Additive manufacturing device and method of operating an additive manufacturing device

Abstract

To provide an additive manufacturing apparatus.SOLUTION: An additive manufacturing apparatus includes: a resin support configured to support a first resin and a second resin; a support plate containing a window; a stage configured to retain one or more cured layers of the first resin or the second resin to form a component disposed on an opposite side of the support plate; a radiant energy device disposed on an opposite side of the resin support from the stage and operable to generate and project radiant energy through the window onto a patterned image; and an actuator assembly that moves the stage in a Z-axis direction and a Y-axis direction.SELECTED DRAWING: Figure 1A

Description

[Technical field]

[0001] The present disclosure relates generally to additive manufacturing devices, and more particularly to assemblies for altering the position of various components of an additive manufacturing device. [Background technology]

[0002] Additive manufacturing is a method in which material is built up layer by layer to form a component. Stereolithography (SLA) is a type of additive manufacturing method that uses a bath of radiant energy curable photopolymer "resin" and a curing energy source such as a laser. Similarly, digital light processing (DLP) three-dimensional (3D) printing uses a two-dimensional image projector to build one layer at a time. For each layer, the energy source paints or flashes a radiographic image of the cross-section of the part onto the surface of the resin. Exposure to radiation cures and solidifies the pattern in the resin, bonding it to the previously cured layer.

[0003] In some examples, additive manufacturing may be accomplished by a "tape casting" step. In this process, resin is deposited on a flexible, radiation transparent resin support, such as a tape or foil, which is fed from a supply reel into the build zone. Radiant energy is generated from a radiant energy device and directed through a window to cure the resin into a component supported by a stage in the build zone. Once the curing of the first layer is complete, the stage and resin support are separated from each other. The resin support is then advanced, delivering new resin to the build zone. A first layer of cured resin is then placed on the new resin and cured through an energy device to form an additional layer of the component. Subsequent layers are added to each previous layer until the component is complete. The tape casting process may be used to form a variety of components. Summary of the Invention [Means for solving the problem]

[0004] One aspect of the present disclosure is an additive manufacturing apparatus that includes a resin support configured to support a first resin and a second resin, a support plate including a window, a stage configured to hold one or more cured layers of the first resin or the second resin to form a component disposed on an opposite side of the support plate, a radiant energy device disposed on an opposite side of the resin support from the stage and operable to generate and project radiant energy through the window in a patterned image, and an actuator assembly that moves the stage in a Z-axis and a Y-axis direction. [Brief description of the drawings]

[0005] [Figure 1A] FIG. 1A is a schematic side view of an additive manufacturing apparatus according to various embodiments of the present invention. [Figure 1B] FIG. 1B is a schematic side view of an additive manufacturing apparatus according to various embodiments of the present invention. [Diagram 2] FIG. 2 is a front perspective view of an additive manufacturing device according to various embodiments of the present invention. [Diagram 3] FIG. 3 is a side perspective view of an additive manufacturing device according to various embodiments of the present invention. [Figure 4] FIG. 4 is a side perspective view of an additive manufacturing device according to various embodiments of the present invention. [Diagram 5] FIG. 5 is a diagram illustrating the operation of an additive manufacturing device according to various embodiments of the present invention. [Figure 6] FIG. 6 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 7] FIG. 7 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 8] FIG. 8 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 9] FIG. 9 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 10] FIG. 10 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 11] FIG. 11 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 12] FIG. 12 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 13] FIG. 13 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 14] FIG. 14 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 15] FIG. 15 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 16] FIG. 16 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 17] FIG. 17 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 18] FIG. 18 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 19] FIG. 19 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 20] FIG. 20 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 21] FIG. 21 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 22] FIG. 22 shows a schematic diagram of an additive manufacturing device in operation according to various embodiments of the present invention. [Diagram 23] FIG. 23 shows a schematic diagram of an additive manufacturing apparatus in operation according to various embodiments of the present invention. [Figure 24] FIG. 24 shows a schematic diagram of an additive manufacturing device in operation according to various embodiments of the present invention. [Diagram 25] FIG. 25 is a side perspective view of an additive manufacturing device according to various embodiments of the present invention. [Figure 26] FIG. 26 is a side perspective view of a frame of an additive manufacturing device according to various embodiments of the present invention. [Figure 27]FIG. 27 is a rear perspective view of a frame of an additive manufacturing device according to various embodiments of the present invention. [Figure 28] FIG. 28 is a side perspective view of a print head of an additive manufacturing device according to various embodiments of the present invention. [Figure 29] FIG. 29 is a cross-sectional view of a print head of an additive manufacturing device taken along line XXIX-XXIX of FIG. 25 in accordance with various embodiments of the present invention. [Diagram 30] FIG. 30 is a plan view of a first slide assembly of an additive manufacturing apparatus according to various embodiments of the present invention. [Diagram 31] FIG. 31 is a plan view of a second slide assembly of an additive manufacturing apparatus according to various embodiments of the present invention. [Diagram 32] FIG. 32 is a side perspective view of an additive manufacturing apparatus having a stage in a first position and a radiant energy device in a first projection position according to various embodiments of the present invention. [Diagram 33] FIG. 33 is a side perspective view of an additive manufacturing apparatus having a stage in a first position and a radiant energy device in a second projection position according to various embodiments of the present invention. [Diagram 34] FIG. 34 is a side perspective view of an additive manufacturing apparatus having a stage in a second position and a radiant energy device in a third projection position according to various embodiments of the present invention. [Diagram 35] FIG. 35 is a side perspective view of an additive manufacturing apparatus having a stage in a second position and a radiant energy device in a fourth projection position according to various embodiments of the present invention. [Diagram 36] FIG. 36 is a side perspective view of an additive manufacturing device according to various embodiments of the present invention. [Figure 37] FIG. 37 is a diagram illustrating the operation of an additive manufacturing device according to various embodiments of the present invention. [Figure 38] FIG. 38 illustrates an exemplary computer system for an additive manufacturing apparatus according to various embodiments of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0006] A full and enabling disclosure of this disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in this specification with reference to the appended claims.

[0007] Repeat use of reference characters in the present specification and drawings is intended to represent like or analogous features or elements of the present disclosure.

[0008] Reference will now be made in detail to the present embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description are used to refer to like or similar parts of the invention.

[0009] As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the individual components. The terms "coupled," "fixed," "attached," and the like, unless otherwise specified herein, refer to both direct coupling, fixing, or attachment, and indirect coupling, fixing, or attachment through one or more intermediate components or features. The terms "upstream" and "downstream" refer to a relative direction with respect to the movement of the resin support along the manufacturing apparatus. For example, "upstream" refers to the direction from which the resin support moves, and "downstream" refers to the direction to which the resin support moves. The term "selectively" refers to the ability of a component to operate in various states (e.g., on and off states) based on manual and / or automatic control of the component.

[0010] The singular forms "a," "an," and the like include plural references unless the context clearly dictates otherwise.

[0011] Approximation language as used herein throughout the specification and claims is applied to modify any quantitative expression that may be permissibly varied without resulting in a change in the basic function to which it pertains. Thus, values ​​modified by terms such as "about," "approximately," "generally," and "substantially" should not be limited to the exact value specified. In at least some cases, the approximation language may correspond to the precision of an instrument for measuring a value, or the precision of a method or apparatus for building or manufacturing a component and / or system. For example, the approximation language may refer to being within a margin of 10 percent.

[0012] Moreover, the technology of the present application is described in connection with exemplary embodiments. The term "exemplary" is used herein to mean "serving as an example, instance, or illustration," and any embodiment described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, unless expressly stated otherwise, all embodiments described herein should be considered exemplary.

[0013] Throughout the specification and claims, range limitations are combinable and interchangeable, and such ranges include and are specific to all subranges contained therein, unless the context or language dictates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

[0014] As used herein, the term "and / or," when used in a list of two or more items, means that any one of the listed items can be used alone, or any combination of two or more of the listed items can be used. For example, if a composition or assembly is described as including components A, B, and / or C, the composition or assembly can include A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C.

[0015] The present invention is generally directed to additive manufacturing apparatuses that perform various manufacturing steps such that successive layers of material are "built up" on top of one another to provide a three-dimensional component, layer by layer. The successive layers typically harden together to form a monolithic component that may have various integral subcomponents. Although additive manufacturing technologies are invented herein as enabling the production of complex objects by building the object piece by piece, layer by layer, variations of the invented additive manufacturing apparatus and technologies are contemplated and are within the scope of the present subject matter.

[0016] The additive manufacturing apparatus can include a support plate, a window supported by the support plate, and a stage movable relative to the window. The additive manufacturing machine can further include a first resin and a second resin deposited as a layer having a desired thickness on a resin support (e.g., a foil, tape, batt, plate, etc.) that is unwound in an X-axis direction from a supply reel or pair of supply reels. In various examples, the first resin can be laterally offset from the second resin in a Y-axis direction.

[0017] The stage is lowered onto the resin so that the work surface, defined by one of the surfaces of the stage or the part being processed, is positioned so that the work surface just touches the resin or compresses it between the resin support and the stage, defining the layer thickness. Radiant energy is used to cure the resin through the resin support. Once curing of the first layer is complete, the stage is retracted and the cured material is removed with it. The resin support is then advanced to expose a new clean area, ready for additional resin to be deposited in the next new cycle.

[0018] In some examples, the additive manufacturing apparatus further includes an actuator assembly including a first actuator configured to move the stage in a Z-axis direction and a second actuator configured to move the stage in a Y-axis direction. Movement of the stage in the Y-axis direction can allow layers of the component to be selectively formed from the first resin and / or the second resin. Thus, the component can be formed from one or more resins.

[0019] 1A and 1B illustrate generally an example of one type of suitable apparatus 10 for forming a component 12 fabricated through one or more layers of at least one cured resin R. The apparatus 10 may include one or more of a support plate 14, a window 16, a stage 18 movable relative to the window 16, and a radiant energy device 20, which in combination may be used to form any number (e.g., one or more) of additively manufactured components 12.

