Patent Description:
Additive manufacturing is a process in which material is built up layer-by-layer to form a component. Stereolithography is a type of additive manufacturing process which employs a tank of liquid radiant-energy curable photopolymer "resin" and a curing energy source such as a laser. Similarly, DLP 3D printing employs a two-dimensional image projector to build components one layer at a time. For each layer, the projector flashes a radiation image of the cross-section of the component on the surface of the liquid or through a transparent object which defines a constrained surface of the resin. Exposure to the radiation cures and solidifies the pattern in the resin and joins it to a previously-cured layer. Other types of additive manufacturing processes utilize other types of radiant energy sources to solidify patterns in resin.

Another prior art method is a so-called "tape casting" process. In this process, a resin is deposited onto a flexible radiotransparent tape that is fed out from a supply reel. An upper plate lowers on to the resin, compressing it between the tape and the upper plate and defining a layer thickness. Radiant energy is used to cure the resin through the radiotransparent tape. Once the curing of the first layer is complete, the upper plate is retracted upwards, taking the cured material with it. The tape is then advanced to expose a fresh clean section, ready for additional resin.

Document <CIT> discloses an apparatus for additive manufacturing according to the related art comprising a resin support defining a build surface, a material depositor, a build station and a radiant energy apparatus.

One problem with existing additive manufacturing processes is that each machine has a limited physical capacity and requires multiple components, thus limiting the ability to scale up production economically.

The present invention is defined by the apparatus for additive manufacturing according to claim <NUM> and the method for producing a component according to claim <NUM>.

This problem is addressed by an additive manufacturing apparatus and method in which one or more of the components are shared by multiple build stations.

According to one aspect of the technology described herein, an additive manufacturing machine includes: a resin support which has at least a portion which is transparent, wherein the resin support defines a build surface; a material depositor operable to deposit a resin which is radiant-energy-curable onto the build surface; at least two build stations, each build station including: a stage positioned adjacent the build surface and configured to hold a stacked arrangement of the resin; one or more actuators operable to manipulate a relative position of the stage and the build surface; and at least one radiant energy apparatus positioned opposite to the stage, and operable to generate and project radiant energy in a predetermined pattern.

According to another aspect of the technology described herein, a method for producing a component layer-by-layer includes: providing a machine including: a resin support which has at least a portion which is transparent, wherein the resin support defines a build surface; and at least two build stations, each build station including: a stage positioned adjacent the build surface and configured to hold a stacked arrangement of one or more cured layers of a radiant-energy-curable resin; and one or more actuators operable to manipulate a relative position of the stage and the build surface; executing a build cycle, including the steps of: depositing on the build surface the resin, positioning the stages relative to the build surface so as to define a layer increment in the resin on the build surface; selectively curing the resin on the build surface using an application of radiant energy in a specific pattern so as to define the geometry of a cross-sectional layer of a component for each of the stages; moving the build surface and the stages relatively apart so as to separate the component from the build surface; and repeating the cycle, for a plurality of layers, until the components are complete.

According to another aspect of the technology described herein, an additive manufacturing machine includes: two or more resin supports, each resin support having at least a portion which is transparent, wherein each resin support defines a build surface; a material depositor operable to deposit a resin which is radiant-energy-curable onto the resin supports; a build station for each resin support, each build station including: a stage positioned adj acent the build surface and configured to hold a stacked arrangement of one or more cured layers the resin; one or more actuators operable to manipulate a relative position of the stage and the build surface; and a radiant energy apparatus disposed opposite to the stages and operable to generate and project radiant energy in a predetermined pattern; and means for delivering radiant energy from the radiant energy apparatus to each of the build stations.

According to another aspect of the technology described herein, a method for producing a component layer-by-layer includes: providing a machine including: two or more resin supports, each resin support having at least a portion which is transparent, wherein each resin support defines a build surface; a build station for each resin support, each build station including: a stage positioned adjacent the build surface and configured to hold a stacked arrangement of one or more cured layers of a radiant-energy-curable resin; one or more actuators operable to manipulate a relative position of the stage and the build surface; a radiant energy apparatus disposed opposite to the stages and operable to generate and project radiant energy in a predetermined pattern; and means for delivering radiant energy from the radiant energy apparatus to each of the build stations; executing a build cycle, including the steps of: depositing on the build surfaces the resin; positioning each of the stages relative to the corresponding build surfaces so as to define a layer increment in the resin on the build surface; selectively curing the resin on the build surface using an application of radiant energy in a specific pattern so as to define the geometry of a cross-sectional layer of a component for each of the stages; moving the build surfaces and the stages relatively apart so as to separate the components from the build surfaces; and repeating the cycle, for a plurality of layers, until the components are complete.

