Additive manufacturing equipment and methods of operating additive manufacturing equipment

Abstract

SOLUTION: An additive manufacturing apparatus includes: a first print module including a first stage holding a first component and a first radiant energy device; a second print module including a second stage holding a second component and a second radiant energy device; and a control system for moving a resin support based on a state of the first and second print modules. The resin support is located between the first stage and the first radiant energy device and between a second stage and the second radiant energy device. The control system includes: a build controller coupled to a computing system and a control device; a user interface coupled to the build controller and the computing system and configured to receive at least one parameter; and an energy device communication bus coupled to the computing system in parallel with the build controller.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present subject matter relates generally to additive manufacturing equipment, and more particularly to control systems and methods for various components of additive manufacturing equipment. [Background technology]

[0002] Additive manufacturing is a method in which material is built layer by layer to form a component. Stereolithography (SLA) is a type of additive manufacturing method that uses a tank 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 part's cross-section 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 achieved through a "tape casting" process. In this process, resin is deposited onto a flexible, radiation-transparent resin support, such as a tape or foil, which is advanced from a supply reel into a 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 first layer has cured, the stage and resin support are separated from each other. The resin support is then advanced, delivering fresh resin into the build zone. A first layer of cured resin is then placed on the fresh resin and cured through an energy device to form additional layers of the component. Subsequent layers are added to each previous layer until the component is complete. Summary of the Invention [Problem to be solved by the invention]

[0004] In some cases, it may be advantageous to implement an additive manufacturing device that includes multiple print modules. In such cases, various components may be shared, while others may be independently controlled. Therefore, a control system is required to control the various components. [Means for solving the problem]

[0005] One aspect of the present disclosure is an additive manufacturing apparatus (10) including a first print module (158a) including a first stage configured to hold a first radiant energy device (20a) and a first component (12a), and a second print module (158b) including a second stage configured to hold a second radiant energy device (20b) and a second component (12b), wherein the first print module (158a) and the second print module (158b) are configured to receive at least a portion of a resin support (26) between the first stage and the first radiant energy device (20a) and between the second stage and the second radiant energy device (20b), and a control system (156) configured to move the resin support (26) by the first print module (158a) and the second print module (158b) based on a state of the first print module (158a) and the second print module (158b). [Brief explanation of the drawings]

[0006] [Figure 1A] FIG. 1 is a schematic front view of an additive manufacturing device according to various aspects of the present disclosure. [Figure 1B] FIG. 1 is a schematic front view of an additive manufacturing device according to various aspects of the present disclosure. [Figure 2] FIG. 1 is a front perspective view of a supply module according to various aspects of the present disclosure. [Figure 3] FIG. 10 is a rear perspective view of a supply module according to various aspects of the present disclosure. [Figure 4]FIG. 1 is a front perspective view of a take-up module according to various aspects of the present disclosure. [Figure 5] FIG. 1 is a rear perspective view of a take-up module according to various aspects of the present disclosure. [Figure 6] FIG. 1 is a schematic front view of an additive manufacturing device according to various aspects of the present disclosure. [Figure 7] 1 illustrates an exemplary control system for additive manufacturing equipment according to various aspects of the present disclosure. [Figure 8] 1 illustrates an exemplary control system for additive manufacturing equipment according to various aspects of the present disclosure. [Figure 9] 1 is a method of operating a manufacturing apparatus according to various aspects of the present disclosure. [Figure 10] 1 is a method of operating a manufacturing apparatus according to various aspects of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0007] A full and enabling disclosure of the present disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth herein, and reference is made to the accompanying drawings, in which:

[0008] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the present disclosure.

[0009] Reference will now be made in detail to the present embodiments of the present disclosure, 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 present disclosure.

[0010] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to denote 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, as well as indirect coupling, fixing, or attachment via one or more intermediate components or features. The terms “upstream” and “downstream” refer to a relative direction with respect to the movement of a resin support along a 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. As used herein, any two components “operably coupled” to each other may be capable of unidirectional or bidirectional communication with each other. For example, a first component operably coupled to a second component may provide instructions from the first component to the second component and / or provide instructions from the second component to the first component. Additionally or alternatively, the first component may receive data from the second component, and / or the second component may receive data from the first component.

[0011] The singular forms "a," "an," and the like include plural references unless the context clearly dictates otherwise.

[0012] As used herein throughout this specification and claims, approximating terms are applied to modify any quantitative expression that can 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 instances, approximating terms 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, approximating terms may refer to being within a margin of 10 percent.

[0013] Furthermore, 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.

[0014] Here and throughout the specification and claims, range limitations are combinable and interchangeable, and such ranges include and specify all subranges subsumed 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.

[0015] As used herein, the word "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 containing components A, B, and / or C, the composition or assembly can contain 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.

[0016] The present disclosure is generally directed to additive manufacturing equipment that performs various manufacturing processes such that successive layers of material are applied to one another to "build" a three-dimensional component layer by layer. The successive layers generally harden together to form a monolithic component that may have various integral subcomponents. Although additive manufacturing technology is described herein as enabling the production of complex objects by building the object point by point, layer by layer, variations on the described additive manufacturing equipment and technology are contemplated and within the scope of the present subject matter.

[0017] The additive manufacturing equipment can include a support plate, a window supported by the support plate, and a stage movable relative to the window. The additive manufacturing equipment can further include resin deposited as a layer having a desired thickness on a resin support (e.g., foil, tape, batt, plate, etc.) delivered from a supply reel. The stage lowers onto the resin such that a work surface defined by one of the surfaces of the stage or the part being processed is positioned so that the work surface just contacts the resin or compresses it between the resin support and the stage, defining the layer thickness. Radiant energy is used to harden the resin through the resin support. Once the first layer has hardened, the stage retracts, removing the hardened material. The resin support is then advanced to expose a fresh, clean section, ready for additional resin to be deposited in the next new cycle.

[0018] In some examples, an additive manufacturing apparatus can include a first print module having a first stage configured to hold a first component and a first radiant energy device. The resin support is configured to be disposed between the first stage and the first radiant energy device. The additive manufacturing apparatus can also include a second print module having a second stage configured to hold a second component and a second radiant energy device. The resin support is configured to be disposed between the second stage and the second radiant energy device.

[0019] A control system is configured to move the resin support through the first print module and the second print module. The control system is configured to handle synchronization of the multiple print modules with various other components of the apparatus. Module synchronization can lead to increased machine output due to the utilization of shared auxiliary processes across multiple print modules.

[0020] 1A and 1B, with reference to the drawings in which identical reference numbers indicate similar elements throughout the various views, schematically illustrate an example of one type of apparatus 10 suitable for forming component 12. Apparatus 10 may include one or more of a support plate 14, a window 16, a stage 18 movable relative to 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.

[0021] In the example illustrated in FIG. 1A, the apparatus 10 may include a supply module 22 including a first mandrel 22A and a take-up module 24 including spaced-apart take-up mandrels 24A such that a resin support 26 extends therebetween. A portion of the resin support 26 may be supported from below by a support plate 14. Suitable mechanical supports (frames, brackets, etc.) and / or alignment devices may be provided for the mandrels 22A, 24A and the support plate 14. The first mandrel 22A and / or the take-up mandrel 24A may be configured to control the speed and direction of the resin support 26 such that a desired tension and velocity are maintained within the resin support 26 via a drive system 28. By way of example and not limitation, the drive system 28 may be configured as individual motors associated with the first mandrel 22A and / or the take-up mandrel 24A. Additionally, various components, such as motors, actuators, feedback sensors, and / or control devices, may be provided to drive the mandrels 22A, 24A to maintain tension on the resin support 26 between the aligned mandrels 22A, 24A and to wind the resin support 26 from the first mandrel 22A onto the winding mandrel 24A.

[0022] 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 into 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, glass, and crystalline minerals such as sapphire or quartz.

[0023] The resin support 26 extends between the supply module 22 and the take-up module 24 and defines a "resin surface" 30, which is shown as a plane but may be arcuate (depending on the shape of the support plate 14). In some examples, the resin 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 of description, the resin surface 30 can 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 can be defined as the direction of movement of the stage 18 relative to the window 16.

[0024] The resin 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. Suitable coatings include: One non-limiting example of a resin support 26 is polytetrafluoroethylene ("PTFE"). In some examples, all or a portion of the resin 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.

[0025] For reference purposes, the area or volume immediately surrounding the location of the transparent portion defined by resin support 26 and window 16 or support plate 14 may be defined as the “build zone,” labeled 32 .

[0026] In some cases, a deposition assembly 34 can be positioned along the resin support 26. In the illustrated embodiment, the material deposition assembly 34 includes a container 36 and a reservoir 40. A conduit 38 extends from the container 36 and conducts resin from the container 36 to the reservoir 40. The conduit 38 can be positioned along the bottom of the container 36 so that the resin R can be gravity-fed from the container 36 to the conduit 38, which can generally prevent the introduction of air into the resin R as it is transferred into and / or through the conduit 38. In some examples, a filter can be positioned upstream, downstream, and / or within the conduit 38 relative to the flow of resin from the container 36 to the reservoir 40. In such cases, the resin can be gravity-fed through a filter before entering the reservoir 40 to capture various agglomerates, partially cured resin pieces, and / or other foreign matter that may affect the resin after it is thinned on the resin support 26 or that may affect the quality of the component 12.

[0027] The reservoir 40 may include an optional assembly for controlling the thickness of resin R applied to the foil resin support 26 as the foil resin support 26 passes under and / or through the reservoir 40. The reservoir 40 may be configured to hold a first amount of resin R and define a thickness of resin R on the foil resin support 26 as the foil resin support 26 moves in the X-axis direction. A container 36 may be positioned above the reservoir 40 in the Z-axis direction or any other location and configured to hold a second amount of resin R. In various embodiments, when the first amount of resin R falls outside a predetermined range, additional resin R is supplied to the reservoir 40 from the container 36.