[0020] In the illustrated example of FIG. 1A, the apparatus 10 includes a feed module 22 that can include a first roller 22A and a take-up module 24 that can include a second roller 24A spaced apart with a resin support 26 extending therebetween. A portion of the resin support 26 can be supported from below by a support plate 14. Suitable mechanical supports (frames, brackets, etc.) and / or alignment devices can be provided for the rollers 22A, 24A and the support plate 14. The first roller 22A and / or the second roller 24A can be configured to control the speed and direction of the resin support 26 such that a desired tension and speed is maintained in the resin support 26 via a drive system 28. By way of example and not limitation, the drive system 28 can be configured as individual motors associated with the first roller 22A and / or the second roller 24A. Additionally, various components such as motors, actuators, feedback sensors, and / or controllers may be provided to drive the rollers 22A, 24A to maintain the resin support 26 tensioned between the aligned rollers 22A, 24A and to wind the resin support 26 from the first roller 22A onto the second roller 24A.

[0021] In various embodiments, the window 16 may be transparent and operably supported by the support plate 14. Additionally, the window 16 and the support plate 14 may be integrally formed such that one or more windows 16 are integrated within the support plate 14. Similarly, the resin support 26 may be transparent or include a transparent portion. As used herein, the terms "transparent" and "radiation transmissive" refer to a material that allows at least a portion of radiant energy of a selected wavelength to pass through. For example, the radiant energy passing through the window 16 and the resin support 26 may be in the ultraviolet spectrum, the infrared spectrum, the visible spectrum, or any other useful radiant energy. Non-limiting examples of transparent materials include polymers, glasses, and crystalline minerals such as sapphire or quartz.

[0022] The resin support 26 extends between the supply module 22 and the take-up module 24 and defines a "build surface" 30, which is shown as planar but may be arcuate (depending on the shape of the support plate 14). In some examples, the build surface 30 may be defined by the resin support 26 and positioned to face the stage 18 with the window 16 on the opposite side of the resin support 26 from the stage 18. For convenience, the build surface 30 may be considered to be oriented parallel to the XY plane of the apparatus 10, and the direction perpendicular to the XY plane is designated as the Z-axis direction (X, Y, and Z are three mutually perpendicular directions). As used herein, the X-axis refers to the machine direction along the length of the resin support 26. As used herein, the Y-axis refers to the transverse direction across the width of the resin support 26 and approximately perpendicular to the machine direction. As used herein, the Z-axis refers to the stage direction, which may be defined as the direction of movement of the stage 18 relative to the window 16.

[0023] The build surface 30 may be configured to be "non-stick", i.e., resistant to adhesion of the cured resin R. The non-stick property may be embodied by a combination of variables, such as the chemistry of the resin support 26, its surface finish, and / or the applied coating. For example, a permanent or semi-permanent non-stick coating may be applied. One non-limiting example of a suitable coating is polytetrafluoroethylene ("PTFE"). In some examples, all or a portion of the build surface 30 may incorporate a controlled roughness or surface texture (e.g., protrusions, dimples, grooves, ridges, etc.) that has non-stick properties. Additionally or alternatively, the resin support 26 may be made in whole or in part from an oxygen permeable material.

[0024] For purposes of reference, the planar or three-dimensional area immediately surrounding the location of the transparency defined by the resin support 26 and the window 16 or support plate 14 may be defined as the “build zone,” labeled 32 .

[0025] In some examples, a material deposition means 34 can be positioned along the resin support 26. The material deposition means 34 can be any device or combination of devices operable to apply a layer of resin R onto the resin support 26. The material deposition means 34 can optionally include an apparatus or combination of apparatuses to define the height of the resin R on the resin support 26 and / or to level the resin R on the resin support 26. Non-limiting examples of suitable material deposition means include a chute, roller, hopper, pump, spray nozzle, spray bar, or print head (e.g., inkjet). In some examples, a doctor blade can be used to control the thickness of the resin R applied to the resin support 26 as the resin support 26 passes through the material deposition means 34.

[0026] 1B, the resin support 26 may be in the form of a vat 36 configured to isolate debris that may contaminate a build from the usable resin R. The vat 36 may include a floor 38 and a peripheral wall 40. The peripheral wall 40 extends from the floor 38. The inner surface of the floor 38 and the peripheral wall 40 define a receptacle 42 for receiving the resin R.

[0027] A drive system 28 (FIG. 1A) may be provided for moving the vat 36 relative to the stage 18 parallel to the X direction between the build zone 32 and a position at least partially outside the build zone 32. However, it will be understood that in other embodiments, the resin support 26 may be stationary without departing from the scope of the present disclosure.

[0028] In some examples, the resin support 26 may be positioned to receive resin R from a material deposition means 34 operable to introduce a layer of resin R to the resin support 26. The material deposition means 34 may optionally include a device or combination of devices for defining a height within the resin and / or leveling the resin R. Non-limiting examples of suitable material deposition means include a chute, a hopper, a pump, a spray nozzle, a spray bar, or a print head (e.g., ink jet).

[0029] 1A and 1B, Resin R includes any radiant energy curable material capable of adhering or bonding fillers (if used) together in a cured state. As used herein, the term "radiant energy curable" refers to any material that solidifies or partially solidifies in response to the application of radiant energy of a particular frequency and energy level. For example, Resin R may include a photopolymer resin that contains a photoinitiator compound that functions to induce a polymerization reaction and change Resin R from a fluid (or powder) state to a solid state. Alternatively, Resin R may include a material that contains a solvent that can be evaporated by the application of radiant energy. Uncured Resin R may be provided in a solid (e.g., granular) or fluid form, including a paste or a slurry.

[0030] Additionally, Resin R can have a relatively high viscosity resin that does not "slump" or flow during the build process. The composition of Resin R can be selected as desired to suit a particular application. Mixtures of different compositions can be used. Resin R may also be selected to have the ability to outgas or burn during further processing, such as a sintering process.

[0031] Additionally or alternatively, Resin R may be selected to be a viscosity-thinnable composition. These compositions decrease in viscosity when subjected to a shear stress or when heated. For example, Resin R may be selected to be shear thinning, such that Resin R exhibits a reduced viscosity as the amount of stress applied to Resin R increases. Additionally or alternatively, Resin R may be selected to decrease in viscosity as Resin R is heated.

[0032] The resin R may contain a filler. The filler may be premixed with the resin R and then loaded into the material deposition means 34. Alternatively, the filler may be mixed with the resin R on the apparatus 10. Fillers include particles conventionally defined as "very small materials". Fillers may include any material that is chemically and physically compatible with the selected resin R. The particles may be of regular or irregular shape, uniform or non-uniform size, and may have variable aspect ratios. For example, the particles may take the form of a powder, globules, or granules, or may be shaped like rodlets or fibers.

[0033] The composition of the filler (including its chemical nature and microstructure) can be selected as desired to suit a particular application. For example, the filler can be metallic, ceramic, polymeric, and / or organic. Other examples of potential fillers include diamond, silicon, and graphite. Mixtures of different compositions can be used. In some instances, the filler composition can be selected for its electrical or electromagnetic properties, for example, the filler composition can be specifically an electrical insulator, a dielectric material, a conductor, and / or a magnetic material.

[0034] The filler may be "fusible," meaning that it can solidify into a mass upon the application of sufficient energy. For example, fusibility is a characteristic of many available powders, including but not limited to polymers, ceramics, glasses, and metals. The ratio of filler to resin R can be selected to suit a particular application. In general, any amount of filler can be used as long as the composite material can flow and be smoothed, and there is enough resin R present to hold the particles of filler together in the cured state.

[0035] The stage 18 is a structure that defines a plane 44, which may be oriented parallel to the build surface 30 or the XY plane. Various devices may be provided for moving the stage 18 relative to the window 16. For example, as shown in FIGS. 1A and 1B, movement may be provided through an actuator assembly 46, which may be coupled to a stationary support 48. In some embodiments, the actuator assembly 46 may include a first actuator 50 between the stage 18 and the stationary support 48, which may move the stage 18 in a first vertical direction (e.g., along the Z-axis direction). The actuator assembly 46 may additionally or alternatively include a second actuator 52 between the stage 18 and the first actuator 50 and / or the stationary support 48, which allows movement in the X-axis direction and / or the Y-axis direction. The actuator assembly 46 may additionally or alternatively include a third actuator 54 between the stage 18 and the second actuator 52 and / or the stage 18, which allows movement in the X-axis direction and / or the Y-axis direction. The actuator assembly 46 may include any device capable of moving the stage 18 in any orientation, such as a ball screw electric actuator, a linear electric actuator, a pneumatic cylinder, a hydraulic cylinder, a delta drive, a belt system, or any other viable device. It will be appreciated that in other examples, the resin support may additionally or alternatively translate in the Y-axis direction (or any other direction).

[0036] The radiant energy device 20 may be configured as any device or combination of devices operable to generate and project radiant energy at the resin R in an appropriate pattern, at appropriate energy levels, and other operating characteristics to cure the resin R during the build process. For example, as shown in FIGS. 1A and 1B, the radiant energy device 20 may include a projector 56, which may generally refer to any device operable to generate a radiant energy patterned image of appropriate energy levels and other operating characteristics to cure the resin R. As used herein, the term "patterned image" refers to a projection of radiant energy that includes an array of one or more individual pixels. Non-limiting examples of patterned image devices include a DLP projector or another digital micromirror device, a two-dimensional array of LEDs, a two-dimensional array of lasers, and / or an optically addressed light valve. In the illustrated example, the projector 56 includes a radiant energy source 58, such as a UV lamp, an image forming device 60 operable to receive a radiant energy beam 62 from the radiant energy source 58 and generate a patterned image 64 that is projected onto the surface of the resin R, and, optionally, focusing optics 66, such as one or more lenses.

[0037] The image forming device 60 may include one or more mirrors, prisms, and / or lenses, and may be equipped with suitable actuators and positioned such that a source beam 62 from the radiant energy source 58 may be converted into a pixelated image 64 in an XY plane coincident with the surface of the resin R. In the illustrated example, the image forming device 60 may be a digital micromirror device.