The invention may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:.

In general, an additive manufacturing machine includes a resin handling assembly, a stage, and a radiant energy apparatus. Several embodiments are disclosed herein, in which one or more of those components are shared for a plurality of build stations. Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views, <FIG> illustrates schematically an example of one known type of additive manufacturing machine <NUM>. Basic components of the exemplary machine <NUM> include a resin handling assembly <NUM>, a stage <NUM>, and a radiant energy apparatus <NUM>.

In the illustrated example, the resin handling assembly <NUM> is a "tape casting"-type device. The resin handling assembly <NUM> includes spaced-apart rollers <NUM> with a flexible polymeric tape or foil <NUM> extending therebetween. A portion of the foil <NUM> is supported from underneath by a support plate <NUM>. Suitable mechanical supports (frames, brackets, etc. - not shown) would be provided for the rollers <NUM> and support plate <NUM>. The foil <NUM> is an example of a "resin support".

Both of the support plate <NUM> and the foil <NUM> are transparent or include a portion or portions that are transparent. As used herein, the term "transparent" refers to a material which allows radiant energy of a selected wavelength to pass through. For example, as described below, the radiant energy used for curing could be ultraviolet light or laser light in the visible spectrum. Non-limiting examples of transparent materials include polymers, glass, and crystalline minerals such as sapphire or quartz.

Appropriate means such as motors, actuators, feedback sensors, and/or controls of a known type (not shown) would be provided for driving the rollers <NUM> in such a manner so as to maintain the foil <NUM> tensioned between the rollers <NUM> and to wind the foil <NUM> from one of the rollers <NUM> to the other roller <NUM>.

The foil <NUM> extending between the rollers <NUM> defines a "build surface" <NUM> which is shown as being planar, but could alternatively be arcuate (depending on the shape of the support plate <NUM>). For purposes of convenient description, the build surface <NUM> may be considered to be oriented parallel to an X-Y plane of the machine <NUM>, and a direction perpendicular to the X-Y plane is denoted as a Z-direction (X, Y, and Z being three mutually perpendicular directions).

The build surface <NUM> may be configured to be "non-stick", that is, resistant to adhesion of cured resin. The non-stick properties may be embodied by a combination of variables such as the chemistry of the foil <NUM>, its surface finish, and/or applied coatings. In one example, a permanent or semi-permanent non-stick coating may be applied. One non-limiting example of a suitable coating is polytetrafluoroethylene ("PTFE"). In one example, all or a portion of the first build surface <NUM> may incorporate a controlled roughness or surface texture (e.g. protrusions, dimples, grooves, ridges, etc.) with nonstick properties. In one example, the foil <NUM> may be made in whole or in part from an oxygen-permeable material.

For reference purposes, an area or volume immediately surrounding the location of the foil <NUM> is defined as a "build zone", labeled <NUM>.

Some means are provided for applying or depositing resin R to the build surface <NUM> in a generally uniform layer. <FIG> shows schematically a material depositor <NUM> which would be understood to include a reservoir for material communicating with the material outlet such as a slot or aperture (not shown). Conventional means such as a doctor blade (not shown) may be used to control the thickness of resin R applied to the foil <NUM>, as the foil <NUM> passes under the material depositor <NUM>.

The resin handling assembly <NUM> shown in <FIG> is merely an example. It will be understood that the principles described herein may be used with any type of resin support. Nonlimiting examples of such resin supports include foils, tapes, plates, and single-layer vats.

