 9 to the frame structure or at least one frame structural element 12.2. Each attachment element can include a mechanical attachment element, such as a bolt element, a clamp element, a rivet element, or the like. Each attachment element can also include other chemical and / or physical attachment elements, such as adhesives, solder, welding, etc.

[0080] As further shown, the responsive suspension system 12 is movably supported relative to the membrane 7 in at least one degree of freedom of movement in the horizontal plane of movement MP, such that the responsive suspension system 12 is movable between a first position (shown in FIGS. 1-4 and 7 ) in which the permeable member 9 suspended by the responsive suspension system 12 is in an operative position, and a second position (shown in FIGS. 5 and 6 ) in which the permeable member 9 suspended by the responsive suspension system 12 is in a non-operative position. Thus, movement of the responsive suspension system 12 to each of the first and second positions effectively effects movement of the permeable member 9 in the operative and / or non-operative positions. Thus, the responsive suspension system 12 includes one or more actuators (not shown) that can provide movement of the responsive suspension system 12 in at least one degree of freedom of movement.

[0081] The apparatus 1 may further comprise a sensor device 14 configured to determine, in particular, the lateral and / or horizontal position of the permeable member 9 relative to the membrane 7. The sensor device 14 may be configured to generate sensor information indicative of, in particular, the position of the permeable member 9. Each piece of sensor information may directly or indirectly indicate a position of the permeable member 9 corresponding to a respective zero vertical position. Thus, the sensor device 14 may be configured to determine whether the permeable member 9 is in and / or is not in a zero vertical position. Alternatively or additionally, each piece of sensor information may directly or indirectly indicate a position of the permeable member 9 corresponding to an operative position and / or a non-operative position. Thus, the sensor device 14 may be configured to determine, for example, whether the permeable member 9 is in or is not in an operative position and / or a non-operative position.

[0082] Each sensor device 14 may comprise one or more sensor elements 14.1, for example comprising at least one of an acoustic sensor element, an electromechanical sensor element, a magnetic sensor element, an electromagnetic sensor element, and an optical sensor element. Each sensor element 14.1 may be provided, for example, together with and / or adjacent to the frame structure of the responsive suspension device 12.

[0083] Returning to the configuration of the bat device 6, FIG. 8 shows an enlarged principle view of an exemplary configuration in which the bat device 6 comprises multiple frame-shaped bat device elements connectable or connected to each other. Each frame-shaped bat device element may form each of the bat device elements 6.2 and 6.3 described above. In particular, the bat device 6 comprises a first frame-shaped bat device element (see element 6.2) and a second frame-shaped bat device element (see element 6.3). The first frame-shaped bat device element comprises at least one first mating surface 6.4, and the second frame-shaped bat device element comprises at least one second mating surface 6.5, which are configured to cooperatively grip the membrane 7 between the first and second frame-shaped bat device elements. In the exemplary embodiment, the first mating surface 6.4 and the second mating surface 6.5 are configured as engaging elements. In particular, the first connecting surface 6.4 is configured as or comprises a receiving portion and is adapted to receive the second connecting element 6.5 as a protrusion that engages in the receiving portion. Furthermore, a bolted connection can alternatively or additionally be provided. This allows for a highly stable attachment of the membrane 7 to the butt device 6, which has a positive effect on the quality of the building process and the resulting three-dimensional model 2.

[0084] 8 further shows that at least one of the first and second frame-shaped bat device elements can be provided with or form a deformation compensation part 6.6, which compensates for the deformation effects of the membrane 7 by gripping the membrane 7 between at least one of the first and second frame-shaped bat device elements. Thus, when no forces acting on the membrane 7 due to movements of the build table 8.1 in at least the direction of the membrane 7 act, the membrane 7 has an approximately flat bottom shape, which allows the membrane 7 to be in the zero state.