[0028] 1B, resin support 26 may be in the form of a vat 42 configured to isolate debris that may contaminate the build from usable resin R. Vat 42 may include a floor 44 and a peripheral wall 46. 46 extends from floor 44. The interior surfaces of floor 44 and peripheral wall 46 define a receptacle 48 for receiving resin R.

[0029] A drive system may be provided for moving vat 42 relative to stage 18 parallel to the X direction between build zone 32 and a position at least partially outside of build zone 32. However, it will be understood that in other embodiments, resin support 26 may be stationary without departing from the scope of the present disclosure.

[0030] 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 at a particular frequency and energy level. For example, resin R may include a photopolymer resin containing a photoinitiator compound that functions to induce a polymerization reaction and change resin R from a liquid (or powder) state to a solid state. Alternatively, resin R may include a material containing a solvent that can be evaporated by the application of radiant energy. Uncured resin R may be provided in a solid (e.g., granular) or liquid form, including a paste or slurry.

[0031] Additionally, Resin R can have a relatively high viscosity 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.

[0032] Additionally or alternatively, Resin R may be selected to be a viscosity-thinnable composition. These compositions decrease in viscosity when subjected to 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.

[0033] Resin R may contain fillers. The fillers may be premixed with resin R and then loaded into deposition assembly 34. Alternatively, the fillers may be mixed with resin R on 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 be in the form of powders, spheres, or granules, or may be rod- or fiber-like.

[0034] 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 may 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 may be selected for its electrical or electromagnetic properties; for example, the filler composition may be specifically an electrical insulator, dielectric material, conductor, and / or magnetic material.

[0035] 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 filler particles together in the cured state.

[0036] In some embodiments, the reclaiming system 50 may be configured to remove at least a portion of the resin R remaining on the foil resin support 26 after the foil resin support 26 is removed from the build zone 32. For example, the reclaiming system 50 may include a collection structure, such as a wiper assembly, a blade assembly, and / or any other removal assembly.

[0037] 1A and 1B, the stage 18 can be oriented parallel to the resin surface 30. Various devices can be provided to move the stage 18 parallel to the Z-axis direction relative to the window 16. For example, as shown in FIGS. 1A and 1B, movement can be provided through an actuation assembly 52, which can be coupled to a stationary support 54. In some embodiments, the actuation assembly 52 can be coupled to a vertical actuator between the stage 18 and the stationary support 54, which allows movement of the stage 18 in a first vertical direction (e.g., along the Z-axis direction). The actuation assembly 52 may also include a lateral actuator 56. The actuation assembly 52 may additionally or alternatively include a lateral actuator 58 between the stage 18 and the vertical actuator 56 and / or the stationary support 54 to enable movement in a second horizontal direction (e.g., along the X-axis and / or Y-axis). In some embodiments, the vertical actuator 56 may be operatively coupled to the lateral actuator 58 such that the stage 18 and the vertical actuator 56 move simultaneously along the lateral actuator 58. The actuation assembly 52 may include any device capable of moving the stage 18 in the first and / or second directions, 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.

[0038] 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 with 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 60, which may generally refer to any device operable to generate a radiant energy image at 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 comprising 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 60 includes a radiant energy source 62 such as a UV lamp, an image forming device 64 operable to receive a radiant source beam 66 from the radiant energy source 62 and generate a patterned image 68 that is projected onto the surface of the resin R, and optionally, a focusing optical system 70 such as one or more lenses.

[0039] The image forming device 64 may include one or more mirrors, prisms, and / or lenses, and may be equipped with suitable actuators and positioned to convert a source beam 66 from the radiant energy source 62 into a pixelated image 68 in the XY plane coincident with the surface of the resin R. In the illustrated example, the image forming device 64 may be a digital micromirror device.

[0040] Projector 60 may incorporate additional components, such as actuators, mirrors, etc., configured to selectively move image-forming device 64 or another portion of projector 60, with the effect of rastering or shifting the position of patterned image 68 on resin surface 30. In other words, patterned image 68 may be moved away from a nominal or starting position.

[0041] In addition to other types of radiant energy devices 20, 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, cure resin R, and scan the beam over the surface of resin R in a desired pattern. For example, a scanning beam device can include a radiant energy source 62 and a beam steering device. The radiant energy source 62 can include any device operable to generate a beam of suitable power and other operating characteristics to cure resin R. Non-limiting examples of suitable radiant energy sources 62 include a laser or an electron beam gun.

[0042] In some examples, the apparatus 10 may include a material retention assembly 72 that may be configured to hold the resin support 26 in place along the support plate 14. In some examples, the material retention assembly 72 may apply a force to a surface of the resin support 26 opposite the resin R. The resin support 26 may include one or more air actuation zones 72a, with each air actuation zone 72a configured to selectively interact with the resin support 26 by forming a plurality of air actuation zones 72a.

[0043] One or more air actuation zones 72a can apply 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 can hold the resin support 26 in a desired position along the length of the support plate 14. One or more air actuation zones 72a can also apply 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 can release the resin support 26 from a module of the apparatus 10, such as the window 16 or the material retention assembly 72. As used herein, a "negative" pressure is any pressure less than ambient pressure adjacent one or more air actuation zones 72a such that fluid can be drawn into the one or more air actuation zones 72a. Conversely, a "positive" pressure is any pressure greater than ambient pressure adjacent one or more air actuation zones 72a such that fluid can be expelled from the one or more air actuation zones 72a. Furthermore, a "neutral" pressure is any pressure that is approximately equal to the ambient pressure proximate one or more air operating zones 72a.

[0044] In some examples, air actuation zone 72a may be fluidly coupled to pneumatic assembly 72b via various hoses and one or more ports. Pneumatic assembly 72b may include any device capable of drawing and / or pushing a fluid, such as air or a process gas (e.g., nitrogen or argon), through one or more air actuation zones 72a. For example, pneumatic assembly 72b may include a pressurized fluid source including a compressor and / or a blower. Pneumatic assembly 72b may additionally or alternatively include any assembly capable of varying pressure, such as a Venturi vacuum pump. In some embodiments, one or more valves and / or switches may be coupled to pneumatic assembly 72b and one or more air actuation zones 72a. The one or more valves and / or switches are configured to adjust the pressure to each of the one or more air actuation zones 72a.

[0045] In some embodiments, the air actuation zone 72a includes one or more openings 72c of any size and shape for interacting with the resin support 26. For example, the openings 72c 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 72c may be defined by a portion of the support plate 14 formed from a porous material or through any other assembly through which fluid can 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.

[0046] In some examples, the air actuation zone 72a may be defined by a plenum 72d. The plenum 72d may be any size and may be similar in shape to or vary in shape from any remaining plenums 72d. In some examples, a gasket may be disposed around the edge of the plenum 72d. Additionally or alternatively, the material retention assembly 72 may include one or more clamps that compressively maintain the resin support 26 along the support plate 14.

[0047] 1A and 1B, the viscosity change assembly 74 may be integrated within the support plate 14 and / or operatively coupled to the resin support 26. The viscosity change assembly 74 may be configured to apply a shear stress to the resin R to change (e.g., reduce) the viscosity of the resin R. Additionally or alternatively, the viscosity change assembly 74 may be configured to heat the resin R to change the viscosity of the resin R.

[0048] In some embodiments, the viscosity modification assembly 74 may be configured to mechanically vibrate one or more portions of the additive manufacturing apparatus 10 to generate shear stress in the resin R. For example, the viscosity modification assembly 74 may include a movement device 74a (e.g., a transducer) operably coupled to the support plate 14. The movement device 74a may be configured to vibrate at least a portion of the support plate 14 or any other module of the apparatus 10, which in turn transfers to the resin R. Additionally and / or alternatively, the movement device 74a may be configured to convert electrical energy into ultrasonic mechanical pressure waves that are transferred to the resin R. For example, the movement device 74a 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 74 may include a fluid, acoustic, motor (e.g., an offset cam), reciprocating piston, or any other movement device 74a in addition to or instead of a transducer, alone or in conjunction with one or the other.

[0049] 1A and 1B, in various embodiments, a gasket 76 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. In various examples, the gasket 76 can be formed from any of a wide variety of resilient elastomers, including, but not limited to, natural rubber and silicone-containing materials.

[0050] The apparatus 10 may include and / or be operatively coupled to a computing system 78. The computing system 78 of FIGS. 1A and 1B is a generalized representation of hardware and software that may be implemented to control the operation of the apparatus 10, including the stage 18, drive system 28, radiant energy device 20, actuation assembly 52, material holding assembly 72, viscosity modification assembly 74, actuators, and some or all of the various components of the apparatus 10 described herein. The computing system 78 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 modules. The same one or more 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.

[0051] Optionally, the modules of apparatus 10 may be surrounded by a housing 80 that may be used to provide a shielding or inert gas (e.g., "process gas") atmosphere using gas ports 82. Optionally, the pressure within housing 80 may be maintained at a desired level above or below atmospheric pressure. Optionally, housing 80 may be temperature and / or humidity controlled. Optionally, ventilation of housing 80 may be controlled based on factors such as time intervals, temperature, humidity, and / or chemical species concentration. In some embodiments, housing 80 may be maintained at a pressure different from atmospheric pressure.

[0052] 2 and 3, exemplary perspective views of a feed module 22 including a first plate 84 are shown, according to exemplary embodiments of the present disclosure. As shown, a feed mandrel 22A can be secured to the first plate 84 and can support and rotate a feed roll 86 (FIG. 6) of a resin support 26 (FIG. 6). In various embodiments, the feed mandrel 22A includes a front portion 88 on a first side 90 of the first plate 84 and a rear portion 92 on an opposing second side 94 of the first plate 84. In some examples, bearings 96 can be positioned along the front portion 88, the rear portion 92, and / or between the front portion 88 and the rear portion 92.

[0053] The front portion 88 of the supply mandrel 22A may include a cylindrical portion 98 configured to receive the supply roll 86 of the resin support 26 therearound. In various examples, the resin support 26 may be operably coupled to a first spool 100 ( FIG. 6 ) (e.g., a cardboard spool, a polymer spool, a paper-based spool, a metal spool, a composite spool, an elastomeric spool, etc.), which may be disposed around the supply mandrel 22A.