The stage <NUM> is a structure defining a planar upper surface <NUM> which is capable of being oriented parallel to the build surface <NUM>. Some means are provided for moving the stage <NUM> relative to the resin handling assembly <NUM> parallel to the Z-direction. In <FIG>, the movement means are depicted schematically as a simple vertical actuator <NUM> connected between the stage <NUM> and a static support <NUM>, with the understanding that devices such as ballscrew electric actuators, linear electric actuators, pneumatic cylinders, hydraulic cylinders, or delta drives may be used for this purpose. In addition to, or as an alternative to, making the stage <NUM> movable, the foil <NUM> could be movable parallel to the Z-direction.

For the purposes of the present invention, the stage <NUM> and the associated movement means such as a vertical actuator <NUM> may be considered to be a "build station", referred to generally at reference numeral <NUM>.

The radiant energy apparatus <NUM> may comprise any device or combination of devices operable to generate and project radiant energy on the resin R in a suitable pattern and with a suitable energy level and other operating characteristics to cure the resin R during the build process, described in more detail below.

In one exemplary embodiment as shown in <FIG>, the radiant energy apparatus <NUM> may comprise a "projector" <NUM>, used herein generally to refer to any device operable to generate a radiant energy patterned image of suitable energy level 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 individual pixels. Non-limiting examples of patterned imaged devices include a DLP projector or another digital micromirror device, a 2D array of LEDs, a 2D array of lasers, or optically addressed light valves. In the illustrated example, the projector <NUM> includes a radiant energy source <NUM> such as a UV lamp, an image forming apparatus <NUM> operable to receive a source beam <NUM> from the radiant energy source and generate a patterned image <NUM> to be projected onto the surface of the resin R, and optionally focusing optics <NUM>, such as one or more lenses.

The radiant energy source <NUM> may comprise any device operable to generate a beam of suitable energy level and frequency characteristics to cure the resin R. In the illustrated example, the radiant energy source comprises a UV flash lamp.

The image forming apparatus <NUM> may include one or more mirrors, prisms, and/or lenses and is provided with suitable actuators, and arranged so that the source beam <NUM> from the radiant energy source <NUM> can be transformed into a pixelated image in an X-Y plane coincident with the surface of the resin R. In the illustrated example, the image forming apparatus <NUM> may be a digital micro-mirror device. For example, the projector <NUM> may be a commercially-available Digital Light Processing ("DLP") projector.

As an option, the projector <NUM> may incorporate additional means (not shown) such as actuators, mirrors, etc. configured to selectively move the image forming apparatus or other part of the projector <NUM>, with the effect of rastering or shifting the location of the patterned image on the build surface <NUM>. Stated another way, the patterned image may be moved away from a nominal or starting location. This permits a single image forming apparatus to cover a larger build area, for example. Means for mastering or shifting the patterned image from the image forming apparatus are commercially available. This type of image projection may be referred to herein as a "tiled image".

In another exemplary embodiment as shown in <FIG>, in addition to other types of radiant energy devices, the radiant energy apparatus <NUM> may comprise a "scanned beam apparatus" <NUM> used herein to refer generally to refer to any device operable to generate a radiant energy beam of suitable energy level and other operating characteristics to cure the resin R and to scan the beam over the surface of the resin R in a desired pattern. In the illustrated example, the scanned beam apparatus <NUM> comprises a radiant energy source <NUM> and a beam steering apparatus <NUM>.

The radiant energy source <NUM> may comprise any device operable to generate a beam of suitable power and other operating characteristics to cure the resin R. Non-limiting examples of suitable radiant energy sources include lasers or electron beam guns.

The beam steering apparatus <NUM> may include one or more mirrors, prisms, and/or lenses and may be provided with suitable actuators, and arranged so that a beam <NUM> from the radiant energy source <NUM> can be focused to a desired spot size and steered to a desired position in plane coincident with the surface of the resin. The beam <NUM> may be referred to herein as a "build beam". Other types of scanned beam apparatus may be used. For example, scanned beam sources using multiple build beams are known, as are scanned beam sources in which the radiant energy source itself is movable by way of one or more actuators.