[0085] FIG. 8 shows that the deformation compensation portion 6.5 of the first or second frame-shaped bat device element can include at least a first auxiliary portion 6.6.1, a second auxiliary portion 6.6.2, and a third auxiliary portion 6.6.3. The at least three auxiliary portions 6.6.1-6.6.3 can form separate parts of the integral first or second frame-shaped bat device element. The second auxiliary portion 6.6.2 can be disposed between or connected to the first and third auxiliary portions 6.6.1 and 6.6.3. The first auxiliary portion 6.6.1 can extend at an angle relative to the membrane 7, the third auxiliary portion 6.6.3 can extend parallel to the membrane 7, and the second auxiliary portion 6.6.2 can extend in a curved manner. This allows for the creation of a so-called Poisson compensation profile.

[0086] 8 further shows that the membrane 7 may comprise a plurality of membrane elements 7.1, 7.2 that are connectable or connected to one another to form the membrane 7. The membrane elements 7.1, 7.2 that form the membrane 7 are typically arranged vertically stacked, i.e., the membrane elements 7.1, 7.2 may be provided as stacked membrane layers. Forming the membrane 7 from a plurality of membrane elements 7.1, 7.2 or membrane layers is advantageous for the desired non-stick behavior of the membrane 7 with respect to various materials, such as the (cured) photocurable resin 3 and the material that forms the transparent member 9.

[0087] The membrane elements 7.1, 7.2 or membrane layers may be bonded to one another by at least one bonding agent, such as an adhesive and / or a cohesive bonding agent. Generally, the bonding of the at least two laminated membrane elements 7.1, 7.2 or membrane layers may be provided or supported by a bonding agent, such as an adhesive. Alternatively or additionally, mechanical bonding of the at least two laminated membrane elements 7.1, 7.2 or membrane layers, for example by force and / or press-fitting, is also conceivable.

[0088] FIG. 8 specifically illustrates that the film 7 may include a first film element 7.1 or film layer having an anti-sticking surface or material that provides an anti-sticking effect against the photocurable resin 3, particularly the resin layer 2.1 formed by curing the photocurable resin 3, and a second film element 7.2 or film layer having an anti-sticking surface or material that provides an anti-sticking effect against the transparent member 9, particularly the upper surface 9.1 of the transparent member 9. These anti-sticking effects allow the resin layer 2.1 formed by (photo)curing the photocurable resin 3 to be easily removed from the film 7. Even if there is mechanical contact between the transparent member 9 and the film 7, as shown in FIG. 4, the transparent member 9 can be easily moved relative to the film 7, for example, from an operating position to a non-operating position. In other words, the frictional effect caused by the movement of the transparent member 9 relative to the film 7 can be significantly reduced.

[0089] Thus, in general, the first membrane element 7.1 or layer may be constituted by any anti-stick or anti-friction material or structure that reduces the sticking or frictional effects between the first membrane element 7.1 and the resin layer 2.1 formed by (photo)curing the photocurable resin 3. By way of example, the first membrane element 7.1 or membrane layer may be made of or comprise at least one fluoropolymer, in particular (poly)tetrafluoroethylene or a (poly)tetrafluoroethylene compound. Similarly, the first membrane element 7.1 or membrane layer may be made of or comprise one or more (viscous) lubricants, for example silicone or including silicone. Each lubricant may comprise one or more anti-stick or anti-friction materials.

[0090] Furthermore, the second membrane element 7.2 or membrane layer may generally be made of any anti-stick or anti-friction material or structure that reduces sticking or friction effects between the second membrane element 7.2 or membrane layer and the permeable member 9. By way of example, the second membrane element 7.2 or membrane layer may be made of or comprise at least one polyester-based polymer, in particular poly(ethylene terephthalate) or a poly(ethylene terephthalate) compound. Similarly, the second membrane element 7.2 or membrane layer may be made of or comprise one or more (viscous) lubricants, such as silicone. Each lubricant may contain one or more anti-stick or anti-friction materials.

[0091] In either case, during the build process, each membrane element 7.1 facing the build platform 8.1 can be used as a so-called zero reference.