[0054] The stopper 102 may be positioned between the cylindrical portion 98 and the first plate 84. Thus, when the resin support 26 is wrapped around the supply mandrel 22A, the stopper 102 defines a first distance d1 between the inner edge of the resin support 26 and the first plate 84. In some examples, the supply mandrel 22A may be configured to move between a disengaged position and an engaged position. During operation, the supply mandrel 22A may be positioned in a disengaged position to allow the first spool 100 and the resin support 26 wrapped therearound to slide along the supply mandrel 22A until an end of the first spool 100 contacts or is proximate to the stopper 102. When the first spool 100 is positioned around the supply mandrel 22A, the supply mandrel 22A is positioned in an engaged position, allowing the first spool 100, and thus the supply roll 86 of resin support 26, to rotate with the supply mandrel 22A.

[0055] In some embodiments, drive system 28 (FIG. 1A) may include a feed actuation assembly 104 operably coupled to rear 92 of feed mandrel 22A. Feed actuation assembly 104 may be configured as one or more motors, actuators, brakes (mechanical and / or electrical), or any other device capable of rotating feed mandrel 22A. Additionally, as shown in FIG. 3, feed actuation assembly 104 may include a transmission 106 in the form of a belt system, a gear system, and / or any other viable system.

[0056] 2 and 3, one or more rollers 108A, 108B and / or tension sensors 110, such as load cells, may be anchored to the first side 90 of the first plate 84. For example, the pair of rollers 108A, 108B may be positioned in the Z-axis direction above the supply mandrel 22A. In some examples, the pair of rollers 108A, 108B may have an axis of rotation 112 that is generally parallel to the axis of rotation 114 of the supply mandrel 22A.

[0057] A tension sensor 110 can be located in the Z-axis direction between the pair of rollers 108A, 108B and the supply mandrel 22A. The tension sensor 110 can be configured as a force transducer that converts the tension or torque provided by the resin support 26 on a load cell into an electrical signal that can be measured by the computer system 78 to determine the tension in the resin support 26. In some embodiments, the resin support 26 can be provided from the supply mandrel 22A around the first roller 108A, the tension sensor 110, and then the second roller 108B.

[0058] 2, cover 116 may be secured to first side 90 of first plate 84. In various examples, cover 116 may be configured to prevent any resin from dripping onto supply roll 86 (FIG. 6) and / or any other modules of apparatus 10. Additionally or alternatively, cover 116 may also prevent damage to various modules of apparatus 10 while supply roll 86 is being loaded onto and / or off of apparatus 10.

[0059] 2 and 3, in some embodiments, a first position sensor 118 may be operably coupled to the first plate 84 and configured to contact the resin support 26. The first position sensor 118, and / or any other sensor, may detect movement of the resin support 26 (e.g., The first position sensor 118 may monitor a distance (e.g., linear distance) and may be located at any point within the feed module 22 or at any other location upstream of the build stage 18. In some embodiments, the first position sensor 118 may be configured as a mechanical, optical, on-axis magnetic, and / or off-axis magnetic, and may be an absolute encoder, an incremental encoder, and / or any other type of viable encoder. Additionally, the first position sensor 118 may be any other type of viable sensor without departing from the scope of this disclosure.

[0060] The supply roll proximity sensor 22 may further include a supply roll proximity sensor 120 that may be configured to detect a distance dfr ( FIG. 6 ) between the supply roll proximity sensor 120 and the supply roll 86 of the resin support 26. As the resin support 26 moves from the supply module 22 to the take-up module 24, the distance between the supply roll proximity sensor 120 and the supply roll 86 of the resin support 26 increases as the radius of the supply roll 86 decreases. This change in distance may be provided to the computing system 78, which may then be used to calculate the radius of the supply roll 86.

[0061] 4 and 5, there are shown front and rear perspective views, respectively, of a winding module 24 including a second plate 122, according to an exemplary embodiment of the present disclosure. As shown, a winding mandrel 24A may be secured to the second plate 122 and configured to support a winding roll 124 (FIG. 6) of resin support 26.

[0062] In various embodiments, the winding mandrel 24A includes a front portion 126 on a first side 128 of the second plate 122 and a rear portion 130 on an opposing second side 132 of the second plate 122. In some examples, bearings 134 may be positioned along the front portion 126, the rear portion 130, and / or between the first portion 126 and the second portion 130 of the winding mandrel 24A.

[0063] The front portion 126 of the winding mandrel 24A can include a cylindrical portion 136 configured to receive the winding roll 124 of the resin support 26 therearound. In various examples, the resin support 26 can be operably coupled to a second spool 138 ( FIG. 6 ) (e.g., a cardboard spool, a polymer spool, a paper-based spool, a metal spool, a composite spool, an elastomeric spool, etc.). The second spool 138 can be disposed around the winding mandrel 24A.

[0064] The stopper 140 may be positioned between the cylindrical portion 136 and the second plate 122. Thus, the resin support 26 is wrapped around the winding mandrel 24A, with the stopper 140 defining a second distance d2 between the inner edge of the resin support 26 and the second plate 122. In some examples, the winding mandrel 24A may be configured to move between a disengaged position and an engaged position. During operation, the winding mandrel 24A may be positioned in a disengaged position to allow the second spool 138 to slide along the winding mandrel 24A until an end of the second spool 138 contacts or is proximate to the stopper 140. When the second spool 138 is positioned around the winding mandrel 24A, the winding mandrel 24A is positioned in an engaged position, allowing the second spool 138, and therefore the winding roll 124 of the resin support 26, to rotate with the winding mandrel 24A.

[0065] Similar to the supply module 22, a second actuating assembly 142 may be operatively coupled to the rear 130 of the take-up mandrel 24A and extend from the second plate 122. The second actuating assembly 142 may be configured as one or more motors, actuators, or any other device capable of rotating the take-up mandrel 24A. Additionally, as shown in FIG. 5, the second actuating assembly 142 may include a transmission 144 in the form of a belt system, a gear system, and / or any other viable system. Additionally, the supply actuation assembly 104 and the second actuation assembly 142 can be operatively coupled with feedback sensors and / or controls that can be provided to drive the mandrels 22A, 24A to maintain the resin support 26 tensioned between the mandrels 22A, 24A and to wind the resin support 26 from the supply mandrel 22A onto the take-up mandrel 24A.

[0066] 4 and 5, one or more rollers may be secured to the first side 128 of the second plate 122. For example, a set of three rollers 146A, 146B, 146C may be located on various portions of the second plate 122. In some examples, each roller 146A, 146B, 146C may have an axis of rotation 148 that is generally parallel to the axis 150 of the winding mandrel 24A.

[0067] The second plate 122 may further support a reclaiming system 50, which may be configured to remove at least a portion of the resin R remaining on the resin support 26 after the resin support 26 is removed from the build zone 32 (FIG. 1A). For example, the reclaiming system 50 may include a wiper assembly, a blade assembly, and / or any other removal assembly for collecting the resin R removed from the resin support 26.

[0068] 4 and 5 , in some embodiments, in addition to or instead of the first position sensor 118 upstream of the build stage 18 ( FIG. 1A ), the apparatus 10 ( FIG. 1A ) can include a second position sensor 152 downstream of the build stage 18. The second position sensor 152, and / or any other sensor, can be capable of monitoring the movement (e.g., linear distance) of the resin support 26 and can be located at any point within the take-up module 24 or at any other location downstream of the build stage 18. In various embodiments, the second position sensor 152 can be used for redundancy and verification of the drive system 28. Additionally or alternatively, the computing system 78 can compare the difference in movement between the first position sensor 118 and the second position sensor 152 to determine whether the drive system 28 is stretching / over-tensioning the resin support 26.

[0069] The winding module 24 may further include a take-up roll proximity sensor 154 that may be configured to detect the distance between the take-up roll 124 of the resin support 26. As the resin support 26 moves from the supply module 22 to the winding module 24, the distance between the take-up roll proximity sensor 154 and the take-up roll 124 of the resin support 26 decreases as the radius of the take-up roll 124 increases. This change in distance may be provided to the computing system 78 and may then be used to calculate the radius of the take-up roll 124.

[0070] 6 and 7, there is shown a schematic front view of an additive manufacturing apparatus 10 and a block diagram of a control system 156 for the additive manufacturing apparatus 10, according to embodiments of the present invention. In various embodiments, the apparatus 10 can include one or more print modules 158. Each print module 158 can include a support plate 14, a window 16, a stage 18, an actuation assembly 52, and / or a radiant energy device 20. As such, each print module 158 can be configured to build a common or different component 12 from any of the other print modules 158. For example, a first component 12 can have a first geometry and a second component 12 can have a second geometry, and the first geometry can be different from the second geometry.

[0071] 6, the resin support 26 may be maintained in a position such that the resin support 26 extends generally in an upstream / downstream direction through each print module 158 relative to movement of the resin support 26 in the X-axis direction. The print module 158 may be positioned between the window 16 and the stage. While in the illustrated embodiment, each print module 158 includes unique components (i.e., devices of any print module), it will be understood that in various embodiments, one or more components of the first print module 158a may be shared with one or more of the other print modules 158b-158n+1. For example, a common window 16 may be shared by two or more print modules 158.

[0072] 6 and 7, control system 156 is configured to control the synchronization of multiple print modules and various other assemblies of apparatus 10. Synchronization of multiple print modules 158 can result in improved repeatability of component builds and improved output of apparatus 10 due to the utilization of shared auxiliary processes across multiple print modules 158.

[0073] In some embodiments, control system 156 is configured to independently monitor each print module 158 and move resin support 26 based on a detected condition of one or more print modules 158. The conditions may include the start of a build process in a print module 158, the restart of a build process in a print module 158, the failure of a build process in a print module 158, the completion of a build process in a print module 158, and / or any other condition that one or more print modules 158 may independently experience during a build process.