[0038] Projector 56 may incorporate additional components, such as actuators, mirrors, etc., configured to selectively move image-forming device 60 or other portions of projector 56 with the effect of rastering or shifting the position of patterned image 64 on build surface 30. In other words, patterned image 64 may be moved away from a nominal or starting position.

[0039] In addition to other types of radiant energy devices 20, the radiant energy device 20 can include a "scanning beam device," as used herein, which generally refers to any device operable to generate a radiant energy beam of suitable energy levels to cure the resin R and scan the beam over the surface of the resin R in a desired pattern. For example, the scanning beam device can include a radiant energy source 58 and a beam steering device. The radiant energy source 58 can include any device operable to generate a beam of suitable power and other operating characteristics to cure the resin R. Non-limiting examples of suitable radiant energy sources 58 include a laser or an electron beam gun.

[0040] In some examples, the apparatus 10 can include a material retention assembly 68 that can be configured to hold the resin support 26 in a predetermined position along the support plate 14. In some examples, the material retention assembly 68 can include one or more air actuation zones 70 having respective air actuation zones 70 configured to selectively interact with the resin support 26 by generating a force on a surface of the resin support 26 that faces the resin R.

[0041] The one or more air actuating zones 70 may apply a negative pressure to a first surface of the resin support 26 opposite the resin R or to a second side of the resin support 26 to create a suction or vacuum on the resin support 26. The negative pressure may hold the resin support 26 in a desired position along the support plate 14. The one or more air actuating zones 70 may also apply a positive pressure to a first surface of the resin support 26 opposite the resin R or to a second side of the resin support 26 to create a pressing force on the resin support 26. The positive pressure may release the resin support 26 from components of the apparatus 10, such as the window 16, the material retention assembly 68, etc. As used herein, a "negative" pressure is any pressure that is less than the ambient pressure adjacent the one or more air actuating zones 70 such that fluid may be drawn into the one or more air actuating zones 70. Conversely, a "positive" pressure is any pressure that is greater than the ambient pressure adjacent the one or more air actuating zones 70 such that fluid may be expelled from the one or more air actuating zones 70. Moreover, a “neutral” pressure is any pressure that is generally equal to the ambient pressure proximate one or more air operating zones 70 .

[0042] In some embodiments, the air operating zones 70 may be fluidly coupled to a pneumatic assembly 72 via various hoses and one or more ports. The pneumatic assembly 72 may include any device capable of vacuuming / pulling and / or pushing a fluid, such as air or a process gas (e.g., nitrogen or argon), through one or more air operating zones 70. For example, the pneumatic assembly 72 may include a pressurized fluid source including a compressor and / or a blower. The pneumatic assembly 72 may additionally or alternatively include any assembly capable of altering air pressure, such as a venturi vacuum pump. In some embodiments, one or more valves and / or switches may be coupled to the pneumatic assembly 72 and one or more air operating zones 70. The one or more valves and / or switches are configured to regulate the pressure to each of the one or more air operating zones 70.

[0043] In some embodiments, the air operating zone 70 includes one or more openings 74 of any size and shape for interacting with the resin support 26. For example, the openings 74 can be any number and combination of holes, slits, or other geometric shapes defined by any component of the additive manufacturing apparatus 10, such as a portion of the support plate 14. Additionally or alternatively, the openings 74 can be defined by a portion of the support plate 14 formed from a porous material, or by any other assembly capable of allowing fluid to travel from a first side of the support plate 14 to a second side of the support plate 14 to interact with the resin support 26.

[0044] In some examples, the air operating zone 70 may be defined by a plenum 76. The plenum 76 may be of any size and may be similar in shape to or vary in shape from any remaining plenum 76. In some examples, a gasket may be disposed around an edge of the plenum 76. Additionally or alternatively, the material retention assembly 68 may include one or more clamps that compressively maintain the resin support 26 along the support plate 14.

[0045] 1A and 1B, the viscosity modification assembly 78 may be integrated into the support plate 14 and / or otherwise operably coupled to the resin support 26. The viscosity modification assembly 78 may be configured to apply a shear stress to the resin R to modify (e.g., reduce) the viscosity of the resin R. Additionally or alternatively, the viscosity modification assembly 78 may be configured to heat the resin R to modify the viscosity of the resin R. It is understood that in an embodiment, the heat provided to heat the resin R to modify the viscosity of the resin R may be within a predetermined range sufficient to modify the viscosity of the resin R without causing crosslinking in the polymer.

[0046] In some embodiments, the viscosity modification assembly 78 may be configured to mechanically vibrate a portion of the support plate 14 to generate shear stress in the resin R. For example, the viscosity modification assembly 78 may include a motion device 80 (e.g., a transducer) operably coupled with the support plate 14. The motion device 80 may be configured to vibrate at least a portion of the support plate 14 or any other module of the apparatus 10, which is then transferred to the resin R. Additionally and / or alternatively, the motion device 80 may be configured to convert electrical energy into ultrasonic mechanical pressure waves that are transferred to the resin R. For example, the motion device 80 may be in the form of an ultrasonic vibration device, such as one that utilizes a piezoelectric transducer. In other embodiments, the viscosity modification assembly 78 may include a fluid, acoustic, motor (e.g., offset cam), reciprocating piston, or any other motion device 80 in addition to or instead of a transducer, alone or in conjunction with one or the other.

[0047] The exercise device 80 may be operatively coupled to a computing system 84. The computing system 84 may include a signal generator that provides electrical impulses to the exercise device 80, the voltage of which may be varied at different frequencies and with different waveforms. The signal may be, for example, a pure sine wave, or may be modulated at one or more other frequencies. Alternatively, the signal may be step-like or spike-like pulses. In some embodiments, the signal generator transmits a signal between 20-80 kHz. For example, the signal is about 60 kHz. The signal generator may, for example, transmit a constant amplitude signal at a constant frequency, or may alternate between one or both of these parameters. The power level may be selected as a percentage of maximum power.

[0048] In other embodiments, the viscosity modification assembly 78 may be configured to induce shear stress in the resin R by other configurations without departing from the scope of the present invention. For example, the viscosity modification assembly 78 may be configured as a probe that may be in close physical contact with the resin support 26 and / or any other unit capable of imparting shear stress to the resin R on the resin support 26. Additionally or alternatively, the viscosity modification assembly 78 may be configured as an ultrasonic or vibration plate that may be operably coupled to any other module of the apparatus 10 that may impart shear stress to the resin support 26 and / or the resin R on the resin support 26.

[0049] 1A and 1B , in various embodiments, a gasket 82 can be disposed between the window 16 and the support plate 14 to isolate the respective movements of the window 16 and the support plate 14 from one another. By isolating the movement of the window 16 from the support plate 14, degradation issues of the device 10 caused by operation of the viscosity change assembly 78 can be mitigated. In various examples, the gasket 82 can be formed from a motion-damping material, such as any of a wide variety of resilient elastomers, including, but not limited to, natural rubber and silicone-containing materials.

[0050] As provided herein, in some examples, the viscosity modification assembly 78 can additionally or alternatively generate heat to modify the viscosity of the Resin R. For example, a rapid heating process such as dielectric or microwave heating can be used to avoid subjecting the Resin R to long heating cycles to reach the operating temperature.

[0051] 1A and 1B is a generalized representation of hardware and software that may be implemented to control the operation of the apparatus 10, including some or all of the stage 18, drive system 28, radiant energy device 20, actuator assembly 46, material holding assembly 68, viscosity modification assembly 78, motion device 80, actuators, and various portions of the apparatus 10 described herein. The computing system 84 may be embodied, for example, by software running on one or more processors embodied in one or more devices, such as a programmable logic controller ("PLC") or microcomputer. Such processors may be coupled, for example, via wired or wireless connections, to process sensors and operational components. The same processor or processors may be used to retrieve and analyze sensor data for statistical analysis and for feedback control. Many aspects of the apparatus 10 may be subject to closed-loop control.

[0052] Optionally, the components of the apparatus 10 may be enclosed by a housing 86 that may be used to provide a shielding or inert gas (e.g., "process gas") atmosphere using gas ports 88. Optionally, pressure within the housing 86 may be maintained at a desired level above or below atmospheric pressure. Optionally, the housing 86 may be temperature and / or humidity controlled. Optionally, ventilation of the housing 86 may be controlled based on factors such as time intervals, temperature, humidity, and / or chemical species concentrations. In some embodiments, the housing 86 may be maintained at a pressure different from atmospheric pressure.

[0053] 2-4, various perspective views of an additive manufacturing apparatus 10 including an actuator assembly 46 are provided in accordance with an exemplary embodiment of the present invention. The exemplary apparatus 10 may include a base structure 90 and a stationary support 48 extending from the base structure 90. In the illustrated embodiment, the actuator assembly 46 is operably coupled to the stationary support 48 and configured to alter the position of the stage 18. However, it will be understood that the actuator assembly 46 may be operably coupled to any other component without departing from the scope of the present invention.

[0054] As shown, the actuator assembly 46 includes a first actuator 50 operably coupled to the stationary support 48. A second actuator 52 may be operably coupled to and movable along the first actuator 50. In addition, a third actuator 54 may be operably coupled to and movable along the second actuator 52. The stage 18 may be operably coupled to and movable along the third actuator 54. In various embodiments, when the first actuator 50 is used to move the stage 18 in the Z-axis direction, the second actuator 52, the third actuator 54, and the stage 18 move along the first actuator 50. When the second actuator 52 is used to move the stage 18 in the X-axis direction, the third actuator 54 and the stage 18 move along the second actuator 52. When the stage 18 moves in the Y-axis direction, the stage 18 moves along the third actuator 54. 2, the first actuator 50 is illustrated translating in the Z direction, the second actuator 52 is illustrated translating in the X direction, and the third actuator 54 is illustrated translating in the Y direction, it will be understood that each actuator may be coupled to and moveable with any other actuator and / or stage 18 without departing from the scope of the present disclosure. It will be understood that the terms "first actuator," "second actuator," and "third actuator" are used herein for clarity. It will be understood that an additive manufacturing apparatus may include any one or more actuators without departing from the scope of the present invention.