The machine <NUM> may include a controller <NUM>. The controller <NUM> in <FIG> is a generalized representation of the hardware and software required to control the operation of the machine <NUM>, including some or all of the resin handling assembly <NUM>, the stage <NUM>, the radiant energy apparatus <NUM>, the imaging apparatus <NUM>, and the various actuators described above. The controller <NUM> 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 a microcomputer. Such processors may be coupled to process sensors and operating components, for example, through wired or wireless connections. The same processor or processors may be used to retrieve and analyze sensor data, for statistical analysis, and for feedback control. Numerous aspects of the machine <NUM> may be subject to closed-loop control. For example, sensors could be used to monitor position, displacement, or movement of any of the components. Process sensors could be used to monitor output power or frequency characteristics of the radiant energy apparatus <NUM>, or forces acting on the apparatus (e.g., stage <NUM> or foil <NUM>). Imaging sensors (e.g. machine vision) could be used to observe the deposition or curing process. Information from any of the sensors could be used to monitor, control, or automate some or all of the operation of the machine <NUM>, in conjunction with appropriate programming of the controller <NUM>.

Optionally, the components of the machine <NUM> may be surrounded by a housing <NUM>, which may be used to provide a shielding or inert gas atmosphere using gas ports <NUM>. Optionally, pressure within the housing could be maintained at a desired level greater than or less than atmospheric. Optionally, the housing could be temperature and/or humidity controlled. Optionally, ventilation of the housing could be controlled based on factors such as a time interval, temperature, humidity, and/or chemical species concentration.

The resin R comprises a material which is radiant-energy curable and which is capable of adhering or binding together the filler (if used) in the cured state. As used herein, the term "radiant-energy curable" refers to any material which solidifies in response to the application of radiant energy of a particular frequency and energy level. For example, the resin R may comprise a known type of photopolymer resin containing photo-initiator compounds functioning to trigger a polymerization reaction, causing the resin to change from a liquid state to a solid state. Alternatively, the resin R may comprise a material which contains a solvent that may be evaporated out by the application of radiant energy. The uncured resin R may be provided in solid (e.g. granular) or liquid form including a paste or slurry.

The resin R is preferably a relatively high viscosity fluid that will not "slump" or run off during the build process. The composition of the resin R may be selected as desired to suit a particular application. Mixtures of different compositions may be used.

The resin R may be selected to have the ability to out-gas or burn off during further processing, such as the sintering process described below.

The resin R may incorporate a filler. The filler may be pre-mixed with resin R, then loaded into the material depositor <NUM>. The filler comprises particles, which are conventionally defined as "a very small bit of matter". The filler may comprise any material which is chemically and physically compatible with the selected resin R. The particles may be regular or irregular in shape, may be uniform or non-uniform in size, and may have variable aspect ratios. For example, the particles may take the form of powder, of small spheres or granules, or may be shaped like small rods or fibers.

The composition of the filler, including its chemistry and microstructure, may 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 may be used. In one example, the filler composition may be selected for its electrical or electromagnetic properties, e.g. it may specifically be an electrical insulator, a dielectric material, or an electrical conductor. It may be magnetic.

The filler may be "fusible", meaning it is capable of consolidation into a mass upon via application of sufficient energy. For example, fusibility is a characteristic of many available powders including but not limited to: polymeric, ceramic, glass, and metallic.

The proportion of filler to resin R may be selected to suit a particular application. Generally, any amount of filler may be used so long as the combined material is capable of flowing and being leveled, and there is sufficient resin R to hold together the particles of the filler in the cured state.

Examples of the operation of the machine <NUM> will now be described in detail with reference to <FIG>. It will be understood that, as a precursor to producing a component and using the machine <NUM>, a component <NUM> is software modeled. e.g., in terms of a tool (energy source raster) path or as a stack of planar layers arrayed along the Z-axis. Depending on the type of curing method used, each layer may be divided into a grid of pixels. The actual component <NUM> may be modeled and/or manufactured as a stack of dozens or hundreds of layers. Suitable software modeling processes are known in the art.

Initially, the build zone <NUM> is prepared with resin R on the build surface <NUM>. For example, the material depositor <NUM> may be used to deposit resin R over the build surface <NUM> of the foil <NUM>.