[0074] Additionally, the control system 156 is also configured to independently disable any of the print modules 158 when a stalled operating condition is detected (e.g., when there is a fault within the respective print module 158, when the component 12 comprising the respective print module 158 is completed), while allowing the other print modules 158 to continue the build process. In some cases, the control system 156 can also enable print recovery if a fault is detected within one of the print modules 158. For example, the control system 156 can remember the defined layer being printed and can reprint the layer to correct the fault and / or resume at any point in the build process by restarting the build process at the defined layer within the respective print module 158 while continuing the progress of the other components 12 in the remaining print modules 158.

[0075] In various embodiments, the control system 156 can provide a resin-coated resin support 26 ( FIG. 1A ) to each of the print modules 158, which is used for current indexing of the resin support 26. As used herein, “index” refers to a predetermined travel distance of the resin support 26. For example, a first index of the resin support 26 can move the resin support 26 a first linear distance from the supply module 22 toward the take-up module 24, and a second index of the resin support 26 can subsequently move the resin support 26 a second linear distance from the supply module 22 toward the take-up module 24. The first linear distance can be approximately equal to, less than, or greater than the second linear distance based on conditions detected within each print module 158. As provided herein, the control system 156 can build one or more components 12 within each print module 158.

[0076] As shown, the control system 156 may include a computing system 78. The computing system 78 may include one or more computing devices 78A. The computing devices 78A may include one or more processors 78B and one or more memory devices 78C. The one or more processors 78B may be microprocessors, microcontrollers, integrated circuits, or other devices, particularly microprocessors. The memory device 78C may include any suitable processing device, such as 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 efficient image rendering), a processing unit that performs other specialized calculations, etc. The memory device 78C 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.

[0077] The memory device 78C may include one or more computer-readable media and may store information accessible by one or more processors 78B, including routines 78D that may be executed by the one or more processors 78B. The memory device 78C may store routines 78D for executing one or more software applications, operating the drive system 28, displaying a user interface, receiving user input, and processing user input. In some implementations, the routines 78D may be executed by one or more processors 78B to cause the one or more processors 78B to perform operations such as, for example, one or more portions of the methods described herein. The routines 78D may be software written in any suitable programming language or may be implemented in hardware. Additionally and / or alternatively, the routines 78D may execute in logically and / or virtually separate threads on the processors 78B.

[0078] The one or more memory devices 78C can also store data 78E that can be retrieved, manipulated, created, or stored by the one or more processors 78B. Data 78E can include, for example, data to facilitate execution of one or more routines, methods, procedures 200 (FIG. 9) and / or methods 300 (FIG. 10) described herein. In various embodiments, the one or more memory devices 78C can serve as a central repository for each of the print modules 158 that are executed simultaneously during a build process, thereby reducing the storage cost and complexity of part versioning across multiple systems.

[0079] The data 78E may be stored in one or more databases. The one or more databases may be connected to the computing system 78 by a high-bandwidth LAN or WAN, or may be connected to the computing system 78 over a network. One or more databases may be split into multiple locally located databases. In some implementations, the data 78E may be received from another device.

[0080] Computing device 78A may also include a communications module or interface 78F used to communicate with one or more other modules of computing device 78 or additive manufacturing equipment 10. Communications interface 78F may include any suitable module for interfacing with one or more networks, including, for example, a transmitter, receiver, port, controller, antenna, or other suitable module.

[0081] 6 and 7, user interface 160 may be operably coupled to computing system 78 via interface communication bus 198. User interface 160 may further be operably coupled to build controller 162 via switch communication bus 199, via build controller communication bus 197 and / or network switch 164. In some instances, build controller 162 may be implemented using a programmable logic controller responsible for controlling various aspects of the build. The build controller 162 may be configured as a controller. The build controller 162 may provide the user interface 160 and some storage. In various embodiments, the build controller 162 may communicate with each of the components described herein. Additionally, the build controller 162 may communicate with the radiant energy devices 20a-20n+1 (e.g., via embedded controllers) utilizing a build controller communication bus 197 and / or a network switch 164.

[0082] In some examples, user interface 160 may receive input related to the build process and / or provide information related to the build process to an operator. Additionally or alternatively, user interface 160 may enable an operator to interact with computing system 78, build controller 162, and / or radiant energy devices 20a-20n+1 to change one or more settings or operations of each print module 158.

[0083] In some examples, user interface 160 may include a display with a touchscreen. The display may be capable of displaying information related to apparatus 10, the build process, the field, and / or any other information. In some embodiments, user interface 160 may also include an input device in the form of circuitry within the touchscreen to receive input corresponding to locations on the display. Other forms of input devices include one or more joysticks, digital input pads, etc., which may be used in place of or in addition to the touchscreen.

[0084] 6 and 7, in various embodiments, the build controller 162 may be operably coupled to one or more control devices 166a-166n+1. As shown, each of the control devices 166a-166n+1 may be coupled in series, with the first control device 166a coupled to the build controller 162. However, it will be understood that any of the control devices 166a-166n+1 may be coupled in parallel, additionally, or alternatively to the build controller 162.

[0085] In some embodiments, the build controller 162 may be configured as a master device in the form of any one of a variety of computing devices that may include a processor and memory. Additionally, the build controller 162 may also include wireless communication and / or any wired communication protocol. For example, the control devices 166a-166n+1 are directly or indirectly connected via one or more communication lines 176, 178, 180, 182, 184 or input / output (I / O) ports included in each of the control devices 166a-166n+1. Each of the control devices 166a-166n+1 may include a power supply, a counter, a communication unit, an I / O unit, etc. The communication lines 176, 178, 180, 182 may assume various topologies, such as line, daisy chain, tree, and star, and / or any other topology. In various embodiments, each of the control devices 166a-166n+1 may be operably coupled to various assemblies of the apparatus 10 through one or more I / O ports. In some examples, each control device 166a-166n+1 includes a defined number of I / O ports, and a maximum input within each control device 166a-166n+1 can be defined.

[0086] In some cases, the build controller 162 and control devices 166a-166n+1 may be configured as an EtherCAT (Ethernet for Control Automation Technology) network that can be used to quickly update data and synchronize control between the devices. In such a case, the build controller 162 may use an Ethernet integration element as a communication module, and the multiple control devices 166a-166n+1 may communicate with each other via a single Ethernet network. An EtherCAT ASIC (Application Specific Integrated Circuit) can be used as a communication module. The build controller 162 and the control devices 166a-166n+1 can use a distributed clock function to synchronize the operations of the control devices 166a-166n+1. The distributed clock function is realized by a synchronization signal from the EtherCAT ASIC, which is a communication module mounted in each of the control devices 166a-166n+1.

[0087] In the illustrated embodiment, the first control device 166a may be operably connected to the build controller 162 via a first communication line 176. The first control device 166a includes a first operating bus 188, which may be in the form of an I / O bus within the first control device 166a, configured to couple the first control device 166a to a power actuation assembly 104 and drive the power feed mandrel 22A. In various embodiments, the feed actuation assembly 104 may include an actuation assembly, which may be in the form of one or more of a stepper motor, a servo motor, and / or any other type of rotary actuator. The feed actuation assembly 104 may also include a feed controller that may provide a generated control signal, such as a pulse-width modulated (PWM) signal or a current control signal, to the actuator to provide a predetermined amount of torque on the feed mandrel 22A. In turn, the feed roll 86 of the resin support 26 coupled to the feed mandrel 22A may also have an amount of torque applied thereto. The feed controller may include control circuitry, such as analog and / or digital control circuitry, having logic for processing various inputs and controlling the actuator, as described herein. The supply controller may further include any combination of software and / or processing circuitry suitable for controlling the actuators. It will be appreciated that the supply controller may be integrated into the actuation assembly, the computing system 78, or may be coupled to the actuators.

[0088] As shown, in some examples, the supply roll proximity sensor 120 may be operably coupled to the first control device 166a through the first operational bus 188. The supply roll proximity sensor 120 may be capable of detecting the distance between the supply roll proximity sensor 120 and the outer periphery of the supply roll 86. In various examples, the supply roll proximity sensor 120 may be an ultrasonic sensor, a radio detection and ranging (RADAR) sensor, a voice navigation and ranging (SONAR) sensor, a light detection and ranging (LIDAR) sensor, a vision-based sensor, and / or any other type of practicable sensor.

[0089] In some embodiments, the first position sensor 118 of the supply module 22 may be operably coupled to the first control device 166a through the first operational bus 188. Generally, the first position sensor 118 can measure and determine the length of linear motion of the resin support 26. The first position sensor 118 can transmit information in the form of a series of pulse trains (or pulse waves) corresponding to the measured motion to the build controller 162, and the build controller interprets the received pulse trains to determine the length of linear motion of the resin support 26. Additionally or alternatively, the first position sensor 118 has processing circuitry capable of determining the rotational speed of a contact portion of the first position sensor 118.

[0090] The tension sensor 110 may be located in the supply module 22 and operably coupled to the first control device 166a through the first operational bus 188. The tension sensor 110 may determine the tension in the resin support 26 between the supply roll 86 and the take-up roll 124. The tension sensor 110 may be a force transducer that converts the tension or torque provided by the resin support 26 on the tension sensor 110 into an electrical signal that can be measured by the computer system 78 to determine the tension in the resin support 26.

[0091] Additionally, the first print module 158a communicates with the first control device over the first operational bus 188. The first print module 158a may be operably coupled to a first build actuator assembly 52a that enables movement of the stage relative to the window 16. The first print module 158a also includes a first build sensor 168a that can detect movement of the stage such that the stage of the first print module 158a is positioned at a position defined by the first actuator assembly 52a.

[0092] 6 and 7, the second control device 166b may be operable to the first control device 166a through a second communication line 178. The second control device 166b includes a second operating bus 190, which may be in the form of an I / O bus within the second control device 166b, that couples the second control device 166b to the second print module 158b. Similar to the first print module 158a, the second print module 158b may include a second build actuation assembly 52b that enables movement of the stage relative to the window 16. The second print module 158b may also include a second build sensor 168b that may be capable of detecting movement of the stage so that the stage of the second print module 158b may be positioned at a position defined by the second actuation assembly 52b.