[0055] 2-4, the resin support 26 may be configured to hold a first and a second material thereon. For example, the first material may be a first resin R1 and the second material may be a second resin R2. As shown, the first resin R1 may be disposed proximate to the second resin R2 in the Y-axis direction. Thus, in some examples, the first resin R1 may be disposed over a first portion of the window 16 as the resin support 26 is translated across the window 16. Similarly, the second resin R2 may be disposed over a second segment of the window 16 that is offset from the first segment as the resin support 26 is translated across the window 16.

[0056] In various embodiments, such as those shown in FIGS. 2-4, the resin support 26 may be in the form of a first resin support 26A configured to have a first resin R1 deposited thereon and a second resin support 26B configured to have a second resin R2 deposited thereon. Each of the first resin support 26A and the second resin support 26B may be operatively coupled to the supply module 22 (FIG. 1A) and the take-up module 24 (FIG. 1A). In some cases, each of the first resin support 26A and the second resin support 26B may be operatively coupled to a common first roller 22A in the supply module 22 and / or a common second roller 24A in the take-up module 24. In such cases, the translational length of the first resin support 26A may be approximately equal to the translational length of the second resin support 26B. However, it will be appreciated that the first resin support 26A may be operatively coupled to different rollers within the supply module 22 and the take-up module 24 from the second resin support 26B such that each resin support 26A, 26B may be translated in the X direction independently of one another.

[0057] 2-4, the material deposition tool 34 may include a first reservoir 92 configured to hold a first resin R1 and a second reservoir 94 configured to hold a second resin R2. As shown, the first reservoir 92 may be configured to hold the first resin R1 and the second reservoir 94 may be configured to hold the second resin R2.

[0058] In some examples, the material deposition means 34 can further include a first container 96 fluidly coupled to the first reservoir 92. A first conduit 98 extends from the first container 96 to direct the first resin R1 from the first container 96 to the first reservoir 92. Similarly, the material deposition means 34 can also include a second container 100 fluidly coupled to the second reservoir 94. A second conduit 102 extends from the second container 100 to direct the second resin R2 from the second container 100 to the second reservoir 94.

[0059] In various embodiments, the material deposition means 34 may further include a first volume sensor 104 and / or a second volume sensor 106. The first volume sensor 104 may be configured to provide a signal to the computing system related to the volume of the first resin R1 in the first reservoir 92. The computing system may be configured to receive the monitoring signal and process such signal using a predetermined algorithm to generate a control signal for controlling the first regulator 108 to allow or restrict the flow of the first resin R1 from the first container 96 to the first reservoir 92. Similarly, the second volume sensor 106 may be configured to provide a signal to the computing system related to the volume of the second resin R2 in the second reservoir 94. The computing system may be configured to receive the monitoring signal and process such signal using a predetermined algorithm to generate a control signal for controlling the second regulator 110 to allow or restrict the flow of the second resin R2 from the second container 100 to the first reservoir 92. In this manner, closed-loop control of the volume of the first resin R1 and the volume of the second resin R2 may be achieved. The first volume sensor 104 and the second volume sensor 106 may each be embodied as one or more imaging sensors or any other vision-based device. The first volume sensor 104 and the second volume sensor 106 may additionally and / or alternatively be configured as any other viable proximity sensor, such as, but not limited to, an ultrasonic sensor, a radar sensor, a LIDAR sensor, etc.

[0060] 2-4, the first thickness assembly 112 can be used to control the thickness of the resin R applied to the resin support 26 as the first resin R1 is deposited thereon. The second thickness assembly 114 can be used to control the thickness of the second resin R2 applied to the resin support 26 as the second resin R2 is deposited thereon. In the illustrated embodiment, the thickness of the first resin R1 can be defined by the use of a doctor blade, and the thickness of the second resin R2 can be defined by the use of a doctor blade. In various embodiments, other material deposition means can be used separately or in combination with the first and second doctor blades, such as, but not limited to, a gravure roll, a metering roll, a weir-based cascade, die casting, and combinations thereof.

[0061] In some embodiments, a common thickness assembly may be used in addition or alternatively with the first thickness assembly 112 and the second thickness assembly 114. For example, a common material deposition device may be used for each of the first resin R1 and the second resin R2. In some examples, the common material deposition means may be configured to act as an overall control of the thickness of the initially deposited layers of the first resin R1 and the second resin R2. The first thickness assembly 112 may then further define the thickness of the first resin R1, and the second thickness assembly 114 may further define the thickness of the second resin R2.

[0062] 2-4, the radiant energy device 20 may be disposed within a base structure 90. Optionally, the radiant energy device 20 may be coupled to an image movement apparatus 116 via a bracket 118. The movement device 80 may include actuators, mirrors, or the like configured to selectively move the radiant energy device 20 or another portion of the radiant energy device 20 with the effect of rastering or shifting the position of the patterned image 64 relative to the window 16. In other words, the patterned image 64 may be moved away from a nominal or starting position. This may, for example, allow a single radiant energy device 20 to cover a larger build zone. This type of image projection may be referred to herein as a "tiled image."

[0063] Additionally or alternatively, the apparatus 10 may include a plurality of radiant energy devices 20 operatively coupled to the build zone 32. Each of the plurality of radiant energy devices 20 may or may not be configured to translate beneath the window 16 and / or support plate 14. Additionally, each of the plurality of radiant energy devices 20 may generate an image 64 that at least partially overlaps with an image 64 of an additional radiant energy device to form a stitched image on the resin R. In various embodiments, the image 64 from each of the plurality of radiant energy devices 20 may have some degree of overlap, with the overlap being a single pixel, less than one pixel (e.g., half a pixel), or two or more pixels. Additionally, in some embodiments, an optical system 66 may be optically coupled to one or more of the radiant energy devices 20. In such a case, at least one of the one or more radiant energy devices 20 and / or the optical system 66 may be translated along the Y-axis and / or otherwise moved through the motion device 80 to generate the patterned image 64 on various portions of the resin support 26.

[0064] Additionally, in some embodiments, the apparatus 10 can include one or more sensors 120 configured to detect information regarding the position of the stage 18, the resin support 26, and / or the radiant energy device 20. For example, the one or more sensors 120 can verify the position of the stage 18 and / or the resin support 26 each time the stage 18 and / or the resin support 26 is moved by the actuator assembly 46. Similarly, the one or more sensors 120 can verify the position of the radiant energy device 20 each time the radiant energy device 20 is translated by the motion device 80. In various embodiments, the one or more sensors 120 can be any combination of devices configured to provide information indicative of the position of the stage 18 and / or the resin support 26, or the position of the radiant energy device 20. For example, the one or more sensors 120 can include a gyroscope, an accelerometer, a proximity sensor, an image sensor, and / or any other possible sensor.

[0065] During operation, the radiant energy device 20 and / or the movement assembly may generate heat. Accordingly, one or more vents and / or fans 122 may be disposed within the base structure 90 to remove heat from the base structure 90. The one or more fans 122 may be configured as any fluid movement device 80 capable of drawing heated air from the base structure 90 to an area proximate to the base structure 90.

[0066] With reference to FIG. 5, a method 200 for operating an additive manufacturing apparatus 10 is provided in accordance with various aspects of the present invention. Various steps of the method 200 are illustrated generally in FIGS. 5-24. The method 200 may be used to operate an additive manufacturing apparatus 10 or any other suitable additive manufacturing apparatus 10. It should be appreciated that the exemplary method 200 is discussed herein only to illustrate exemplary aspects of the present subject matter and is not intended to be limiting. Any of the steps in FIG. 5 may be omitted without departing from the scope of the present disclosure.

[0067] 5 and 6, the method 200 may include, at step 202, depositing layers of a first uncured resin and a second uncured resin onto a resin support 26. In various embodiments, the first resin R1 may be laterally offset in the Y direction from the second resin R2 on the resin support 26. Additionally, a gap 124 may be defined between the laterally offset first and second resins R1, R2.

[0068] The resin support 26 may also be in the form of a first resin support 26A having a first resin R1 laminated thereon and a second resin support 26B having a second resin R2 laminated thereon. Each of the first resin support 26A and the second resin support 26B may be operatively coupled to the supply module 22 and the take-up module 24. Conversely, the first resin R1 and the second resin R2 may be deposited on a common resin support 26.

[0069] While the first resin R1 and / or the second resin R2 are being deposited on the resin support 26 and / or after the first resin R1 and / or the second resin R2 are being deposited on the resin support 26, the resin support 26 may be translated in the X-axis direction to the build zone 32.

[0070] 5 and 7, in step 204, the method 200 may include placing the stage 18 in a first curing position by moving the stage 18 such that a working surface of the stage 18 and / or the component 12 held by the stage 18 contacts the first resin R1. As the stage 18 moves to the first curing position, a working surface of the stage 18 and / or the component 12 held by the stage 18 contacts the first resin R1.

[0071] As shown in Figures 5 and 8, in step 206, the method 200 can include curing a portion of the first resin R1 while the stage 18 is in a first curing position relative to the window 16 by applying radiant energy from the radiant energy device 20 through the window 16 and the resin support 26. As provided herein, the radiant energy can be in the form of a first patterned image 64 that transmits through at least a portion of the window 16. The portion of the cured first resin R1 forms a layer of the component 12 carried by the stage 18. In the embodiment of Figure 8, the patterned image 64 is approximately equal to the width of the first resin R1 in the Y-axis direction. However, the first portion can be any width (variable or constant) in the Y-axis direction.

[0072] 5 and 9, in step 208, the method 200 may include separating the component 12 from the resin support 26 by changing the position of the stage 18 via the actuator assembly 46. It will be appreciated that the stage 18 may move in the X-axis, Y-axis, and / or Z-axis directions.

[0073] 5 and 10, in step 210, the method 200 may include placing the stage 18 in a second curing position by moving the stage 18 such that a working surface of the component 12 held by the stage 18 contacts the second resin R2. As the stage 18 moves to the second curing position, the working surface of the component 12 held by the stage 18 contacts the second resin R2.