Different materials may also be supplied to the build surface <NUM>, at different times during the build (i.e. the material combination of the resin may be changed one or more times during the build). More than one material may also be supplied to different areas on a given build surface <NUM>, at the same time. Optionally, any of the individual layers may comprise two or more material combinations. <FIG> illustrates an exemplary layer <NUM> showing a cross-section of the component <NUM> superimposed thereupon. The layer <NUM> is divided into a first section <NUM> including a first combination of resin R and filler, and a second section <NUM> including a second combination of resin R and filler. A dashed line <NUM> indicates the division between the two sections <NUM>, <NUM>. The shape, size, and number of sections, and number of different material combinations within a given layer may be arbitrarily selected. If multiple material combinations are used in one layer, then the deposition steps described above would be carried out for each section of the layer.

After the material is deposited, the machine <NUM> (or parts thereof) is configured or positioned to define a selected layer increment relative the build surface <NUM>. The layer increment is defined by some combination of the thickness to which the resin R is applied and the operation of the stage <NUM>. For example, the stage <NUM> could be positioned such that the upper surface <NUM> is just touching the applied resin R, or the stage <NUM> could be used to compress and displace the resin R to positively define the layer increment. The layer increment affects the speed of the additive manufacturing process and the resolution of the component <NUM>. The layer increment can be variable, with a larger layer increment being used to speed the process in portions of a component <NUM> not requiring high accuracy, and a smaller layer increment being used where higher accuracy is required, at the expense of process speed.

Once the resin R has been applied and the layer increment defined, the radiant energy apparatus <NUM> is used to cure a two-dimensional cross-section or layer of the component <NUM> being built.

Where a projector <NUM> is used, the projector <NUM> projects a patterned image representative of the cross-section of the component <NUM> through the support plate <NUM> and foil <NUM> to the resin R. This process is referred to herein as "selective" curing. It will be understood that photopolymers undergo degrees of curing. In many cases, the radiant energy apparatus <NUM> would not fully cure the resin R. Rather, it would partially cure the resin R enough to "gel" and then a post-cure process (described below) would cure the resin R to whatever completeness it can reach. It will also be understood that, when a multi-layer component is made using this type of resin R, the energy output of the radiant energy apparatus <NUM> may be carefully selected to partially cure or "under-cure" a previous layer, with the expectation that when the subsequent layer is applied, the energy from that next layer will further the curing of the previous layer. In the process described herein, the term "curing" or "cured" may be used to refer to partially-cured or completely-cured resin R. During the curing process, radiant energy may be supplied to a given layer in multiple steps (e.g. multiple flashes) and also may be supplied in multiple different patterns for a given layer. This allows different amounts of energy to be applied to different parts of a layer.

Once curing of the first layer is complete, the stage <NUM> is separated from the build surface <NUM>, for example by raising the stage <NUM> using the vertical actuator <NUM>. It will be understood that the resin R and/or cured layer do not necessarily join, stick, or bond with the build surface <NUM>. Accordingly, as used herein the term "separate" refers to the process of moving two elements apart from each other and does not necessarily imply the act of breaking a bond or detaching one element from another.

Subsequent to separation, the build surface <NUM> may be cleaned or otherwise rejuvenated and prepared for re-use. For example, advancing the foil <NUM> provides a clean surface. As the foil <NUM> advances, the material depositor <NUM> would be used to apply resin R to the build surface <NUM> to ready it for curing again.

After separation, the component <NUM> and/or the stage <NUM> may be cleaned to remove uncured resin R, debris, or contaminants between curing cycles. The cleaning process may be used for the purpose of removing resin R that did not cure or resin R that did not cure enough to gel during the selective curing step described above. For example, it might be desired to clean the component <NUM> and/or the stage <NUM> to ensure that no additional material or material contamination is present in the final component <NUM>. For example, cleaning could be done by contacting the component <NUM> and/or the stage <NUM> with a cleaning fluid such as a liquid detergent or solvent.

This cycle of preparing the build surface <NUM>, optionally imaging deposited resin R, incrementing a layer, selectively curing, separating the component <NUM> from the build surface <NUM>, imaging the resin R and cleaning the component <NUM> and/or stage <NUM> would be repeated as necessary until the entire component <NUM> is complete.

Where a scanned beam apparatus is used for the build cycle described above, instead of a projector, the radiant energy source <NUM> emits a build beam <NUM> and the beam steering apparatus <NUM> is used to cure the resin R by steering a focal spot of the build beam <NUM> over the exposed resin R in an appropriate pattern.