[0093] Similarly, third print module 158c may be operably coupled to second control device 166b through second operation bus 190. Third print module 158c may include a third build actuation assembly 52c that enables movement of the stage relative to window 16. Third print module 158c also includes a third build sensor 168c, which may detect movement of the stage such that the stage of third print module 158c is positioned at a position defined by third actuation assembly 52c.

[0094] Additionally, the viscosity change assembly 74 may also be operably coupled to the second control device 166b via the second operational bus 190. As provided herein, the viscosity change assembly 74 may be configured to apply shear stress to the resin R to change (e.g., decrease) the viscosity of the resin R. Additionally, or alternatively, the viscosity change assembly 74 may be configured to heat the resin R to change the viscosity of the resin R. It will be appreciated that each print module 158a-158n+1 may include a common or independent viscosity change assembly 74. Additionally, or alternatively, the viscosity change assembly 74 may include various independently operable sections, such that each print module 158a-158n+1 is associated with a respective independently operable section of the viscosity change assembly 74.

[0095] 6 and 7, the third control device 166c may be operable by the second control device 166b through a third communication line 180. The third control device 166c includes a third operating bus 192, even in the form of an I / O bus within the third control device 166c, coupling the third control device 166c to the fourth print module 158d. The fourth print module 158d may include a fourth build actuation assembly 52d that enables movement of the stage relative to the window 16. The fourth print module 158d also includes a fourth build sensor 168d that can detect movement of the stage such that the stage of the fourth print module 158d is positioned at a position defined by the fourth actuation assembly 52d.

[0096] Similarly, fifth print module 158e may be operably coupled to third control device 166c through third operation bus 192. Fifth print module 158e may include a fifth build actuation assembly 52 that enables movement of the stage relative to window 16. Fifth print module 158e also includes a fifth build sensor 168e that can detect movement of the stage of fifth print module 158e such that the stage is positioned at a position defined by fifth actuation assembly 52e.

[0097] Additionally, the material holding assembly 72 may be operatively coupled to the third control device 166c through a third operational bus 192. As provided herein, the material holding assembly 72 may be configured to hold the resin supports 26 in place along the support plate 14 of one or more print modules 158. It is understood that each print module 158a-158n+1 may include a common or independent material holding assembly 72. Additionally or alternatively, the material holding assembly 72 may include various independently operable sections, such that each print module 158a-158n+1 is associated with a respective independently operable section of the material holding assembly 72.

[0098] 6 and 7, the nth control device 166n may be operably connected to the third control device 166n by an nth communication line 182. The nth control device 166n includes an nth operation bus 194, which may be in the form of an I / O bus within the nth control device 166n, coupling the nth control device 166n and the nth print module 158n. The nth print module 158n may include an nth build actuation assembly 52 that enables movement of the stage relative to the window 16. The nth print module 158n also includes an nth build sensor 168n that may detect movement of the stage such that the stage of the nth print module 158n is positioned at a position defined by the nth actuation assembly 52n.

[0099] The pneumatic control system 170 may also be operably coupled to the nth control device 166n via the nth operational bus 194. The pneumatic control system 170 may be fluidly coupled to the material retention assembly 72 and / or any other module or assembly of the apparatus 10 via various hoses and one or more ports. The pneumatic control system 170 may include any device capable of vacuuming / sucking and / or pushing a fluid, such as air or a process gas (e.g., nitrogen or argon), to a module or assembly of the apparatus 10. For example, the pneumatic control system 170 may include a pressurized fluid source including a compressor and / or a blower. The pneumatic control system 170 may additionally or alternatively include any assembly capable of varying pressure, such as a Venturi vacuum pump. In some embodiments, one or more valves and / or switches may be coupled to the pneumatic control system 170. In such examples, the valves and / or switches may be operably coupled to the nth control device 166n and the build controller 162 and / or the computing system 78.

[0100] 6 and 7 , in addition to or instead of the first position sensor 118 upstream of one or more print modules 158, the apparatus 10 may include a second position sensor 152 downstream of one or more print modules 158. The second position sensor 152 may communicate with the nth control device 166n through an nth operational bus 194. The second position sensor 152, and / or any other sensor, can monitor the movement (e.g., linear distance) of the resin support 26 and can be located at any point within the take-up module 24 or at any other location downstream of one or more print modules 158. The second position sensor 152 can transmit information in the form of a series of pulse trains (or pulse waves) corresponding to the measured movement to the computing system 78, which interprets the received pulse trains to determine the length of linear movement of the resin support 26. Alternatively, the second position sensor 152 has processing circuitry capable of determining the rotational speed of the contact portion of the second position sensor 152.

[0101] The take-up module 24 may also include a take-up proximity sensor 154 operable with the nth control device 166n through an nth operating bus 194. The take-up roll proximity sensor 154 may detect the distance between the take-up roll proximity sensor 154 and the outer periphery of the take-up roll 124. For example, like the supply roll proximity sensor 120, the take-up roll proximity sensor 154 may be configured as an ultrasonic sensor, a radio detection and ranging (RADAR) sensor, a sound navigation and ranging (SONAR) sensor, a light detection and ranging (LIDAR) sensor, a vision-based sensor, and / or any other type of viable sensor.

[0102] In the illustrated embodiment, the nth control device 166n may be operable with a reel actuation assembly 142 configured to drive the reel mandrel 24A via the nth operating bus 194. In various embodiments, the reel actuation assembly 142 may include an actuator, which may be in the form of one or more of a stepper motor, a servo motor, and / or any other type of rotary actuator. The reel actuation assembly 142 may also include a reel controller, which may provide a generated control signal, such as a pulse-width modulated (PWM) signal or a current control signal, to the actuator to provide a predetermined amount of torque on the reel mandrel 24A. The reel roll 86 of the resin support 26, coupled to the reel mandrel 24A, may then have the amount of torque applied to it. The reel controller may include control circuitry, such as analog and / or digital control circuitry, having logic for processing various inputs and controlling the actuator, as described herein. The reel controller may further include any combination of software and / or processing circuitry suitable for controlling the actuator. It will be understood that the reel controller may be integrated with the actuation assembly, the build controller 162, the computing system 78, or may be coupled to the actuator.

[0103] 6 and 7, the n+1th control device 166n+1 is operable to the n+1th control device 166n+1 via the n+1th communication line 184. The n+1th control device 166n+1 includes an n+1th operation bus 196, which may take the form of an I / O bus within the n+1th control device 166n+1 coupling the I / O bus within the n+1th control device 166n+1 to the n+1th print module 158n+1. The n+1th print module 158n+1 may include an n+1th build actuation assembly 52n+1 that enables movement of the stage relative to the window 16. The n+1st print module 158n+1 also includes an n+1th build sensor 168n+1, which may detect movement of the stage such that the stage of the n+1th print module 158n+1 is positioned at a position defined by the n+1th actuation assembly 52n+1.

[0104] The resin mixing assembly 172 is operable with the (n+1)th control device 166n+1 through the (n+1)th operational bus 196. For example, the resin mixing assembly 172 may be configured to agitate the resin before it is deposited onto the resin support 26. In some cases, the deposition assembly 34 may receive the resin from the resin mixing assembly 172. The deposition assembly 34 may also be operable with the (n+1)th control device 166n+1. The resin deposition assembly 34 may be any device or combination of devices operable to apply the resin R onto the resin support 26.

[0105] The thickness sensor 174 may also operate with the (n+1)th control device 166n+1 via the (n+1)th operational bus 196. The thickness sensor 174 is configured to determine the thickness of the resin deposited on the resin support 26. The thickness sensor 174 may be embodied as one or more confocal, imaging sensors, or any other vision-based device. The thickness sensor 174 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.

[0106] In some embodiments, the landfill system 50 may be operable with the n+1 control device 166n+1 through the n+1 operating bus 196. , may be configured to remove at least a portion of the resin R remaining on the foil resin support 26 after the foil resin support 26 is removed from the build zone 32.

[0107] It will be understood that any of the modules, assemblies, etc. described herein can operate with any of the control devices 166 (e.g., the first control device 166a, the second control device 166b, the third control device 166c, the nth control device 166n, the n+1th control device 166n+1) without departing from the teachings of the present disclosure. Furthermore, each of the modules, assemblies, etc. described herein can be independently coupled with any control device 166, with the build controller 162, and / or with the computing system 78 without departing from the scope of the present disclosure.

[0108] 6 and 7, in various embodiments, one or more radiant energy devices 20a-20n+1 may be coupled in parallel to computing system 78 via energy device communication bus 186. Each of radiant energy devices 20a-20n+1 may be configured to generate a radiant energy patterned image of suitable energy levels and other operating characteristics to cure resin R. It will be understood that the patterned images emitted from each of one or more radiant energy devices 20a-20n+1 may be different from one another, similar to one another, common to at least one of the remaining one or more radiant energy devices 20a-20n+1, and / or different from at least one of the remaining one or more radiant energy devices 20a-20n+1.

[0109] In some examples, a network switch 164 may operably couple the energy device communication bus 186 to the user interface 160. The network switch 164 may enable various inputs for controlling or modifying the performance of one or more of the radiant energy devices 20a-20n+1 via the user interface 160. Additionally, a network attached storage device (NAS) 187 may be operably coupled to the energy device communication bus 186. The NAS device 187 includes a NAS controller and one or more storage devices. The NAS device 187 is configured to communicate with a network, local devices such as the computing system 78, and peripheral devices such as the radiant energy devices 20a-20n+1.