[0074] As shown in Figures 5 and 11, in step 212, the method 200 can include curing a portion of the second resin R2 while the stage 18 is in a second curing position relative to the window 16 by applying radiant energy from the radiant energy device 20 through the window 16 and the resin support 26. As provided herein, the radiant energy can form a patterned image 64 that transmits through at least a portion of the window 16. The portion of the cured second resin R2 forms a layer of the component 12 held by the stage 18. In the embodiment of Figure 11, the patterned image 64 is approximately equal to the width of the second resin R2 in the Y-axis direction. However, the second portion can be any width (variable or constant) in the Y-axis direction.

[0075] 5 and 12, in step 214, the method 200 may include separating the component 12 from the resin support 26 by changing the position of the stage 18 via the actuator assembly 46. It will be appreciated that the stage 18 may move in the X-axis, Y-axis, and / or Z-axis directions.

[0076] As shown in FIG. 5 and FIG. 13, in step 216, after the component 12 is separated from the resin support 26, the method 200 can include translating the resin support 26 so that new first resin R1 and second resin R2 are positioned between the window 16 and the stage 18. However, it will be understood that in various embodiments, the resin support 26 supporting each resin can be translated after a portion of either resin has hardened. Additionally or alternatively, the resin support 26 can be moved whenever the next layer to be formed requires new resin. For example, if the first resin R1 forms the first layer and the second resin R2 forms the second layer, the resin support 26 can be moved after the second layer. If the first resin R1 forms the first and second layers, the resin support 26 can be moved between the first and second layers even if the second resin R2 remains unused between the first and second layers.

[0077] While the resin support 26 is translated, the stage 18 and the component 12 attached to the stage 18 can be moved based on the next layer to be formed. For example, in the illustrated embodiment, the third layer has a first resin R1 included therein. Thus, the stage 18 can be moved in the Y-axis direction to a position above the first resin R1.

[0078] 5 and 14, in step 218, the method 200 may include positioning the stage 18 in a third curing position by moving the stage 18 such that a working surface of the component 12 held by the stage 18 contacts the first resin R1. As the stage 18 moves to the third curing position, the working surface of the component 12 held by the stage 18 contacts the first resin R1.

[0079] As shown in Figures 5 and 15, in step 220, the method 200 can include curing a portion of the first resin R1 while the stage 18 is in a third curing position relative to the window 16 by applying radiant energy from the radiant energy device 20 through the window 16 and the resin support 26. As provided herein, the radiant energy can be in the form of a patterned image 64 that transmits through at least a portion of the window 16. The portion of the cured first resin R1 forms a layer of the component 12 held by the stage 18. In the embodiment of Figure 15, the patterned image 64 is smaller than the width of the first resin R1 in the Y-axis direction. However, the cured portion can be of any width (variable or constant) in the Y-axis direction.

[0080] 5, 16, and 17, in step 222, the method 200 may include separating the component 12 from the resin support 26 by changing the position of the stage 18 via the actuator assembly 46. It will be appreciated that the stage 18 may move in the X-axis, Y-axis, and / or Z-axis directions.

[0081] 5 and 18, in step 224, the method 200 may include positioning the stage 18 in a fourth curing position by moving the stage 18 such that a working surface of the component 12 held by the stage 18 contacts the second resin R2. As the stage 18 moves to the fourth curing position, the working surface of the component 12 held by the stage 18 contacts the second resin R2.

[0082] As shown in FIG. 5 and FIG. 19, in step 226, the method 200 can include curing a portion of the second resin R2 while the stage 18 is in the fourth curing position relative to the window 16 by applying radiant energy from the radiant energy device 20 through the window 16 and the resin support 26. As provided herein, the radiant energy can form a patterned image 64 that transmits through at least a portion of the window 16. The portion of the cured second resin R2 forms a layer of the component 12 held by the stage 18. In the embodiment of FIG. 19, the patterned image 64 is smaller than the width of the second resin R2 in the Y-axis direction. However, the cured portion can be of any width (variable or constant) in the Y-axis direction.

[0083] 5 and 20, in step 230, the method 200 may include separating the component 12 from the resin support 26 by changing the position of the stage 18 via the actuator assembly 46. It will be appreciated that the stage 18 may move in the X-axis, Y-axis, and / or Z-axis directions.

[0084] As shown in Figures 5 and 21, in step 232, after the component 12 is separated from the resin support 26, the method 200 may include translating the resin support 26 so that new first resin R1 and second resin R2 are positioned within the build zone 32.

[0085] 5 and 22, in step 234, the method 200 may include moving the stage 18 in an X-axis direction, a Y-axis direction, and / or a Z-axis direction to position the stage 18 in a fifth curing position such that the working surface of the component 12 is held by the stage 18 in contact with both the first resin R1 and the second resin R2. As the stage 18 moves to the fifth curing position, the working surface of the component 12 held by the stage 18 is in contact with the first resin R1 and the second resin R2.

[0086] 5 and 23, in step 236, the method 200 may include curing a portion of the first resin R1 and the second resin R2 while step 18 is in a fifth curing position with respect to the window 16 by applying radiant energy from the radiant energy device 20 through the window 16 and the resin support 26. As provided herein, the radiant energy may form a patterned image 64 that is transmitted through at least a portion of the window 16.

[0087] 5 and 24, in step 238, the method 200 may include separating the component 12 from the resin support 26 by changing the position of the stage 18 via the actuator assembly 46. It will be appreciated that the stage 18 and resin support 26 may be moved to any number of curing positions (one or more) to form each layer of the component 12 based on the component design.

[0088] 25-34, various views of an additive manufacturing apparatus 10 are shown in accordance with various embodiments of the present invention. Only certain components of the additive manufacturing apparatus are shown in FIGS. 25-34 for clarity, however, it will be understood that the additive manufacturing apparatus may include any of the functionality described in the present invention. Furthermore, it will be understood that the additive manufacturing apparatus may perform any other method, such as the method 200 described in FIGS. 5-24 and / or the method 400 described in FIG. 36.

[0089] 25-34, the additive manufacturing apparatus can include a frame 126 and an actuator assembly 46 configured to move various components of the additive manufacturing apparatus relative to one another. In some examples, the frame 126 can include a frame structure 128 and can be operably coupled to and / or operably support various components of the additive manufacturing apparatus. As shown, the frame 126 can support a build plate 130, a support plate 14, and / or a base plate 132.

[0090] The build plate 130 can support a first actuator 50. In some embodiments, the first actuator 50 can enable movement of the stage 18 in a first vertical direction (e.g., along the Z-axis direction). The first actuator 50 can include any device capable of moving the stage 18 in the Z-axis direction, such as a ball screw electric actuator, a linear electric actuator, a pneumatic cylinder, a hydraulic cylinder, a delta drive, a belt system, or any other viable device.

[0091] The print head 134 may be operably coupled to the first actuator 50. In such examples, the print head 134 may be configured to translate through actuation of the first actuator 50 or otherwise. The print head 134 may further be operably coupled to the stage 18. In some examples, the print head 134 may include a clamp 136, and / or any other mechanism for holding the stage 18 on the print head 134.

[0092] The frame 126 may further be operably coupled to the support plate 14. In various embodiments, the windows 16 may be operably supported by the support plate 14. Additionally, the windows 16 and the support plate 14 may be integrally formed such that one or more windows 16 are integrated within the support plate 14.

[0093] 25-34 , a base plate 132 may be secured to a bottom of the frame structure 128. A first slide assembly 138 may be operatively coupled to the base plate 132. The first slide assembly 138 may be configured to guide movement of the base plate 132 relative to a mounting plate 140, which may be held in a substantially stationary position within the additive manufacturing apparatus. However, it will be understood that the mounting plate 140 may be movable.

[0094] In the embodiment shown in FIGS. 25-34, one or more guides 142 may be operably coupled to the base plate 132. The guides 142 may move along a track 144 operably coupled to the mounting plate 140. As described in more detail below, the first slide assembly 138 may allow the frame 126, and therefore the stage 18, to translate in the Y-axis direction along the track 144 such that the frame 126, and therefore the stage 18, may be lowered onto the first resin R1 and / or the second resin R2. As provided herein, the first resin R1 may be separated from the second resin R2 by a gap 124. Thus, the stage 18 may be moved to different resins to form different portions of the component 12. It is understood that in other embodiments, the track 144 may be operably coupled to the base plate 132 and the guides 142 may be operably coupled to the mounting plate 140 without departing from the scope of the present disclosure. Additionally, it will be understood that the first slide assembly 138 may include any component that allows for movement of the base plate 132 relative to the mounting plate 140 without departing from the teachings provided herein.

[0095] In various embodiments, a second actuator 52 may be operatively coupled to the base plate 132 and the mounting plate 140. The second actuator 52 may be configured to move the base plate 132 in the Y-axis direction relative to the mounting plate 140. The second actuator 52 may include any feasible device, such as a ball screw electric actuator, a linear electric actuator, a pneumatic cylinder, a hydraulic cylinder, a delta drive, a belt system, or any other feasible device.

[0096] 25-34, in various embodiments, a radiant energy device 20 may be operatively coupled to the frame 126 and positioned on the opposite side of the window from the stage 18 in the Z direction. In the illustrated embodiment, the radiant energy device 20 may include a pair of projectors 56. However, it will be understood that the radiant energy device 20 may be configured as any apparatus or combination of apparatus operable to generate and project radiant energy at the resin R in a suitable pattern, at suitable energy levels and other operating characteristics to cure the resin R during the build process.

[0097] In some embodiments, the radiant energy device 20 may be operably coupled to the carrier plate 146. In some examples, the radiant energy device 20 may include one or more carrier rails 148 coupled to the carrier plate 146 to hold the radiant energy device 20 relative to the carrier plate 146.

[0098] In some embodiments, the radiant energy device 20 may be movably coupled to the frame 126. For example, a second slide assembly 150 may be disposed between the carrier plate 146 and the base plate 132. The second slide assembly 150 may be configured to guide the movement of the carrier plate 146 relative to the base plate 132. Thus, in some embodiments, the stage 18 and the radiant energy device 20 may move relative to one another relative to the mounting plate, by way of example of the first slide assembly 138, and the radiant energy device 20 may move relative to the stage 18 by way of example of the second slide assembly 150.