[0092] Additionally or alternatively, the transparent member 9 may be provided, in particular on its upper surface 9.1, with a respective anti-stick surface or material to provide an anti-stick effect to the membrane 7, in particular to the lower surface of the membrane 7 facing the transparent member 9 in the operating position. Likewise, the transparent member 9 may be at least partially coated with one or more (viscous) lubricants, for example of or including silicone. Each lubricant may comprise one or more anti-stick or anti-friction materials.

[0093] Figure 9 shows an alternative embodiment of the device 1 which differs from the embodiment shown in Figures 1 to 7 in that the responsive suspension device 12 is arranged to suspend the build platform 8.1. All the explanations relating to the responsive suspension of the transparent member 9 by the responsive suspension device 12 apply equally.

[0094] The device 1 according to the exemplary embodiment shown in the figure selectively and continuously cures the photocurable resin 3 supplied in the receiving volume 6.1 of the vat device 6 by means of electromagnetic waves emitted from at least one irradiation device 5, thereby enabling the implementation of an additive manufacturing method for a three-dimensional object 2.

[0095] The method includes at least one step of moving the permeable member 9 in the horizontal operating plane MP, in particular in an operating position in which the permeable member 9 provides mechanical support to the membrane 7 of the vat device 6, and / or moving the permeable member 9 in the horizontal operating plane MP in a non-operating position in which the permeable member 9 does not provide mechanical support to the membrane 7 of the vat device 6.

[0096] When implemented in an additive manufacturing apparatus 1 having a bottom-up configuration as shown in Figures 1 to 7, the method particularly comprises the steps of: (i) moving the build platform 8.1 downwards towards the membrane 7 of the vat device 6 and exerting a force F on the membrane 7 (as shown in Figure 2) to cause a temporary deflection or deformation of the membrane 7 relative to its zero state (as shown in Figure 1); (ii) causing the deflection or deformation of the membrane 7 to move downwards the transparent member 9 arranged in an operating position below the membrane 7, so that one or more suspension elements 12.1 of the suspension device 12 suspending the transparent member 9 move from an initial state (as shown in Figure 1) to a compressed state (as shown in Figure 2); (iii) returning the one or more suspension elements 12.1 to their initial state, so that the transparent member 9 moves upwards to a zero vertical position (as shown in Figure 3); and (iv') optionally detecting the amount of light passing through the transparent member 9, for example via the sensor device 14. (iv) when the transparent member 9 is returned to the zero vertical position and placed at the zero vertical position, the irradiation device 5 irradiates electromagnetic waves to generate a cured resin layer 2.1; (v) when the light-transmitting member 9 is moved to a non-operating position (shown in FIG. 5) and the modeling table 8.1 to which the cured resin layer 2.1 is attached is moved upward (because the light-transmitting member 9 is not present below the cured resin layer 2.1 in at least one non-operating position), the suction effect between the cured resin layer 2.1 and the light-transmitting member 9 is particularly eliminated or reduced; (vi) when the modeling table 8.1 is moved upward to form a space for a new resin layer between the cured resin layer 2.1 and the film 7; and (vii) repeating steps (i) to (vi) one or more times until a three-dimensional object 2 of the desired configuration is constructed.

[0097] The steps (i) to (vii) can also be carried out by an additive manufacturing apparatus 1 having a similar top-down configuration.

[0098] This particular effect of compensating for or at least reducing the respective portions of deflection or deformation of the membrane 7 can be improved by each upward movement of the transparent member 9 towards the build platform 8.1. In particular, the upward movement of the transparent member 9 increases the mechanical contact area between the transparent member 9 and the membrane 7, resulting in an improved effect of compensating for or at least reducing the respective portions of deflection or deformation of the membrane 7.

