Patent ID: 12233600

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

In additive fabrication, irrespective of the particular mechanism by which layers of material are formed, the material is usually formed on some kind of surface usually referred to as a build surface. The build surface is typically part of a component of the additive fabrication device referred to as a build platform. The build platform may, in some additive fabrication devices, be configured to move within the fabrication device so that material can be deposited at an appropriate position on the build surface. For instance, build platforms are frequently configured to move in a vertical direction between the formation of each layer so that a new layer may be formed on top of a previously-formed layer.

Typically in additive fabrication (e.g., inverted stereolithographic three-dimensional (3D) printing), the build platform moves in a vertical direction to lower into a resin basin that includes liquid resin. The resin basin that includes the liquid resin includes a bottom film layer. The basin may be disposed above a curing light that exposes the liquid resin disposed between the film layer and the build platform (or previously-formed layer) causing the liquid resin to cure on the bottom of the build platform and adhere to the film layer. Thereafter, the fabrication device separates the newly cured resin layer adhered to the film layer by raising the build platform to a second vertical position, allowing more liquid resin to flow into to the space disposed between the bottom of the build platform and the film layer. The fabrication device iteratively repeats the process described above for each layer of a printed part until the printed part is complete.

Inverted stereolithographic 3D printing requires a separation of the previously-formed layer of cured material from the film layer. The forces resisting this separation are both chemical (e.g., if the material has cured to the film layer and formed a chemical bond) and fluidic (e.g., from the inrush of viscous fluid into the widening gap beneath the part) and generally scales with the characteristic area of the previously-formed layer being separated. This process of separation may be similar to more common separations of adhesive interfaces, for example, the removal of common adhesive tape from a surface.

In some current implementations, the bottom film layer of the basin is a rigid film layer (i.e., not flexible). Accordingly, the fabrication device must exert a high amount of force to separate the entire cured resin layer of a printed part that is adhered to the rigid film layer for each printed layer. The high amount of force is transferred to the printed part reduce print quality of the printed part. In some examples, the bottom film layer includes a flexible film layer instead of the rigid film layer to reduce the amount of force required to separate the cured resin that is adhered to the flexible film layer. In these examples, the flexible film layer is “peeled” away from the cured resin such that only a portion of the cured resin is separated at a time (i.e., localizing the peel). As such, peeling only the portion of the cured resin layer reduces the amount of force required as compared to the rigid film layer. However, in these examples, the flexible film layer is peeled with a relatively small angle between the cured resin layer of the printed part and the flexible film layer. Accordingly, the small angle exerts substantial and variable forces on the printed part by peeling a significant portion of the flexible film layer at a given time. The high forces required to separate the rigid film layer and flexible film layer (e.g., using a small peel angle) may result in reduced quality of printed parts and reduced longevity of the film layer. Moreover, forces that vary with part geometry have been shown to cause visible artifacts in printed parts.

Implementations herein are directed toward systems and methods of separating the film layer and the previously-formed layer by increasing the peel angle between the film layer and the previously-formed layer across a print area. Increasing the peel angle minimizes the overall force required to separate the cured resin layer of the printed part and the film layer by localizing the peel area. Moreover, increasing the peel angle reduces the variability of force on part geometry of the printed part, thereby improving print performance and reducing the risk of damage to the print substrate.

Following below are more detailed descriptions of various concepts related to, and implementations of, techniques for peeling a flexible film layer from a newly cured layer of a printed part. It should be appreciated that various aspects described herein may be implemented in any of numerous ways. Examples of specific implementations are provided herein for illustrative purposes only. In addition, the various aspects described in the implementations below may be used alone or in any combination, and are not limited to the combinations explicitly described herein. In particular, while the following describes implementations in which one or more components may be located within a basin, it may be appreciated that the one or more components may be located within an additive fabrication device in proximity to the basin and the same results achieved.

FIGS.1A and1Bdepict an illustrative additive fabrication device comprising a basin configured as per any of the implementations discussed below. In some implementations, an illustrative stereolithographic printer100includes a support base101, a display and control panel108, and a reservoir and dispensing system104for storage and dispensing of photopolymer resin. The support base101may contain various mechanical, optical, electrical, and electronic components that may be operable to fabricate objects using the system. During operation, photopolymer resin (i.e., liquid resin) may be dispensed from the dispensing system104into a resin basin (i.e., basin)120. The control panel108may include data processing hardware115in communication with the control panel108. The data processing hardware115may be in communication with each component of the stereolithographic printer100. Moreover, a user may provide instructions to the data processing hardware115to execute operations on the stereolithographic printer100by interacting with the control panel108.