[0099] In the embodiment shown in FIGS. 25-34, one or more guides 152 may be operably coupled to the carrier plate 146. The guides 152 may move along rails 154 that are operably coupled to the base plate 132. As described in more detail below, the second slide assembly 150 allows the radiant energy device 20 to translate in the Y-axis along the second slide assembly 150 to align the radiant energy device 20 with various portions of the resin support 26. It is understood that in other embodiments, the rails 154 may be operably coupled to the carrier plate 146 and the guides 152 may be operably coupled to the base plate 132 without departing from the scope of the present disclosure. Additionally, it is understood that the second slide assembly 150 may be operably coupled to any other component, such as the frame 126 or the mounting plate 140, without departing from the scope of the present invention.

[0100] In various embodiments, a third actuator 54 may be operatively coupled to the carrier plate 146 and the base plate 132. The third actuator 54 may be configured to move the carrier plate 146 in a Y-axis direction relative to the base plate 132. The third actuator 54 may include any operable device, such as a ball screw electric actuator, a linear electric actuator, a pneumatic cylinder, a hydraulic cylinder, a delta drive, a belt system, or any other operable device.

[0101] 25, a cover 156 can be operatively coupled to the frame 126 and configured to shield the area between the lens of the radiant energy device 20 and the support plate 14. In various embodiments, the shield can be configured to prevent light within various spectrums and / or all light from passing therethrough.

[0102] 28 and 29, the printhead 134 can include a printhead mounting plate 158, one or more printhead arms 160 extending from the printhead mounting plate 158, and a mounting assembly 162. The printhead 134 can be configured to selectively hold the stage 18.

[0103] 29, the stage 18 is a structure that can be oriented parallel to the build surface 30 or XY plane and defines a plane 44. The stage 18 may further include one or more stage rails 164 configured to interact with the print head 134. One or more datums 166 may also be disposed on and / or integrally formed with the stage 18. In some instances, the stage 18 may further include one or more handles 168.

[0104] 28 and 29 , the clamp 136 of the mounting assembly 162 can selectively hold the stage 18 relative to the print head 134. Additionally, the mounting assembly 162 can further include an anchor plate 170 and a clamp plate 172. In operation, the anchor plate 170 can maintain a common position when the clamp 136 is in both the unlocked and locked positions. The clamp plate 172 can be operatively coupled to a clamp arm 174. The clamp plate 172 and the clamp arm 174 can move in conjunction with one another when the clamp 136 moves from the unlocked position to the locked position and vice versa.

[0105] The clamp arm 174 can include one or more protrusions 176 configured to be positioned within one or more rails 154 of the stage 18. In some examples, the one or more protrusions 176 can define a notch 178 to aid in positioning the stage 18 relative to the protrusions 176. The one or more protrusions 176 within the one or more rails 154 of the stage 18 can align one or more datums 166 of the stage 18 with a locator 180 within the mounting assembly 162. In various embodiments, when the clamp 136 moves to the locked position, the distance between the bottom of the locator 180 and the top of the clamp arm 174 increases in the Z-axis direction. The increased spacing creates an expansion force on the rails 154 and one or more datums 166 of the stage 18, thereby holding the stage 18 in place relative to the print head 134.

[0106] 30 and 31 , as provided herein, the mounting plate 140 can have a pair of tracks 144 operably coupled thereto. A plurality of guides 142 can be coupled to the base plate 132 and configured to move along the first slide assembly 138. As shown, a second actuator 52 can be operably coupled to the base plate 132 and the mounting plate 140 to move the base plate 132 relative to the mounting plate 140. In some instances, the second actuator 52 can be configured to move the base plate 132 between a first position and a second position.

[0107] In the first position, the stage 18 may be lowered by the first actuator 50 (FIG. 25) to a position above at least a portion of the first resin R1. When in the first position, the guide 142 may contact the first pair of stops 182. In the second position, the stage 18 may be lowered by the first actuator 50 (FIG. 25) to a position above at least a portion of the second resin R2. When in the second position, the guide 142 may contact the second pair of stops 184. Of course, the first slide assembly 138 may include a single first stopper and / or a single second stopper without departing from the scope of the present invention.

[0108] In various embodiments, each of the first pair stoppers 182 and the second pair stoppers 184 may be adjustable. For example, the first pair stoppers 182 and the second pair stoppers 184 may be formed with fine threads (e.g., 100 threads per inch (TPI)) and are adjustable end stops that allow for precise positioning of the respective pairs of end stoppers 182, 184. In some embodiments, one or more guides 142 may include hardened standoffs 186 configured to engage the end stoppers 182, 184. The standoffs 186 may be removable and replaceable, thereby allowing for easy replacement of the standoffs 186 in use as they wear out from use and / or for any other reason.

[0109] 31 , as provided herein, the second slide assembly 150 can include a pair of rails 154 operably coupled to the base plate 132. The second slide assembly 150 can also include one or more guides 152 coupled to the carrier plate 146. The guides 152 can be configured to move along the pair of rails 154. As shown, the third actuator 54 can be operably coupled to the base plate 132 and the carrier plate 146 and can move the carrier plate 146 relative to the base plate 132. In some cases, the third actuator 54 can be configured to move the carrier plate 146 between the first position and the second position.

[0110] In the first position, the radiant energy device 20 may be disposed at a first location relative to the window 16 and / or base plate 132. When in the first position, the guide 152 may contact a first stop 188. In the second position, the radiant energy device 20 may be disposed at a second location relative to the window 16 and / or base plate 132 that is offset from the first location in the Y-axis direction. When in the second position, the guide 152 may contact a second stop 190.

[0111] In the illustrated embodiment of FIG. 31, a first stop 188 may be operably coupled to the base plate 132. A second stop 190 may be operably coupled to a flange 192 of the base plate 132. In various embodiments, each of the first and second end stops may be adjustable. For example, the first and second end stops may be in the form of fine threaded (e.g., 100 TPI) adjustable end stops that allow for precise positioning of each of the first and second end stops. In some embodiments, a first standoff 186 may be supported by the carrier plate 146 and configured to align with the first end stop. The second standoff 186 may be operably coupled to an opposite end of the carrier plate 146 and / or a guide 152 of the second slide assembly 150. Each of the first standoff 186 and the second standoff 186 may be removable and replaceable, thereby allowing for easy replacement of the standoff 186 in use as it becomes worn from use and / or for any other reason.

[0112] 32-34, various perspective views of an additive manufacturing apparatus having an actuator assembly 46 are provided in accordance with various aspects of the present invention. As provided herein, the additive manufacturing apparatus may be configured to deposit a first resin R1 and a second resin R2 onto a resin support 26. The first resin R1 may be laterally offset in the Y direction from the second resin R2 on the resin support 26. Additionally, a gap 124 may be defined between the laterally offset first and second resins R1, R2.

[0113] The actuator assembly 46 may include a first actuator 50 that moves the stage 18 to a plurality of positions along the Z-axis. The actuator assembly 46 may also include a second actuator 52 that may be associated with a first slide assembly 138. The first slide assembly 138 may be configured to move the stage 18 relative to the mounting plate 140. In addition, the actuator assembly 46 may include a third actuator 54 that may be associated with a second slide assembly 150. The second slide assembly 150 may be configured to move the radiant energy device 20 relative to the frame 126 and / or the window 16.

[0114] During operation, the resin support 26 may be maintained in a generally consistent position. Conversely, the stage 18 and / or the radiant energy device 20 may be movable relative to the resin support 26 such that the first resin R1 (or various portions of the first resin R1) and / or the second resin R2 (or various portions of the second resin R2) may be selectively cured.

[0115] 32, the first slide assembly 138 may be disposed in a first position relative to the mounting plate 140. In the first position, the guide 142 of the first slide assembly 138 may contact and / or be adjacent to the first pair stopper 182. In the first position, the stage 18 may be substantially aligned in the Y-axis direction with the first resin R1.

[0116] 32, the second slide assembly 150 may be in a first position. In the first position, the guide 152 of the second slide assembly 150 may abut and / or be adjacent to the first stop 188 of the second slide assembly 150. In the first position, the radiant energy device 20 may be in a first position relative to the window 16. Thus, the radiant energy device 20 may be directed toward a first portion of the first resin R1.

[0117] 33, while the first slide assembly 138 is in the first position, the second slide assembly 150 may be in a second position. In the second position, the guide 152 of the second slide assembly 150 may abut and / or be adjacent to the second stop 190 of the second slide assembly 150. In the second position, the radiant energy device 20 may be in a second position relative to the window 16. Thus, the radiant energy device 20 may be directed toward a second portion of the first resin R1.

[0118] 34, the first slide assembly 138 may also be disposed in a second position relative to the mounting plate 140. In the second position, the guide 142 of the first slide assembly 138 may contact and / or be adjacent to the second pair stopper 184. In the second position, the stage 18 may be substantially aligned in the Y-axis direction with the second resin R2.

[0119] 34, the second slide assembly 150 may be in a first position. In the first position, the guide 152 of the second slide assembly 150 may abut and / or be adjacent to the first stop 188 of the second slide assembly 150. In the first position, the radiant energy device 20 may be in a third position relative to the window 16. Thus, the radiant energy device 20 may be directed toward a first portion of the second resin R2.

[0120] 35, while the first slide assembly 138 is in the second position, the second slide assembly 150 may be in the second position. In the second position, the guide 152 of the second slide assembly 150 may abut and / or be adjacent to the second stop 190 of the second slide assembly 150. In the second position, the radiant energy device 20 may be in a fourth position relative to the window 16. Thus, the radiant energy device 20 may be directed toward a second portion of the second resin R2.