[0110] The NAS controller may include a network interface for enabling connection to and transfer of data from a network, and a local device interface for enabling transfer of data to and from a computing system 78. The storage device interface is configured to communicate with a storage device to obtain status information for the storage device and to facilitate data transfer between the storage device and the network and / or computing system 78. The local peripheral interface enables transfer of data to and from the network and / or computing system 78 to one or more radiant energy devices 20a-20n+1. The NAS processor oversees the overall operation of the NAS controller and coordinates functions among the various modules of the NAS controller described above. Memory is provided for storing programs for enabling the NAS processor to perform its functions.

[0111] Referring now to Figure 8, there is shown a block diagram of a control system 156 for an additive manufacturing apparatus 10 in accordance with an exemplary embodiment of the present invention. It will be understood that each of the components shown in Figure 8 may operate as described herein (e.g., as described with reference to Figures 6 and 7).

[0112] With further reference to FIG. 8, in some embodiments, a portion of the device 10 includes a communication line 17 6. For example, as shown, the build controller 162 may be operably coupled to the feed actuation assembly 104. The feed actuation assembly 104 may include a feed controller that can provide a generated control signal, such as a pulse-width modulated (PWM) signal or a current control signal, to an actuator to provide a predetermined amount of torque to the feed mandrel 22A. The feed controller may include control circuitry, such as analog and / or digital control circuitry, having logic for processing various inputs and controlling the actuator, as described herein. The feed controller may further include any combination of software and / or processing circuitry suitable for controlling the actuator. Additionally, the feed actuation assembly 104 may include a first operating bus 188, which may be a form of I / O bus, that couples the feed actuation assembly 104 to one or more additional components of the apparatus 10. For example, the first operating bus 188 may be operably coupled to the feed roll proximity sensor 120, the first position sensor 118, the tension sensor 110, and / or the first print module 158a.

[0113] In the example shown in FIG. 8 , the viscosity change assembly 74 may be operably coupled to the supply actuation assembly 104 via a communication line 178. The communication line 178 may be operably coupled to a first operating bus 188 and / or any other I / O port of the supply actuation assembly 104. In some examples, the viscosity change assembly 74 may include a controller having control circuitry, such as analog and / or digital control circuitry, having logic for processing various inputs and controlling the viscosity change assembly 74, as described herein. The controller may further include any combination of software and / or processing circuitry suitable for controlling the viscosity change assembly 74. Additionally, the viscosity change assembly 74 may include a second operating bus 190, which may be a form of an I / O bus, that couples the viscosity change assembly 74 to one or more additional components of the apparatus 10. For example, the second operating bus 190 may be operably coupled to the second print module 158b and / or the third print module 158c.

[0114] In the example shown in FIG. 8 , the material retention assembly 72 may be operably coupled to the viscosity change assembly 74 via a communication line 180. The communication line 180 may be operably coupled to a second operating bus 190 and / or any other I / O port of the viscosity change assembly 74. In some examples, the material retention assembly 72 may include a controller having control circuitry, such as analog and / or digital control circuitry, having logic for processing various inputs and controlling the material retention assembly 72, as described herein. The controller may further include any combination of software and / or processing circuitry suitable for controlling the material retention assembly 72. Additionally, the material retention assembly 72 may include a third operating bus 192, which may be a form of I / O bus, coupling the material retention assembly 72 to one or more additional components of the apparatus 10. For example, the third operating bus 192 may be operably coupled to the fourth print module 158d and / or the fifth print module 158e.

[0115] Further, in the example shown in FIG. 8 , the take-up actuation assembly 142 may be operably coupled to the material holding assembly 72 via a communication line 182. The communication line 182 may be operably coupled to a third operational bus 192 and / or any other I / O port of the material holding assembly 72. In some examples, the take-up actuation assembly 142 may include a controller having control circuitry, such as analog and / or digital control circuitry, having logic for processing various inputs and controlling the take-up actuation assembly 142, as described herein. The controller may further include any combination of software and / or processing circuitry suitable for controlling the take-up actuation assembly 142. Further, the take-up actuation assembly 142 may include a fourth operational bus 194, which may be a form of I / O bus, coupling the take-up actuation assembly 142 to one or more additional components of the apparatus 10. For example, , the fourth operational bus 194 is operable with the nth print module 158 n , the air control system 170 , the second position sensor 152 , and / or the take-up proximity sensor 154 .

[0116] Further, in the example shown in FIG. 8 , the deposition assembly 34 may be operably coupled to the take-up actuation assembly 142 via a communication line 184. The communication line 184 may be operably coupled to a fourth operation bus 194 and / or any other I / O ports of the take-up actuation assembly 142. In some examples, the deposition assembly 34 may include a controller having control circuitry, such as analog and / or digital control circuitry, having logic for processing various inputs and controlling the deposition assembly 34, as described herein. The controller may further include any combination of software and / or processing circuitry suitable for controlling the deposition assembly 34. Further, the deposition assembly 34 may include an n+1 operation bus 196, which may be in the form of an I / O bus, that couples the deposition assembly 34 to one or more additional portions of the apparatus 10. For example, the n+1 operation bus 196 may be operably coupled to the n+1 print module 158n+1, the mixing assembly 172, the thickness sensor 174, and / or the regeneration system 50.

[0117] It will be understood that any first portion described herein may include a controller operably coupled to build controller 162. Furthermore, any additional components may be coupled in parallel and / or series with the first portion without departing from the scope of the present disclosure. Thus, the illustrated topology is an exemplary control system 156 of apparatus 10 and is not intended to be limiting in any way. Additionally, any portion may be positioned within any branch of the topology without departing from the scope of the present disclosure. As used herein, a portion of an apparatus may include any assembly, module, sensor, actuator, or other element within apparatus 10.

[0118] Having described the configuration and structure of additive manufacturing equipment according to various embodiments of the present invention, FIG. 9 illustrates a procedure 200 for operating an additive manufacturing equipment, and FIG. 10 illustrates a method 300 for a build process for an additive manufacturing equipment. The procedure 200 and / or method 300 may be used to operate an additive manufacturing equipment having any of the features described with respect to FIGS. 1A-8. It should be understood that the exemplary procedure 200 and / or exemplary method 300 are discussed herein only to illustrate exemplary aspects of the present subject matter and are not intended to be limiting. Furthermore, the steps illustrated in the exemplary procedure 200 and / or exemplary method 300 may be performed in any order without departing from the scope of the present disclosure.

[0119] 9, during operation, various portions of the build product may be completed remotely and / or within the equipment, while other portions of the build procedure may be completed by the equipment. For example, procedure 200 may include a remote process 202 having one or more steps that may be completed by equipment remote from the additive manufacturing equipment and / or an online process 210 having one or more steps that may be completed by components of the additive manufacturing equipment.

[0120] In the illustrated example, process 202 of defining one or more components to be built in one or more print modules can be completed remotely. For example, a three-dimensional design model of the part may be defined prior to manufacturing in step 204. In this regard, a mock-up or prototype of the part can be scanned to determine three-dimensional information about the part. As another example, a model of the component can be built using a suitable computer-aided design (CAD) to define the three-dimensional design model of the component. The design model can include 3D numerical coordinates of the component's configuration, including both the exterior and interior surfaces of the component. For example, the design model can define the body, surfaces, and / or internal passages, such as openings, support structures, etc. In some exemplary embodiments, the three-dimensional design model is defined in step 206, e.g., by defining the center (e.g., vertical axis) of the component. ) axis or any other suitable axis. Each slice can define a thin cross-section of the component relative to the height of the slice. At 208, the multiple consecutive cross-sectional slices are stored as images that together form the 3D component.

[0121] The online process 210 may include defining parameters for the build process. For example, in step 212, the parameters for the build process may be defined. In step 214, the parameters may be entered into the computing system via a user interface. In step 216, the computing system may also receive images of the components. Based on the parameters and the entered parameters, in step 218, a build file for each component to be built may be created and stored within the device and / or any other location accessible by the device's control device. In some cases, in step 220, a build parameter check may be performed to verify whether the parameter set for each build module is compatible with the device.

[0122] Once the file is saved, the print process can be initiated in step 222. In such case, parameters associated with one or more devices operatively coupled to the build controller are directed to the build controller in step 224. From the build controller, shared parameters of the print configuration (e.g., resin support speed, slurry thickness, etc.) can be directed to shared components of the equipment. Additionally, different print configurations can be sent to each print module. In step 226, parameters associated with the radiant energy source, such as the image to be emitted by each of the radiant energy devices, can be directed to the NAS device. Once each system has received the appropriate information, the build process is executed in step 228.

[0123] In various embodiments, the computing system is configured to provide instructions to each of the components in the apparatus to build one or more predetermined components during a build process. For example, the computing system may provide instructions to at least one of the first actuation assembly or the second actuation assembly of the drive system. For example, in some examples, the first actuation assembly can receive instructions to control the supply mandrel to achieve a target tension on the resin support, and the second actuation assembly can receive instructions to control at least one of the speed, distance, or acceleration of movement of the resin support from the supply module to the take-up module. In various embodiments, the first actuation assembly and the second actuation assembly can operate independently of each other. The drive system can receive multiple inputs from one or more supply module sensors, such as a first position sensor, a tension sensor, a supply roll proximity sensor, or any other sensor in the apparatus. Additionally or alternatively, the multiple inputs can be provided by one or more take-up module sensors, such as a second position sensor, a take-up roll proximity sensor, or any other sensor in the apparatus.

[0124] The target length may be a user-input value and / or may be generated by the computing system and received by the computing system. The target distance may be based on various factors such as the dimensions of the component being formed, the dimensions of each stage, the number of print modules in the apparatus, the number of print modules used in the printing process, the number of radiant energy devices in the apparatus, the number of radiant energy devices used in the printing process, the size of each window in each print module of the apparatus, the size of each window in each print module used in the printing process, the size of the layer of the component being formed in each print module, the thickness of the layer of the component just formed, the distance between each print module of the apparatus, the distance between each print module used in the printing process, etc. The target length of linear motion is determined for each successive layer of the component during the build process. The torque command may be the same and / or may vary, and when the control system, the first controller, and / or the second controller operate the first and second actuating assemblies to move the resin support a target distance (or within a target distance range) at a target tension (or within a target tension range), one or more suitable timing algorithms are used to intermittently and / or constantly update the torque command via the control loop.