[0099] Aspects of the present invention are also given in the following items, the gist of which may be combined in any combination. 1. An additive manufacturing device that hardens a photocurable resin to produce a three-dimensional object by additive manufacturing, and in particular, an additive manufacturing device with a bottom-up configuration, a vat device defining a receiving volume for receiving a photocurable resin, the bottom of the receiving volume being defined by a membrane, in particular an elastic membrane; - a build stage device, in particular including a build stage arranged above the membrane and operatively supported with at least one degree of freedom of movement relative to the membrane; - at least one irradiation device, in particular a digital light irradiation device, configured to irradiate with electromagnetic waves to selectively and continuously harden the resin supplied to the receiving volume and to additively manufacture a three-dimensional object in a build direction. 2. The additive manufacturing device of claim 1, further comprising a transparent member arranged below the membrane, the transparent member being movably supported within a horizontal operating plane so as to be movable between at least one operating position in which the transparent member is arranged below the membrane and provides mechanical support to the membrane, and at least one non-operating position in which the transparent member is not arranged below the membrane and does not provide mechanical support to the membrane. 3. The additive manufacturing apparatus according to claim 2, wherein in the zero state of the membrane, a gap exists between the membrane and the transparent member. 4. The layered manufacturing device according to any one of 1 to 3 above, wherein the operating surface is a horizontal plane parallel to the base surface of the membrane or the modeling surface of the modeling table. 5. An additive manufacturing apparatus described in any one of 1 to 4, wherein the movement of the at least one degree of freedom of the transparent member is lateral movement of the transparent member about a horizontal axis, particularly an axis parallel to the base surface of the membrane, and / or the movement of the at least one degree of freedom of the transparent member is rotational movement of the transparent member about a vertical axis, particularly an axis perpendicular to the base surface of the membrane. 6. An additive manufacturing device as described in any one of 1 to 5, further comprising an actuator device that can be coupled to or is coupled to the transparent member, and that applies a driving force to the transparent member to move the transparent member from at least one operating position to at least one non-operating position and vice versa. 7. The additive manufacturing apparatus according to any one of 1 to 6, further comprising a control device configured to control movement of the transparent member between the operating position and the non-operating position and vice versa. 8. An additive manufacturing apparatus as described in any one of 1 to 7, wherein in at least one operating position, the transparent member compensates for deformation, particularly curvature, of the membrane resulting from movement of the build table towards the membrane, particularly downward movement. 9. The layered manufacturing apparatus according to any one of 1 to 8 above, further comprising a response suspension device configured to suspend the transparent member. 10. An additive manufacturing apparatus as described in 8, wherein the responsive suspension device comprises one or more suspension elements, and the one or more suspension elements are adjustable in a suspension direction of the suspension device, particularly in a direction corresponding to the manufacturing direction. 11. An additive manufacturing apparatus according to claim 9, wherein at least one suspension element is configured as or comprises a spring element, in particular a compression spring element. 12. An additive manufacturing device described in any one of items 9 to 11, wherein the responsive suspension device is supported so that it can move with at least one degree of freedom of movement relative to the membrane in a horizontal plane of movement, and is movable between at least one first position in which the transparent member suspended by the responsive suspension device is in its operating position, and at least one second position in which the transparent member suspended by the responsive suspension device is in its non-operating position. 13. An additive manufacturing apparatus according to any one of 1 to 12, further comprising at least one sensor device including one or more sensor elements configured to determine the lateral and / or horizontal position of the transparent member, in particular relative to the membrane. 14. An additive manufacturing apparatus as described in claim 13, wherein at least one sensor device is configured to generate sensor information indicative of a position corresponding to an operating position of the transparent member. 15. An additive manufacturing apparatus as described in claim 14, wherein one or more sensor elements are configured as or comprise electric, optical, electro-optical, magnetic or electro-magnetic sensor elements. 16. An additive manufacturing apparatus according to any one of 1 to 15, wherein the transparent member is configured as a glass plate, particularly a borosilicate glass plate, or includes a glass plate, particularly a borosilicate glass plate. 