[0121] During operation, each of the slide assemblies may be manipulated in any order to form the component 12 formed from one or both of the first and second resins R1, R2. In some examples, the radiant energy device 20 may be configured as any device or combination of devices operable to generate and project radiant energy onto the resin R in a suitable pattern with suitable energy levels and other operational characteristics to cure the first resin R1 and / or the second resin R2 during the build step. Additionally, the radiant energy device 20 may or may not be configured to translate under the window 16 and / or the support plate 14. For example, as shown in FIGS. 31-34, the radiant energy device 20 may include a first projector 56 and a second projector 56. Each of the first projector 56 and the second projector 56 may generate an image 64 that at least partially overlaps with an image 64 of an additional radiant energy device to form a stitched image 64 on the first resin R1 and / or the second resin R2. In various embodiments, the images 64 from each of the multiple radiant energy devices 20 can have some overlap, which can be a single pixel, less than one pixel (e.g., ½ pixel), or more than one pixel. Additionally or alternatively, the radiant energy device 20 can be capable of performing a scanning process in which successive patterned images 64 are emitted from the radiant energy device 20 as the radiant energy device 20 is translated along the motion device 80. Thus, in some embodiments, the image 64 from the first projector 56 and the image 64 from the second projector 56 can be stitched together statically or mechanically. Additionally or alternatively, the multiple images 64 from the first projector 56 can be stitched together when the third actuator 54 changes the position of the first projector 56. Similarly, the multiple images 64 from the second projector 56 may be stitched together when the third actuator 54 changes the position of the second projector 56.

[0122] Additionally, in some embodiments, the apparatus 10 can include one or more sensors 194 configured to detect information regarding the position of the print head, the frame 126, and / or the radiant energy device 20. For example, the one or more sensors 194 can verify the position of the stage 18 each time the stage 18 is moved. Additionally or alternatively, the one or more sensors 194 can verify the position of the frame 126 each time the frame 126 is translated. Additionally or alternatively, the one or more sensors 194 can verify the position of the radiant energy device 20 each time the radiant energy device 20 is translated by the motion device 80. In various embodiments, the one or more sensors 194 can be any combination of devices configured to provide information indicative of the position of the print head, the frame 126, and / or the radiant energy device 20. For example, the one or more sensors 194 can include a gyroscope, an accelerometer, a proximity sensor, an image sensor, and / or any other possible sensor.

[0123] 36, a perspective view of an additive manufacturing apparatus according to various embodiments of the present invention is provided. As provided herein, the additive manufacturing apparatus may be configured to deposit a first resin R1 and a second resin R2 onto a resin support 26. The first resin R1 may be laterally offset in the Y direction from the second resin R2 on the resin support 26. Additionally, a gap may be defined between the laterally offset first and second resins R1, R2.

[0124] As shown, in various embodiments, the frame 126 may be movable relative to the support plate 14 and the window 16. Thus, in some instances, there may be little or no relative movement between the resin support 26 and the support plate 14 and window 16 in the Y axis direction.

[0125] In some embodiments, an opening 196 may be defined between the support plate 14 and the frame 126 to accommodate movement of the frame 126 relative to the support plate 14. The opening 196 may have a length in the Y-axis direction at least equal to the length of movement of the build plate 130 when the frame 126 is moved from the first position to the second position.

[0126] With reference to Figure 37, an apparatus 400 for operating an additive manufacturing apparatus 10 is provided. The method 400 may be used to operate the additive manufacturing apparatus 10 or any other suitable additive manufacturing apparatus 10. It should be appreciated that the exemplary method 400 is discussed herein only to illustrate exemplary aspects of the present subject matter and is not intended to be limiting. Any of the steps of Figure 36 may be omitted without departing from the scope of the present disclosure.

[0127] At 402, the method 400 may include depositing a layer of a first uncured resin and a layer of a second uncured resin on a resin support. In various embodiments, the first resin may be laterally offset in the Y direction from a second resin R2 on the resin support. Further, a gap may be defined between the laterally offset first and second resins R1, R2.

[0128] The resin support may also be in the form of a first resin support having the first resin deposited thereon and a second resin support having the second resin deposited thereon. Each of the first and second resin supports may be operatively coupled to a supply module and a take-up module. Conversely, the first and second resins may be deposited on a common resin support.

[0129] At 404, the method 400 may include moving the resin support in the X-axis direction to the build zone while the first resin and / or the second resin are being deposited on the resin support and / or after deposition of the first resin and / or the second resin on the resin support. As provided herein, the resin support may be moved by a drive assembly.

[0130] At 406, the method 400 can include placing the stage in a first curing position by moving the stage such that a working surface of the stage and / or a component held by the stage contacts the first resin. As provided herein, an additive manufacturing apparatus includes a frame. The frame can include a frame structure, a build plate, a support plate, and / or a base plate.

[0131] The build plate may support a first actuator. In some embodiments, the first actuator may enable movement of the stage in a first vertical direction (e.g., along a Z-axis direction). The print head may be operably coupled to the first actuator. In such an example, the print head may be configured to be translated or otherwise moved in the Z-axis direction by the actuator. The print head may further be operably coupled to the stage.

[0132] A base plate may be secured to a bottom of a frame structure. A first slide assembly may be operably coupled to the base plate. The first slide assembly may guide movement of the base plate in a Y-axis direction relative to the mounting plate. The mounting plate may be held in a substantially stationary position within the additive manufacturing apparatus. In various embodiments, a second actuator may be operably coupled to the base plate and the mounting plate. The second actuator may be configured to move the base plate in a Y-axis direction relative to the mounting plate.

[0133] At 408, the method 400 can include positioning a radiant energy device at the first projection location. In various embodiments, the radiant energy device can be operatively coupled to the frame and positioned on the opposite side of the window from the stage in the Z direction. In some embodiments, the radiant energy device can be movably coupled to the frame. For example, a second slide assembly can be disposed between the carrier plate and the base plate. The second slide assembly can guide the movement of the carrier plate relative to the base plate. Thus, in some embodiments, the stage and the radiant energy device can move relative to each other relative to the mounting plate, for example by the first slide assembly, and the radiant energy device can move relative to the stage, for example by the second slide assembly.

[0134] At 410, the method 400 can include curing a portion of the first resin while the stage is in the first curing position and curing the first projection position by applying radiant energy from the radiant energy device through a window in the support plate and the resin support. As provided herein, the radiant energy can form a patterned image that is transmitted through at least a portion of the window.

[0135] At 412, the method 400 can include positioning the radiant energy device at a second projection location. The second projection location is offset from the first curing location in a Y-axis direction. In various embodiments, the radiant energy device is moved from the first projection location to the second projection location by translating along a second slide assembly. A third actuator is operably coupled to the base plate of the frame and to the carrier plate operably coupled to the radiant energy device and can move the radiant energy device relative to the stage and / or the resin support.

[0136] At 414, the method 400 can include curing a portion of the first resin while the stage is in the first curing position and curing the resin at a second projection position by applying radiant energy from the radiant energy device through a window in the support plate and the resin support. As provided herein, the radiant energy can form a patterned image that is transmitted through at least a portion of the window.

[0137] At 416, the method 400 may include positioning the stage at a second curing position by moving the stage such that a work surface of the stage and / or a component held by the stage contacts the first resin and / or the second resin, the second curing position being offset in the Y-axis direction from the first curing position.

[0138] At 418, the method 400 can include positioning a radiant energy device at a first projection location. Then, at 420, the method 400 can include curing a portion of the second resin while the stage is in the second curing location and curing the radiant energy device at the first projection location by applying radiant energy from the radiant energy device through a window in the support plate and the resin support. As provided herein, the radiant energy can form a patterned image that is transmitted through at least a portion of the window.

[0139] At 422, the method 400 can include positioning the radiant energy device at a second projection location, the second projection location being offset in the Y-axis direction from the first curing location. In various embodiments, the radiant energy device is moved from the first projection location to the second projection location by translating along the second slide assembly.

[0140] At 424, the method 400 may include curing a portion of the second resin while the stage is in the second curing position and curing the radiant energy device at the second projection position by applying radiant energy from the radiant energy device through windows in the support plate and the resin support.

[0141] FIG. 38 illustrates certain components of a computing system 84 according to an exemplary embodiment of the present disclosure. The computing system 84 may include one or more computing devices 84A that may be used to implement the methods 200, 400 described herein. The computing device 84A may include one or more processors 84B and one or more memory devices 84C. The one or more processors 84B may include any suitable processing device, such as a microprocessor, a microcontroller, an integrated circuit, an application specific integrated circuit (ASIC), a digital signal processor (DSP), a field programmable gate array (FPGA), a logic device, one or more central processing units (CPUs), a graphics processing unit (GPU) (e.g., dedicated to efficiently rendering images), other processing units performing specialized calculations, etc. The memory device 84C may include one or more non-transitory computer-readable storage media, such as RAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, etc., and / or combinations thereof.

[0142] The memory device 84C may include one or more computer-readable media and may store information accessible by the one or more processors 84B, including instructions 84D that may be executed by the one or more processors 84B. The instructions 84D may include one or more steps of the methods 200, 400 described above, such as performing operations in the additive manufacturing apparatus 10 described herein. The memory device 84C may store instructions 84D for executing one or more software applications, for displaying a user interface, for receiving user input, for processing user input. In some implementations, the instructions 84D may be executed by the one or more processors 84B to cause the one or more processors 84B to perform operations, such as, for example, one or more portions of the methods 200, 400 described herein. The instructions 84D may be software written in any suitable programming language or may be implemented in hardware. Additionally and / or alternatively, the instructions 84D may be executed in logically and / or virtually separate threads on the processor 84B.

[0143] The one or more memory devices 84C can also store data 84E that can be retrieved, manipulated, created, or stored by the one or more processors 84B. The data 84E can include, for example, data to facilitate execution of the methods 200, 400 described herein. The data 84E can be stored in one or more databases. The one or more databases can be connected to the computing system 84 by a high bandwidth LAN or WAN, or can also be connected to the computing system 84 via a network. One or more databases can be partitioned to be located in multiple locations. In some implementations, the data 84E can be received from another device.

[0144] Computing device 84A may also include a communications portion or interface 84F used to communicate with computer 84 or one or more other components of additive manufacturing apparatus 10. Communications interface 84F may include any suitable components for interfacing with one or more networks, including, for example, a transmitter, a receiver, a port, a controller, an antenna, or other suitable components.