[0125] While the resin support is being moved, the deposition assembly can receive resin from the resin mixing assembly, which is then deposited onto the resin support. The resin is then transferred to one or more print modules.

[0126] Once the resin is placed in one or more print modules, a stage of each print module used for a defined layer can be moved toward the resin. Once the stage is in a defined position, as determined by a build sensor in each print module, a corresponding radiant energy device in the print module can emit a defined image to at least partially cure a portion of the resin, thereby forming a new layer of the component. As each image is emitted from the respective radiant energy device, the corresponding stage is moved further away from the resin support, and the resin support is moved to deliver an additional portion of resin to each defined print module.

[0127] In various embodiments, the distance traveled by the resin support can vary from one layer to the next. For example, the control system can determine that a fault has occurred within one of the print modules. If the control system determines that a fault has occurred within one of the print modules, the print module can pause the build process for that component, while the remaining components in the other print modules can continue to build. Similarly, if the control system determines that one of the components has finished building but the other components have not, the print module can stop actuating the stage for that component, while the remaining components in the other print modules continue to build. Similarly, the control system can determine that a print module is not being used in the build process. Based on operational variations between the various print modules, the control system can vary the length of travel of the resin support for each layer of component 12.

[0128] Referring now to FIG. 10 , a method 300, or build process, includes initiating a build in step 302. The build process may be initiated via a user interface operably coupled to the computing system of the device and / or via any other method. As provided herein, in step 304, various parameters are input to the device to define a build of one or more components. In such cases, the parameters are associated with one or more devices operably coupled to the build controller. From the build controller, shared parameters of the print configuration (e.g., resin support speed, slurry thickness, etc.) can be directed to the shared components of the device. Additionally, different print configurations can be sent to each print module. Parameters related to the radiant energy source, such as the image to be emitted by each of the radiant energy devices, can be directed to the NAS device.

[0129] Next, in step 306, the build controller performs preprint system checks to ensure that each subsystem of the utilized device is ready to begin the build. If any of the subsystems fails the checks, a notification is generated in step 308 and method 300 can resume at step 302. In some cases, the notification is provided on a user interface.

[0130] If each of the subsystems passes the check at 306, the method 300 includes initializing communication between the build controller and each of the radiant energy devices at step 310. Once communication is established at 310, the method 300 may include setting the deposition assembly to an initial height at step 312. The initial height may be a pre-calibrated height and / or a defined thickness of a first layer of one or more components to be built.

[0131] Next, in step 314, the method 300 may include transferring resin from the mixing assembly or another supply source to a reservoir of the deposition assembly. In some cases, the deposition reservoir may continue to receive resin until a predetermined volume is detected.

[0132] In step 316, the method 300 may include initiating a resin support calibration move in which the resin support is moved from the supply module to the take-up module. During the resin support calibration move, the linear motion of the resin support may be calibrated based on data provided by the first position sensor and / or the second position sensor. Additionally or alternatively, the height of the resin thickness deposition assembly may be calibrated based on the resin thickness measured by the thickness sensor.

[0133] In step 318, method 300 may include determining whether to complete the resin flush. The determination may be made based on a detected variation in resin thickness exceeding a predetermined range of resin thickness, as detected by the thickness sensor during step 316. The thickness variation may be caused by particulates and / or foreign matter present in the reservoir of the deposition assembly. If a variation in resin thickness is determined, method 300 may include flushing the resin in step 320. To flush the resin, a device or combination of devices that defines the height of the resin on the resin support may be moved to an elevated height while the resin support is moved.

[0134] If it is determined in step 318 that a resin flash is not required and / or after a resin flash in step 320, method 300 may include performing a deposition assembly height adjustment. The height adjustment may be based on data provided by the thickness sensor during step 310, such that a requested resin casting thickness in the print parameters may be provided to one or more downstream print modules.

[0135] In step 324, method 300 can include refilling the reservoir of the deposition assembly. In some cases, the deposition reservoir can continue to receive resin until a predetermined volume is detected. In various examples, a volume sensor can be disposed within the deposition assembly configured to alert a user that the predetermined volume has been achieved, and / or the sensor can be operably coupled to a control valve that stops the transfer of resin from the container to the reservoir after the predetermined volume has been achieved.

[0136] In step 326, method 300 includes performing a resin support recoat. The resin support recoat can provide a resin-coated resin support to each of the print modules used during the current index of the resin support. As provided herein, the system can build one or more components into each print module in the apparatus. Alternatively, for various reasons, fewer than all print modules may be used for a particular index of the resin support. If various print modules are not being used for a particular index, the resin support recoat area can be reduced relative to the resin support recoat area when each print module is being used.

[0137] Once the resin support has been moved to place the resin within the one or more print modules, the method 300 may include actuating a material retention assembly to hold the resin support in place within the one or more print modules in step 328. In various embodiments, the material retention assembly may include a pneumatic assembly, a clamp, a combination thereof, and / or any other retention device.

[0138] In step 330, method 300 can include loading layer images into each of the radiant energy devices to be used during a particular indexing of the resin support. In step 332, method 300 can include moving each stage of the print module used for the first indexing to a layer-specific print position. As discussed herein, each print module can be configured to build common or different components from any of the other print modules. Based on potential variations in layer count and / or component design, each of the stages can be moved to common and / or different heights from any of the other stages in the machine.

[0139] Once each stage is moved to a layer-specific print position, in step 334, method 300 can include instructing each of the energy sources to write or flash a layer image of a cross section of the part onto the surface of the resin. The exposure to radiation cures and solidifies the pattern in the resin, bonding it to a previously cured layer of the component. In some examples, method 300 can include emitting a first image from a first radiant energy device onto a first portion of the resin disposed between the first radiant energy device and the first stage, and a second image from a second radiant energy device onto a second portion of the resin disposed between the second radiant energy device and the second first stage.

[0140] In step 336, method 300 can include moving each stage of the print module used for the first indexing to a separate position. As discussed herein, each print module can be configured to build common or different components from any of the other print modules. Based on potential variations in layer count and / or component design, each of the stages can be moved to a common and / or different height from any of the other stages in the apparatus.

[0141] In step 338, the method 300 may include deactivating the material retention assembly to release the resin support in one or more print modules.

[0142] In step 340, method 300 may include determining whether additional layers should be formed for any of the one or more components in the apparatus. If any additional layers are to be formed, method 300 may proceed to step 342. In step 342, the control system may determine whether the resin support should be moved for the second index and / or whether a new resin thickness is required for the second index. If the resin support should be moved for the second index and / or if a new resin thickness is required for the second index, method 300 may return to step 318. If the control system determines that the resin support should not be moved for the second index and / or a new resin thickness is not required for the second index, method 300 may include performing a resin support index movement in step 344, such that the resin support moves a short index distance to position a new resin-coated resin support section in each print module for the next layer build.

[0143] Steps 328-344 continue the build process layer by layer until a resin flash is achieved. If a subsequent resin flush is to be performed, method 300 may return to step 318. When the next resin flush is performed in step 320, thickness sensor data, first position sensor data, and / or second position data are recorded for calibration of the deposition assembly height and resin support linear travel distance for the next index.

[0144] If, in step 340, the control system determines that the system has reached the last layer of the build process, method 300 can proceed to step 346. In step 346, method 300 can include draining any remaining resin from a reservoir of the deposition assembly. In such a case, a valve in the deposition assembly can be closed to prevent additional resin from being transferred to the reservoir. Additionally, a device or combination of devices that defines the height of the resin above the resin support can be moved to an elevated height while moving the resin support to drain any resin remaining in the reservoir.

[0145] In step 348, as each build process in the print module is completed, the respective stage may be raised to a preset removal position for component removal. Once each stage is raised, method 300 may end in step 350. In some examples, a notification may be provided by a control system, such as a user interface, indicating that the process is complete and each component is ready to be removed from the apparatus.

[0146] It should be understood that the additive manufacturing equipment described herein is intended to illustrate aspects of the present subject matter only. In other exemplary embodiments, the additive manufacturing equipment may have any other suitable configuration, and any other suitable additive manufacturing techniques may be used. Furthermore, the additive manufacturing equipment and processes or methods described herein may be used to form components using any suitable material. For example, the material may be plastic, metal, concrete, ceramic, polymer, epoxy, photopolymer resin, or any other suitable material that may be embodied in a layer of sheet material in any other suitable form, such as a slurry, resin, or sheet material 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 may be made of part, all, or several of a material, including, but not limited to, pure metal, nickel alloy, chromium alloy, titanium, titanium alloy, magnesium, magnesium alloy, aluminum, aluminum alloy, iron, iron alloy, stainless steel, and nickel- or cobalt-based superalloy (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 generally be referred to as "additive materials."

[0147] Aspects of the present disclosure are provided by the subject matter of the following sections, which are intended to cover all appropriate combinations unless otherwise indicated based on the logic or context of the sections and / or associated figures and descriptions:

[0148] a first print module including a first stage configured to hold a first radiant energy device and a first component; a second print module including a second stage configured to hold a second radiant energy device and a second component, the first print module and the second print module configured to receive at least a portion of a resin support between the first stage and the first radiant energy device and between the second stage and the second radiant energy device; Based on the states of the first print module and the second print module, a control system configured to move the resin support by the first print module and the second print module; Additive manufacturing equipment, including:

[0149] the first print module further includes a first actuator and a first build sensor; the second print module further including a second actuator and a second build sensor; the aforementioned additive manufacturing equipment.

[0150] the first component has a first geometric shape; the second component has a second geometric shape; the first geometric shape is different from the second geometric shape; the aforementioned additive manufacturing equipment.

[0151] the control system includes a build controller operably coupled to a computing system; the build controller is further coupled to one or more control devices. the aforementioned additive manufacturing equipment.