17. The layered manufacturing apparatus according to any one of 1 to 16, wherein the bat device comprises a plurality of frame-shaped bat device elements that are connectable to or connected to each other, and that constitute the bat device. 18. The additive manufacturing apparatus described in 17, wherein the bat device comprises a first frame-shaped bat device element and a second frame-shaped bat device element, the first frame-shaped bat device element having at least one first joining surface, and the second frame-shaped bat device element having at least one second joining surface, the at least one first joining surface and the at least one second joining surface being configured to cooperatively grip the membrane between the first frame-shaped bat device element and the second frame-shaped bat device element. 19. An additive manufacturing device as described in 18 or 19, wherein at least one of the first frame-shaped bat device element and the second frame-shaped bat device element is provided with a deformation compensation unit that compensates for the deformation effect of the membrane, which causes the bottom of the receiving volume to become uneven, in at least one operating state of the membrane. 20. An additive manufacturing apparatus as described in 19, wherein the deformation compensation section comprises at least a first auxiliary section, a second auxiliary section, and a third auxiliary section, the first auxiliary section extending at an angle to the membrane, the third auxiliary section extending parallel to the membrane, and the second auxiliary section being positioned between the first auxiliary section and the third auxiliary section and extending in a curved manner. 21. An additive manufacturing device according to any one of 1 to 20, wherein the membrane comprises a plurality of membrane elements connectable or connected to each other, stacked vertically to form the membrane. 22. An additive manufacturing apparatus as described in paragraph 20, wherein the membrane comprises a first membrane element including an anti-sticking surface or anti-sticking material that enables an anti-sticking effect on the resin supplied to the receiving volume, and a second membrane element including an anti-sticking surface or anti-sticking material that enables an anti-sticking effect on the transparent member. 23. An additive manufacturing apparatus as described in 22, wherein the first membrane element is made of or contains at least one of a fluoropolymer, in particular tetrafluoroethylene or a tetrafluoroethylene compound, and / or the second membrane element is made of or contains at least one of a polyester-based polymer, in particular poly(ethylene terephthalate) or a poly(ethylene terephthalate) compound. 24. An additive manufacturing apparatus according to any one of 21 to 23, wherein the plurality of film elements are bonded to one another by an adhesive and / or a cohesive binder. 25. A manufacturing method for stacking a three-dimensional object by selectively and continuously curing resin supplied into a receiving volume of a vat device using electromagnetic waves irradiated from at least one irradiation device of an additive manufacturing device, particularly an additive manufacturing device described in any one of 1 to 24 above, comprising: An additive manufacturing method comprising at least a step of moving the transparent member in a horizontal operating plane in at least one operating position in which the transparent member is positioned below the membrane and provides mechanical support to the membrane of a bat device of the additive manufacturing device, and / or a step of moving the transparent member in a horizontal operating plane in at least one non-operating position in which the transparent member is not positioned below the membrane of the additive manufacturing device and does not provide mechanical support to the membrane of a bat device of the additive manufacturing device. 26. (i) moving the build table downward in the direction of the membrane of the vat device of the additive manufacturing device, thereby applying a force to the membrane that geometrically deforms the membrane, in particular, that curves the membrane, and moving the build table in the direction of the surface of the transparent member arranged below the membrane; (ii) moving the permeable member downward by deforming the membrane, thereby moving one or more suspension elements of a responsive suspension system suspending the permeable member from an initial state to a compressed state; (iii) operating the one or more suspension elements to return them to their initial state, thereby moving the transparent member upward to an operating position where the transparent member is positioned below the membrane and provides mechanical support to the membrane of the vat device of the additive manufacturing device; (iv) a step of irradiating electromagnetic waves from an irradiation device to form a cured resin layer; (v) reducing or eliminating the suction effect between the cured resin layer and the permeable member by moving the permeable member to at least one inoperative position; (vi) moving the build platform upward to form a space between the cured resin layer and the new resin layer film; (vii) repeating steps (i) to (vi) one or more times; 26. The additive manufacturing method according to 25 above, further comprising at least one step of:

Claims

1. An additive manufacturing apparatus that cures a photocurable resin to additively manufacture a three-dimensional object, particularly an additive manufacturing apparatus having a bottom-up configuration, a vat device defining a receiving volume for receiving a photocurable resin, the bottom of the receiving volume being defined by a membrane, in particular an elastic membrane; - a build stage device, in particular including a build stage arranged above the membrane and operatively supported with at least one degree of freedom of movement relative to the membrane; - a permeable element arranged below the membrane, supported so as to be movable in a horizontal plane of operation so as to be able to move between at least one operating position where it is arranged below the membrane and provides mechanical support to the membrane, in particular when it is deformed, and at least one non-operating position where it is not arranged below the membrane and does not provide mechanical support to the membrane; - an additive manufacturing apparatus comprising at least one irradiation device, in particular a digital light irradiation device, which is arranged below the transparent member and is configured to irradiate electromagnetic waves to selectively and continuously harden the resin supplied to the receiving volume and to additively manufacture a three-dimensional object in a manufacturing direction.

2. The layered manufacturing apparatus according to claim 1 , wherein in the zero state of the membrane, a gap exists between the membrane and the permeable member.

3. 3. The layered manufacturing apparatus according to claim 1, wherein the operating surface is a horizontal plane parallel to the base surface of the membrane or the modeling surface of the modeling table.

4. 4. The additive manufacturing apparatus according to claim 1, wherein the movement of the at least one degree of freedom of the transparent element is a lateral movement of the transparent element about a horizontal axis, in particular an axis parallel to a base plane of the membrane, and / or the movement of the at least one degree of freedom of the transparent element is a rotational movement of the transparent element about a vertical axis, in particular an axis perpendicular to the base plane of the membrane.

5. 5. The additive manufacturing apparatus according to claim 1, further comprising an actuator device coupleable or coupled to the transparent member, for applying a driving force to the transparent member to move the transparent member from at least one operating position to at least one non-operating position and vice versa.

6. The additive manufacturing apparatus of any one of claims 1 to 5, further comprising a controller configured to control movement of the transparent member between the operative position and the non-operative position and vice versa.

7. 7. The additive manufacturing apparatus according to claim 1, wherein in at least one operating position, the transparent element compensates for deformations, in particular curvatures, of the membrane resulting from movements of the build table towards the membrane, in particular downward movements.

8. The additive manufacturing apparatus according to any one of claims 1 to 7, further comprising a response suspension device configured to suspend the transparent member.

9. 9. The additive manufacturing apparatus according to claim 8, wherein the responsive suspension system comprises one or more suspension elements, the one or more suspension elements being adjustable in a suspension direction of the suspension system, in particular in a direction corresponding to the build direction.

10. 10. The additive manufacturing apparatus according to claim 9, wherein the at least one suspension element is configured as or comprises a spring element, in particular a compression spring element.

11. 11. The additive manufacturing apparatus of claim 8, wherein the responsive suspension device is supported so as to be movable with at least one degree of freedom of movement in a horizontal plane of movement relative to the membrane, and is movable between at least one first position in which the transparent member suspended by the responsive suspension device is in an operative position, and at least one second position in which the transparent member suspended by the responsive suspension device is in a non-operative position.

12. 12. The additive manufacturing apparatus according to any one of claims 1 to 11, further comprising at least one sensor device comprising one or more sensor elements configured to determine the lateral and / or horizontal position of the transparent member, in particular relative to the membrane.

13. The additive manufacturing apparatus of claim 12 , wherein the at least one sensor device is configured to generate sensor information indicative of a position corresponding to an operating position of the transmissive member.

14. 14. The additive manufacturing apparatus of claim 13, wherein the one or more sensor elements are configured as or comprise electrical, optical, electro-optical, magnetic or electromagnetic sensor elements.

15. 15. The additive manufacturing apparatus according to claim 1, wherein the transparent element is configured as or comprises a glass plate, in particular a borosilicate glass plate.

16. The additive manufacturing apparatus according to any one of claims 1 to 15, wherein the bat device comprises a plurality of frame-shaped bat device elements that are connectable or connected to each other to form the bat device.