Optionally, a scanned beam apparatus may be used in combination with a projector. For example, a scanned beam apparatus may be used to apply radiant energy (in addition to that applied by the projector) by scanning one or multiple beams over the surface of the uncured resin R. This may be concurrent or sequential with the use of the projector.

Either curing method (projector or scanned) results in a component <NUM> in which the filler (if used) is held in a solid shape by the cured resin R. This component may be usable as an end product for some conditions. Subsequent to the curing step, the component <NUM> may be removed from the stage <NUM>.

If the end product is intended to be composed of the filler (e.g. purely ceramic, glass, metallic, diamond, silicon, graphite, etc.), the component <NUM> may be treated to a conventional sintering process to burn out the resin R and to consolidate the ceramic or metallic particles. Optionally, a known infiltration process may be carried out during or after the sintering process, in order to fill voids in the component with a material having a lower melting temperature than the filler. The infiltration process improves component physical properties.

The above-described machine <NUM> incorporates a single build station <NUM>. The productivity of an additive manufacturing machine may be increased and its cost and complexity may be decreased using an apparatus of the same general type in which multiple build stations <NUM> are provided, such that the apparatus can form multiple layers simultaneously, where the multiple build stations <NUM> share at least one component of the overall machine.

In one basic embodiment, an additive manufacturing machine includes a plurality of build stations <NUM> sharing a common resin support.

For example, <FIG> illustrates a machine <NUM> having a plurality of build stations <NUM> arranged in proximity to a single resin support <NUM> such as a foil similar to foil <NUM> described above. A portion of the resin support <NUM> is supported from underneath by a support plate <NUM>. The machine <NUM> is generally similar to machine <NUM>, and components or portions of machine <NUM> not specifically described may be considered to be identical to corresponding components of the machine <NUM>. In the embodiment of <FIG>, an individual radiant energy apparatus <NUM> (e.g. a projector as described above) is provided for each build station <NUM>.

Optionally, means may be provided for controlling lift-up of the resin support <NUM> during the separation step of the build process (where the resin support is a foil). For example, one or more restraints <NUM> (e.g. long or short bars or rollers) may be provided which extend across all or some portion of the resin support <NUM>. They may contact the resin support <NUM> or be positioned some distance above it. The restraints <NUM> may be fixed or moveable. They may extend in any direction across the resin support <NUM>.

The build stations <NUM> (and associated radiant energy sources <NUM>) may be arranged in various configurations relative to the resin support <NUM>. Example configurations are shown in <FIG>.

<FIG> illustrates a configuration in which plurality of build stations <NUM> are aligned in series relative to a direction of movement of the resin support <NUM>. This may also be described as an upstream/downstream relationship. In this configuration, the resin support <NUM> has an overall working length "L" sufficient to accommodate the build stations <NUM> plus some additional area as required for the material depositor <NUM>. The resin support <NUM> has an overall width "W" wide enough to accommodate the build area of a single build station <NUM>.

<FIG> illustrates a configuration in which build stations <NUM> are aligned in parallel relative to a direction of movement of a resin support <NUM>. This may also be described as a parallel or side-by-side relationship. In this configuration, the resin support <NUM> has an overall working length "L" sufficient to accommodate the length of one build station <NUM> plus some additional area as required for the material depositor <NUM>. The resin support <NUM> has an overall width "W" wide enough to accommodate the combined width of the plurality of build stations <NUM>.

<FIG> illustrates a configuration which a plurality of build stations <NUM> are arrayed in a series-parallel relationship. This may also be described as a two-dimensional array having rows and columns. In this configuration, the resin support <NUM> has an overall working length "L" sufficient to accommodate the length of the plurality of build stations plus some additional area as required for the material depositor <NUM>. The resin support <NUM> has an overall width "W" wide enough to accommodate the combined width of the plurality of build stations <NUM>.

In the configurations shown in <FIG>, resin R may be applied tothe resin support <NUM>, <NUM> as a series of parallel "lanes" <NUM>, <NUM>, respectively, whereone lane <NUM>, <NUM> is provided for each corresponding column of build stations <NUM>. This avoids wasting resin R applied in the spaces between the build stations <NUM>. Furthermore, the width of the lanes may be varied per layer in accordance with the width of the component <NUM> being built.