[0145] It should be understood that the additive manufacturing apparatus is described herein only to illustrate aspects of the present subject matter. In other exemplary embodiments, the additive manufacturing apparatus can have any other suitable configuration and can use any other suitable additive manufacturing technique. Furthermore, the additive manufacturing apparatus and methods 200, 400 described herein can be used to form components using any suitable material. For example, the material can be plastic, metal, concrete, ceramic, polymer, epoxy, photopolymer resin, or any other suitable material that can be embodied in a layer of a sheet material in any other suitable form having any suitable consistency, viscosity, or material properties. For example, according to various embodiments of the present subject matter, the additively manufactured components described herein can be formed in part, in whole, or in combination with materials including, but not limited to, pure metals, nickel alloys, chromium alloys, titanium, titanium alloys, magnesium, magnesium alloys, aluminum, aluminum alloys, iron, iron alloys, stainless steel, and nickel or cobalt based superalloys (e.g., those available under the name Inconel® available from Special Metals Corporation). These materials are illustrative of materials suitable for use in the additive manufacturing methods described herein and may be generally referred to as "additive materials."

[0146] Aspects of the invention are provided by the subject matter of the following sections, which are intended to cover all appropriate combinations unless otherwise indicated by logic or by the context of the sections and / or the associated figures and descriptions.

[0147] (Appendix 1) a resin support configured to support the first resin and the second resin; a support plate including a window; a stage configured to hold one or more cured layers of the first resin or the second resin to form a component disposed on an opposing side of the support plate; a radiant energy device disposed on an opposite side of the resin support from the stage and operable to generate and project radiant energy through the window into a patterned image; an actuator assembly for moving the stage in a Z-axis direction and a Y-axis direction;

[0021] An additive manufacturing device comprising:

[0148] (Appendix 2) the first resin is laterally offset from the second resin in a Y-axis direction; 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses.

[0149] (Appendix 3) A gap is formed between the first resin and the second resin. 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses.

[0150] (Appendix 4) The resin support is a first resin support onto which the first resin is deposited; a second resin support onto which the second resin is deposited; 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses, comprising:

[0151] (Appendix 5) The actuator assembly is further configured to move the radiant energy device along the Y-axis direction relative to the resin support. 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses.

[0152] (Appendix 6) a material deposition means configured to deposit the first resin and the second resin onto the resin support, the material deposition means including a first reservoir for holding the first resin and a second reservoir for holding the second resin; 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses, further comprising:

[0153] (Appendix 7) a frame operatively coupled to the stage, the radiant energy device, and the support plate, the frame further coupled to a mounting plate; A first slide assembly; Further comprising: the frame, the stage, the radiant energy device, and the support plate are movable relative to the mounting plate along the first slide assembly. 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses.

[0154] (Appendix 8) an actuator of the actuator assembly operably coupled to the frame and the mounting plate; the actuator is configured to move the frame along the first slide assembly between a first position and a second position. 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses.

[0155] (Appendix 9) a second slide assembly operatively coupled to the radiant energy device and the frame; Further comprising: the radiant energy device is movable relative to the frame along the second slide assembly; 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses.

[0156] (Appendix 10) a third actuator operably coupled to the frame and to the radiant energy device; Further comprising: the third actuator is configured to move the radiant energy device along the second slide assembly between a first position and a second position. 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses.

[0157] (Appendix 11) a frame operatively coupled to the stage, the radiant energy device, and the actuator assembly; Further comprising: the frame, the stage, and the radiant energy device are movable relative to the support plate along a first slide assembly. 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses.

[0158] (Appendix 12) depositing a layer of a first resin and a layer of a second resin on a resin support; The resin support is translated in an X-axis direction; placing a stage at a first curing position such that a work surface contacts the first resin; curing a portion of the first resin while the stage is in the first curing position; placing the stage at a second curing position; the second curing position is offset in a Y-axis direction from the first curing position; curing a portion of the second resin while the stage is in the second curing position. A method of operation of an additive manufacturing device.

[0159] (Appendix 13) curing the portion of the first resin while the stage is in the first curing position to form a first layer of a component; curing the portion of the second resin while the stage is in the second curing position forms a second layer of the component. A method of operating an additive manufacturing device as described in one or more of the preceding clauses.

[0160] (Appendix 14) curing the portion of the first resin while the stage is in the first curing position forms a first portion of a layer of a component; curing the portion of the second resin while the stage is in the second curing position forms a second portion of the layer of the component. A method of operating an additive manufacturing device as described in one or more of the preceding clauses.

[0161] (Appendix 15) Positioning a radiant energy device at a first projection location; curing the portion of the first resin while the radiant energy device is in the first projection position. A method of operating one or more of the above-mentioned additive manufacturing devices.

[0162] (Appendix 16) Positioning the radiant energy device at a second projection location; the second projection position is offset in a Y-axis direction from the first projection position; curing the portion of the first resin while the radiant energy device is in the second projection position. A method of operating an additive manufacturing device as described in one or more of the preceding clauses.

[0163] (Appendix 17) a frame including a frame structure having a build plate, a support plate, and a base plate coupled to each other, the support plate including a window; a first actuator operably coupled to the build plate; a printhead operably coupled to the first actuator, the first actuator configured to move the printhead relative to a Z axis; a stage operatively coupled to the print head; a radiant energy device operably coupled to the frame and positioned on an opposite side of the window from the stage along the Z axis; a first slide assembly operably coupled to the base plate and mounting plate of the frame, the first slide assembly configured to guide movement of the frame relative to the mounting plate in a Y-axis direction; 1. An additive manufacturing device comprising:

[0164] (Appendix 18) the first slide assembly includes a track operably coupled to the mounting plate and one or more guides operably coupled to the base plate; the one or more guides are slidable along the track; 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses.

[0165] (Appendix 19) a second slide assembly disposed between the radiant energy device and the frame structure; Further comprising: the second slide assembly is configured to guide movement of the radiant energy device relative to the window. 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses.

[0166] (Appendix 20) the second slide assembly includes a rail operably coupled to the frame structure and one or more guides; one or more of the guides are slidable along the rail; 13. An additive manufacturing apparatus as set forth in one or more of the preceding clauses.

[0167] This specification uses examples to disclose the invention, including the best mode, and also enables any person skilled in the art to practice the invention, including making and using any device or system, and practicing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they contain structural elements that do not differ from the literal language of the claims, or if they contain equivalent structural elements that do not differ substantially from the literal language of the claims.

Claims

1. a resin support configured to support the first resin and the second resin; a support plate including a window; a stage configured to hold one or more cured layers of the first resin or the second resin to form a component disposed on an opposing side of the support plate; a radiant energy device disposed on an opposite side of the resin support from the stage and operable to generate and project radiant energy through the window into a patterned image; an actuator assembly for moving the stage in a Z-axis direction and a Y-axis direction; a frame operatively coupled to the stage, the radiant energy device, and the support plate, the frame further coupled to a mounting plate; A first slide assembly; Including, the frame, the stage, the radiant energy device, and the support plate are movable relative to the mounting plate along the first slide assembly. Additive manufacturing equipment.

2. The first resin is laterally offset from the second resin in a Y-axis direction.

10. The additive manufacturing device of claim 1.

3. A gap is formed between the first resin and the second resin.

3. An additive manufacturing apparatus according to claim 1 or claim 2.

4. The resin support is a first resin support on which the first resin is deposited; a second resin support on which the second resin is deposited; 3. The additive manufacturing apparatus of claim 2 , comprising:

5. The actuator assembly is further configured to move the radiant energy device along the Y-axis direction relative to the resin support.

3. An additive manufacturing apparatus according to claim 1 or claim 2.

6. a material deposition means configured to deposit the first resin and the second resin on the resin support, the material deposition means including a first reservoir for holding the first resin and a second reservoir for holding the second resin; 3. The additive manufacturing apparatus of claim 1 or claim 2, further comprising:

7. an actuator of the actuator assembly operably coupled to the frame and the mounting plate; the actuator is configured to move the frame along the first slide assembly between a first position and a second position.

10. The additive manufacturing device of claim 1.

8. a second slide assembly operatively coupled to the radiant energy device and the frame; Further comprising: the radiant energy device is movable relative to the frame along the second slide assembly; 8. The additive manufacturing device of claim 7.

9. a third actuator operably coupled to the frame and to the radiant energy device; Further comprising: the third actuator configured to move the radiant energy device along the second slide assembly between a first position and a second position.

9. The additive manufacturing device of claim 8.

10. a frame operatively coupled to the stage, the radiant energy device, and the actuator assembly; Further comprising: the frame, the stage, and the radiant energy device are movable relative to the support plate along a first slide assembly.

3. An additive manufacturing apparatus according to claim 1 or claim 2.

11. depositing a layer of a first resin and a layer of a second resin on a resin substrate; placing a stage at a first curing position such that a work surface contacts the first resin; a frame operatively coupled to the stage, the radiant energy device, and the actuator assembly; curing a portion of the first resin while the stage is in the first curing position; placing the stage at a second curing position; the second curing position is offset from the first curing position in a Y-axis direction; the frame, the stage, and the radiant energy device are movable relative to a support plate along a first slide assembly; curing a portion of the second resin while the stage is in the second curing position. A method of operation of an additive manufacturing device.

12. curing the portion of the first resin while the stage is in the first curing position forms a first layer of a component; curing the portion of the second resin while the stage is in the second curing position forms a second layer of the component.

12. A method of operating an additive manufacturing device according to claim 11.

13. curing the portion of the first resin while the stage is in the first curing position forms a first portion of a layer of a component; curing the portion of the second resin while the stage is in the second curing position forms a second portion of the layer of the component.

13. A method of operating an additive manufacturing device according to claim 11 or claim 12.

14. Positioning a radiant energy device at a first projection location; curing the portion of the first resin while the radiant energy device is in the first projection position.

13. A method of operating an additive manufacturing device according to claim 11 or claim 12.

Images