17. 17. The additive manufacturing apparatus of claim 16, wherein the bat device comprises a first frame-shaped bat device element and a second frame-shaped bat device element, the first frame-shaped bat device element comprising at least one first mating surface, and the second frame-shaped bat device element comprising at least one second mating surface, the at least one first mating surface and the at least one second mating surface configured to cooperatively grip the membrane between the first frame-shaped bat device element and the second frame-shaped bat device element.

18. 18. An additive manufacturing apparatus as described in claim 16 or 17, wherein at least one of the first frame-shaped bat device element and the second frame-shaped bat device element is provided with a deformation compensation part that compensates for the deformation effect of the membrane, which causes the bottom of the receiving volume to become uneven, in at least one operating state of the membrane.

19. 19. An additive manufacturing apparatus as described in claim 18, wherein the deformation compensation portion comprises at least a first auxiliary portion, a second auxiliary portion, and a third auxiliary portion, the first auxiliary portion extending at an angle to the film, the third auxiliary portion extending parallel to the film, and the second auxiliary portion being disposed between the first auxiliary portion and the third auxiliary portion and extending curvedly.

20. The layered manufacturing apparatus according to any one of claims 1 to 19, wherein the film comprises a plurality of film elements connectable or connected to each other, stacked in a vertical direction to form the film.

21. 21. The additive manufacturing apparatus of claim 20, wherein the membrane comprises a first membrane element including an anti-stick surface or anti-stick material that provides an anti-stick effect to the resin supplied to the receiving volume, and a second membrane element including an anti-stick surface or anti-stick material that provides an anti-stick effect to the transparent member.

22. 22. The additive manufacturing apparatus of claim 21, wherein the first membrane element is made of or comprises at least one fluoropolymer, in particular tetrafluoroethylene or a tetrafluoroethylene compound, and / or the second membrane element is made of or comprises at least one polyester-based polymer, in particular poly(ethylene terephthalate) or a poly(ethylene terephthalate) compound.

23. 23. The additive manufacturing apparatus according to any one of claims 20 to 22, wherein the membrane elements are bonded to one another by an adhesive and / or a cohesive bonding agent.

24. A manufacturing method for stacking a three-dimensional object by selectively and continuously curing resin supplied to a receiving volume of a vat device by electromagnetic waves irradiated from at least one irradiation device of an additive manufacturing apparatus, particularly an additive manufacturing apparatus according to any one of claims 1 to 23, comprising: An additive manufacturing method comprising at least a step of moving the transparent member in a horizontal operating plane in at least one operating position in which the transparent member is positioned below the membrane and provides mechanical support to the membrane of the bat device of the additive manufacturing device, and / or a step of moving the transparent member in a horizontal operating plane in at least one non-operating position in which the transparent member is not positioned below the membrane of the additive manufacturing device and does not provide mechanical support to the membrane of the bat device of the additive manufacturing device.

25. (i) moving the build table downward in the direction of the membrane of the vat device of the additive manufacturing device to apply a force to the membrane that geometrically deforms the membrane, in particular, that curves the membrane, and moving the build table in the direction of the surface of the transparent member arranged below the membrane; (ii) causing the membrane to deform, thereby moving the permeable member downward, thereby moving one or more suspension elements of a responsive suspension system suspending the permeable member from an initial state to a compressed state; (iii) operating the one or more suspension elements to return them to their initial state, thereby moving the transparent member upward to an operating position where the transparent member is positioned below the membrane and provides mechanical support to the membrane of the vat device of the additive manufacturing device; (iv) forming a cured resin layer by irradiating electromagnetic waves from an irradiation device; (v) reducing or eliminating the suction effect between the cured resin layer and the permeable member by moving the permeable member to at least one inoperative position; (vi) moving the build platform upward to form a space between the cured resin layer and the new resin layer film; (vii) repeating steps (i) to (vi) one or more times; The additive manufacturing method according to claim 24, further comprising at least one step of:

Images