As an alternative to providing individual radiant energy apparatuses <NUM>, one or more radiant energy apparatuses <NUM> may be shared by multiple build stations <NUM>. For example, <FIG> illustrates a machine <NUM> having a plurality of build stations <NUM> generally similar to machine <NUM> and including a resin support <NUM>. In this embodiment, a single radiant energy apparatus <NUM> (e.g. a projector as described above) is provided for all of the build stations <NUM>. The machine <NUM> is further provided with some image shifting means for directing radiant energy from the radiant energy apparatus <NUM> to the build stations <NUM>. One possible image shifting means comprises beam steering optics <NUM>, for example one or more lenses <NUM> connected to actuators <NUM>. The beam steering optics <NUM> are operable to receive the patterned image from the radiant energy apparatus <NUM> and direct it to a selected one of the build stations <NUM>. The operation of the beam steering optics <NUM> is arranged so that images can be projected to different build stations <NUM> sequentially or at different times.

Another possible image shifting means is physical movement of the radiant energy apparatus <NUM>. For example, it could be mounted to an actuator <NUM> (e.g. a ballscrew electric actuator, linear electric actuator, pneumatic cylinder, hydraulic cylinder, or delta drive) configured to selectively move the radiant energy apparatus <NUM> into alignment with a selected one of the build stations <NUM>.

As another alternative to providing individual radiant energy apparatuses <NUM>, <FIG> illustrates a machine <NUM> having a plurality of build stations <NUM> generally similar to machine <NUM> and including a resin support <NUM>. In this embodiment, a single radiant energy apparatus <NUM> (e.g. a projector as described above) is provided for all of the build stations <NUM>. The machine <NUM> is further provided with beam splitting optics, for example one or more prisms <NUM> and lenses <NUM>. The beam splitting optics are operable to receive the patterned image from the radiant energy apparatus <NUM> and direct it all or a group of build stations <NUM> simultaneously.

The concepts illustrated in <FIG> and <FIG> can be combined in various ways. For example, the build stations <NUM> are configured in a two-dimensional array as shown in <FIG>, a single radiant energy apparatus could be provided with beam splitting optics as described in <FIG> for a single row or column of the build stations <NUM>. Image shifting means could then be used to align the radiant energy patterned image from the radiant energy apparatus <NUM> with adjacent rows or columns of the build stations <NUM>.

The basic build cycle for machines <NUM>, <NUM>, <NUM> having multiple build stations <NUM> to form a component <NUM> is substantially as described above for each individual build station <NUM>. However, the provision of multiple build stations <NUM> permits variations in the overall process cycle, in particular how the resin R is provided and cycled through the build stations <NUM>.

One example of the potential process is shown in <FIG> shows a clean layer of uncured resin R. Initially, a component layer <NUM> is formed by selective curing at each of the spaced-apart build stations <NUM>, <FIG>. The resin support <NUM> is then advanced its full working length L to expose fresh uncured resin R, <FIG>. The selective curing at each of the spaced-apart build stations <NUM> is repeated as shown in <FIG>, followed by again advancing the resin support <NUM> its full working length L, <FIG>.

Another example of a potential cycle is shown in <FIG> shows a clean layer of uncured resin R. Initially, a component layer <NUM> is formed by selective curing at each of the spaced-apart build stations <NUM>, <FIG>. The resin support <NUM> is then advanced and increment approximately equal to the length of one build station <NUM>, <FIG>. The selective curing in each of the spaced-apart build stations <NUM> is repeated and shown in <FIG>. This results an array of cured component layers <NUM> spaced closely adjacent each other on the resin R. This step may be followed by advancing the resin support <NUM> its full working length L to expose fresh uncured resin R, <FIG>. This cycle spaces the component layers more closely and tends to avoid waste of resin R.

In the embodiments described above, multiple build stations <NUM> are provided using a single resin support <NUM>, and single or multiple radiant energy apparatuses <NUM> are provided. Alternatively, an additive manufacturing machine may incorporate multiple build stations and multiple resin supports all collectively sharing one radiant energy apparatus <NUM>.