[0152] the one or more control devices include a first control device and a second control device; the first control device includes a first communication line operably coupled to the build controller and a first operational bus operably coupled to the first print module; the second control device includes a second communication line operably coupled to the first control device and a second operating bus operably coupled to the second print module; the aforementioned additive manufacturing equipment.

[0153] The aforementioned additive manufacturing device, wherein the build controller is operably coupled to a user interface.

[0154] The aforementioned additive manufacturing equipment, wherein the control system further includes an energy device communication bus operably coupling one or more radiant energy devices to the computing system.

[0155] The aforementioned additive manufacturing equipment, wherein a network attached storage device is operably coupled to the energy device communication bus and configured to store data relating to one or more images emitted by the first radiant energy device or the second energy device.

[0156] the control system is configured to receive defined parameters of a build process and an image for each layer of the first component and the second component; the parameters are directed to the build controller and the images are provided to the network attached storage device; the aforementioned additive manufacturing equipment.

[0157] Provides build process parameters to the control system, applying resin to the resin support and performing a first indexing of the resin support by moving the resin support a first linear distance to the first print module and the second print module; moving a first stage in the first print module to a first stage position based on the provided parameters for forming a first layer of a first component; moving a second stage in the second print module to a second stage position based on the provided parameters for forming a first layer of a second component; emitting a first image from a first radiant energy device onto a first portion of resin disposed between a first radiant energy device and the first stage; emitting a second image from the second radiant energy device onto a second portion of the resin disposed between the second radiant energy device and the second first stage; How additive manufacturing equipment works.

[0158] The aforementioned method of operating further comprising calibrating a resin deposition assembly and a drive system before moving the resin support to the first print module and the second print module.

[0159] determining a thickness of the resin on the resin support; flushing the resin from the deposition assembly when the thickness variation exceeds a predetermined range; The aforementioned way of working.

[0160] The aforementioned method of operating wherein the first stage position is offset in the Z axis direction from the second stage position.

[0161] performing a second indexing of the resin support, and moving the resin support a second linear distance different from the first linear distance when a fault is detected in the first print module or the second print module; The aforementioned way of working.

[0162] performing a second indexing of the resin support, and moving the resin support a second linear distance different from the first linear distance when at least one of the first component or the second component is completed and the other of the first component or the second component is building; The aforementioned way of working.

[0163] each of the first stage and the second stage is moved to a separation position prior to performing a second indexing of the resin support to move the resin support a second linear distance; The aforementioned way of working.

[0164] a first print module including a first stage configured to hold a first component and a first radiant energy device; a second print module including a second stage and a second radiant energy device configured to hold a second component, with a resin support configured to be disposed between the first stage and the first radiant energy device and between the second stage and the second radiant energy device; a control system configured to move the resin support based on a state of the first print module and the second print module; Including, The control system includes: a build controller operably coupled to the computing system and the one or more control devices; a user interface operatively coupled to the build controller and the computing system, the user interface configured to receive one or more parameters; an energy device communication bus operably coupled to the computing system in parallel with the build controller; Additive manufacturing equipment, including:

[0165] The aforementioned additive manufacturing equipment, wherein the one or more control devices include a first control device coupled to the build controller and a second control device coupled to the first control device.

[0166] the one or more control devices include a first control device and a second control device; the first control device includes a first communication line operably coupled to the build controller and a first operational bus operably coupled to the first print module; the second control device includes a second communication line operably coupled to the first control device and a second operating bus operably coupled to the second print module; the aforementioned additive manufacturing equipment, including

[0167] the first print module and the second print module are coupled in series with the build controller; the first radiant energy device and the second energy device are coupled in series with the computer system; the aforementioned additive manufacturing equipment.

[0168] This description uses examples to disclose the concepts presented herein, including the best mode, and also enables any person skilled in the art to practice the disclosure, including making and using any device or system, and performing any incorporated methods. The patentable scope of the disclosure 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 include elements that do not differ from the literal language of the claims, or if they include equivalent elements that do not substantially differ from the literal language of the claims.

[0169] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 239,530, filed September 1, 2021, the contents of which are incorporated herein by reference in their entirety. [Explanation of symbols]

[0170] 10 Additive Manufacturing Equipment 12a First Component 12b Second Component 20a First radiant energy device 20b Second radiant energy device 26 Resin support 156 Control System 158a First Print Module 158b Second Print Module

Claims

1. a first print module (158a) including a first stage (18) configured to hold a first component (12) and a first radiant energy device (20); a second print module (158b) including a second stage (18) configured to hold a second component (12) and a second radiant energy device (20), wherein a resin support (26) is configured to be located between the first stage (18) and the first radiant energy device (20) and between the second stage (18) and the second radiant energy device (20); a control system (156) configured to move the resin support (26) based on the status of the first print module (158a) and the second print module (158b); Including, The control system (156) a build controller (162) operably coupled to the computing system (78) and at least one control device (166); a user interface (160) operably coupled to the build controller (162) and the computing system (78) and configured to receive at least one parameter; an energy device communication bus (186) operably coupled to the computing system (78) in parallel with the build controller (162); Including, providing the control system (156) with build process parameters; Setting the deposition assembly (34) to an initial height; Recoating the resin support (26) performing a first indexing of the resin support (26) to which resin has been applied, such that the first print module (158a) and the second print module (158b) move the resin support (26) a first linear distance; Additive manufacturing equipment.

2. The at least one control device (166) includes a first control device (166a) coupled to the build controller (162) and a second control device (166b) coupled to the first control device (166a).

10. The additive manufacturing device of claim 1.

3. The at least one control device (166) includes a first control device (166a) and a second control device (166b); the first control device (166a) includes a first communication line (176) operably coupled to the build controller (162) and a first operating bus (188) operably coupled to the first print module (158a); the second control device (166b) includes a second communication line (176) operably coupled to the first control device (166a) and a second operating bus (190) operably coupled to the second print module (158b); 3. The additive manufacturing device of claim 2.

4. The first print module 158a and the second print module 158b are connected in series with the build controller 162, the first radiant energy device (20) and the second radiant energy device (20) are coupled in series with the computing system (78); 4. The additive manufacturing device of claim 3.

5. An additive manufacturing device (10) comprising: a first print module (158a) including a first stage (18) configured to hold a first additive manufacturing component (12) and a first radiant energy device (20); a second print module (158b) including a second stage (18) and a second radiant energy device (20) configured to hold a second additive manufacturing component (12), the first print module (158a) and the second print module (158b) configured to receive at least a portion of a resin support (26) between the first stage (18) and the first radiant energy device (20) and between the second stage (18) and the second radiant energy device (20); a shared component (12) of the additive manufacturing device (10) operably coupled to the first print module (158a) and the second print module (158b); a control system (156) configured to control the first print module (158a), the second print module (158b), and the shared component (12) based on at least one parameter defining a build of the first additive manufacturing component (12) and the second additive manufacturing component (12); Including, the first additively manufactured component (12) has a first geometric shape; the second additively manufactured component (12) has a second geometric shape; the first geometric shape and the second geometric shape are different; Additive manufacturing equipment.

6. the at least one parameter includes a shared parameter related to at least one of a resin support rate and a slurry thickness directed to a shared component (12) of the additive manufacturing equipment (10); 6. The additive manufacturing device of claim 5.

7. the at least one parameter includes a first parameter associated with a first print configuration of the first print module (158a); 6. The additive manufacturing device of claim 5.

8. the at least one parameter includes a second parameter associated with a second print configuration of the second print module (158b); the second parameter is different from the first parameter; 8. The additive manufacturing device of claim 7.

9. The control system (156) is further configured to initiate a pre-print system check to ensure that each subsystem of the additive manufacturing equipment (10) utilized is ready to start a build.

6. The additive manufacturing device of claim 5.

10. the control system (156) includes a build controller (162) operably coupled to a computing system (78); The build controller (162) is further coupled to at least one control device (166).

10. Additive manufacturing equipment according to claim 9.

11. The control system (156) is further configured to flush resin from the deposition assembly (34).

6. The additive manufacturing device of claim 5.

12. The control system (156) is further configured to set an initial pile height; the initial deposition height is based at least in part on a defined thickness of a first layer of the first additively manufactured component (12) or the second additively manufactured component (12); 12. Additive manufacturing equipment according to claim 11.

13. The control system (156) is further configured to operate a material holding assembly (72) to hold the resin support (26) in a predetermined position in at least one of the first printing module (158a) and the second printing module (158b).

12. Additive manufacturing equipment according to claim 11.

14. providing the control system (156) with parameters for the build process; Setting the deposition assembly (34) to an initial height; Carry out a recoat of the resin support (26), performing a first indexing of the resin support (26) to which resin has been applied, such that the resin support (26) is moved a first linear distance to a first print module (158a) and a second print module (158b); How additive manufacturing equipment works.

15. moving a first stage (18) of the first print module (158a) to a first stage (18) position based on the parameters to form a first layer of a first additively manufactured component (12); moving a second stage (18) of the second print module (158b) to a second stage (18) position based on the parameters to form a first layer of a second additively manufactured component (12); 15. A method of operating an additive manufacturing device according to claim 14.

16. emitting a first image from the first radiant energy device (20) onto a first portion of the resin located between the first radiant energy device (20) and a first stage (18); irradiating a second image from the second radiant energy device (20) onto a second portion of the resin located between the second radiant energy device (20) and a second stage (18); 15. A method of operating an additive manufacturing device according to claim 14.

17. calibrating a resin deposition assembly (34) and a drive system before transferring the resin support (26) to the first print module (158a) and the second print module (158b); further comprising:

15. A method of operating an additive manufacturing device according to claim 14.

18. performing a second indexing of the resin support (26) to move the resin support (26) a second linear distance different from the first linear distance when a failure is detected in the first print module (158a) or the second print module (158b); 15. A method of operating an additive manufacturing device according to claim 14.

19. moving the first stage (18) and the second stage (18) to a spaced apart position before performing a second indexing of the resin support (26) to move the resin support (26) a second linear distance; 15. A method of operating an additive manufacturing device according to claim 14.

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