For example, <FIG> illustrates a machine <NUM> having a plurality of build stations <NUM> generally similar to machine <NUM>. Each build station <NUM> is associated with an individual resin support <NUM> (e.g. foil, plate, or vat). Each resin support <NUM> may be provided with an individual material depositor <NUM>, or a shared material depositor may be used. In this embodiment, a single radiant energy apparatus <NUM> (e.g. a projector as described above) is provided for all of the build stations <NUM>. Means are provided for physically moving the radiant energy apparatus <NUM>. For example, the radiant energy apparatus <NUM> could be mounted to an actuator <NUM> (e.g. a ballscrew electric actuator, linear electric actuator, pneumatic cylinder, hydraulic cylinder, or delta drive) configured to selectively move the radiant energy apparatus <NUM> into alignment with a selected one of the build stations <NUM>.

Alternatively, means may be provided for moving the other components of the machine <NUM> (i.e. build stations <NUM>, resin supports <NUM>, and material depositors <NUM>). In the illustrated example, these other components are mounted to a support frame <NUM> which is in turn mounted to an actuator <NUM>. The actuator <NUM> is configured to selectively move the support frame <NUM> and attached components into alignment with the radiant energy apparatus <NUM>.

As another alternative to providing individual radiant energy apparatuses <NUM>, <FIG> illustrates a machine <NUM> having a plurality of build stations <NUM> generally similar to machine <NUM>. Each build station <NUM> is associated with an individual resin support <NUM> (e.g. foil, plate, or vat). Each resin support <NUM> may be provided with an individual material depositor <NUM>, or a shared material depositor may be used. In this embodiment, a single radiant energy apparatus <NUM> (e.g. a projector as described above) is provided for all of the build stations <NUM>. Means are provided for directing the image. One possible image shifting means comprises beam steering optics, for example one or more lenses <NUM> connected to actuators <NUM>. The beam steering optics are operable to receive the patterned image from the radiant energy apparatus <NUM> and direct it to a selected one of the build stations <NUM>. The operation of the beam steering optics is arranged so that images can be projected to different build stations <NUM> in sequence or at different times.

As another alternative to providing individual radiant energy apparatuses <NUM>, <FIG> illustrates a machine <NUM> having a plurality of build stations <NUM> generally similar to machine <NUM>. Each build station <NUM> is associated with an individual resin support <NUM> (e.g. foil, plate, or vat). Each resin support <NUM> may be provided with an individual material depositor <NUM>, or a shared material depositor may be used. In this embodiment, a single radiant energy apparatus <NUM> (e.g. a projector as described above) is provided for all of the build stations <NUM>. The machine <NUM> is further provided with beam splitting optics, for example one or more prisms <NUM> and lenses <NUM> The beam splitting optics are operable to receive the patterned image from the radiant energy apparatus <NUM> and direct it all or a group of build stations <NUM>.

For any of the embodiments described herein, the build stations <NUM> may be operated in unison or independently. For example, two or more stages <NUM> can move simultaneously, or sequentially. Optionally, one or more build stations <NUM> could be turned off completely for maintenance, or because they are not needed for a particular build.

The method and apparatus described herein has several advantages over the prior art. In particular, it will permit increasing additive manufacturing production rate and scale while reducing the cost and complexity of the machines.

Claim 1:
An additive manufacturing machine <NUM>, <NUM>, <NUM>), comprising two or more resin supports ( <NUM>, <NUM>, <NUM>), each resin support ( <NUM>, <NUM>, <NUM>) having at least a portion which is transparent, wherein each resin support (<NUM>, <NUM>, <NUM>) defines a build surface (<NUM>); a material depositor (<NUM>) operable to deposit a resin which is radiant-energy-curable onto the resin supports (<NUM>, <NUM>, <NUM>); a build station (<NUM>) for each resin support ( <NUM>, <NUM>, <NUM>), each build station (<NUM>) including:
a stage (<NUM>) positioned adjacent the build surface (<NUM>) and configured to hold a stacked arrangement of one or more cured layers of the resin; and
one or more actuators operable to manipulate a relative position of the stage (<NUM>) and the build surface (<NUM>);
a radiant energy apparatus (<NUM>, <NUM>) disposed opposite to the stages (<NUM>) and operable to generate and project radiant energy in a predetermined pattern; and
means for delivering radiant energy from the radiant energy apparatus (<NUM>, <NUM>) to each of the build stations (<NUM>).