The build platform105may be positioned along a vertical axis103(oriented along the z-axis direction as shown inFIGS.1A-B) such that the downward-facing layer (lowest z-axis position) of an object being fabricated, or the downward-facing layer of the build platform105itself, is a desired distance along the z-axis from the bottom121of the basin120. The desired distance may be selected based on a desired thickness of a layer of solid material to be produced on the build platform105or onto a previously formed layer of the object being fabricated. In the example ofFIGS.1A and1B, a first build surface106is defined on the bottom of the build platform105and faces in the −z direction, towards the basin120. The build platform105may be removable from the stereolithographic printer100. For instance, the build platform105may be attached to an arm (e.g., pressure fit or fastened onto) and may be removed from the printer so that a part attached to the build surface106of the platform can be removed.

In the example ofFIGS.1A and1B, the bottom121of the basin120may be transparent to actinic radiation that is generated by a radiation source (not shown) located within the support base101, such that liquid photopolymer resin located between the bottom121of basin120and the bottom facing portion of build platform105or an object being fabricated thereon, may be exposed to the radiation. Upon exposure to such actinic radiation, the liquid photopolymer resin may undergo a chemical reaction, sometimes referred to as “curing,” that substantially solidifies and attaches the exposed resin to the downward-facing portion of build platform105or to an object being fabricated thereon.FIGS.1A and1Brepresent a configuration of the stereolithographic printer100prior to formation of any layers of an object on build platform105, and for clarity also omits any liquid photopolymer resin from being shown within the depicted basin120.

Following the curing of a layer of material, build platform105may be moved along the vertical axis of motion103in order to reposition the build platform105for the formation of a new layer and/or to impose separation forces upon any bond with the bottom121of basin120. In addition, the basin120is mounted onto the support base such that the stereolithographic printer100may move the basin along horizontal axis of motion110, the motion thereby advantageously introducing additional separation forces in at least some cases. The basin120may include a wiper126that is additionally provided, capable of motion along the horizontal axis of motion110and may be removably coupled or otherwise mounted onto the support base at109.

FIG.1Billustrates a schematic cross sectional view of the basin120inFIG.1A. The basin may include a flexible film layer121. The flexible film layer121is coupled to side walls122positioned at each end of the basin120to allow liquid resin R to be disposed within the basin120. The basin120also includes a blade124operable to move from a first end of the basin120to a second end of the basin120. In some examples, the blade124extends across the entire width of the flexible film layer121. Alternatively, the blade124may extend across a portion of the width of the flexible film layer121. Optionally, the data processing hardware115may instruct the operation of the blade124. In some implementations the flexible film layer121forms a hard stop loop121,121aat one end of the basin200. Optionally, the flexible film layer121includes the hard stop loop121ato restrict the blade124from reaching the side wall122. The basin120may also include a print substrate125. The platform109provides structural support at the bottom of the basin120and is coupled to the side walls122at each end of the basin120. In some examples, the basin120includes one or more air inlets127. The air inlets127are configured to allow forced air into the basin120or allow a vacuum to draw air from the basin120. The term “vacuum” as used in this application refers to a lower pressure region compared to a surrounding region. The term “pulling vacuum” refers to a process of depressurizing a region. For example, the air inlets127can depressurize the region between the flexible film layer121and the print substrate125such that the pressure in this region is lower than the atmospheric pressure. In some examples, the flexible film layer121is tensioned over the print substrate125. The air inlets127are configured to allowed forced air into the basin120to inflate the flexible film layer121(e.g., increasing the pressure between the flexible film layer121and the print substrate125), and the tension of the flexible film layer121will cause the flexible film layer121to return to its initial position (e.g., laminated over the print substrate125) when the forced air stops (e.g., without actively depressurizing the region (e.g., evacuating air from) between the flexible film layer121and the print substrate125). According to some implementations, the basin200,300,400,500,600,700,800,900,1000,1100,1200,1300, and1400, as shown inFIGS.2-14, respectively, may be employed in system100as the basin120.

FIGS.2A-2Killustrate cross-sectional schematic views of an example basin200in which the peeling mechanism includes a blade, according to some examples. In the example ofFIGS.2A-2K, the basin200includes a blade202, a flexible film layer204, a print substrate206, side walls208, and liquid resin R. The basin200also includes a first end203and a second end205. The side walls208are coupled to the flexible film layer204at the first end203and the second end205of the basin200, respectively, to allow the liquid resin R to be disposed within the basin200. The print substrate206may be a glass material that focuses a curing light220towards the printed part P. That is, the print substrate206may act as a window for the curing light220(FIG.2B). In each ofFIGS.2A-2K, the build platform105includes a printed part P affixed to the build platform105interacting with the basin200.

As discussed above, the platform105may include a first build surface106upon which an initial layer L of the part P is formed by curing a thickness of the photopolymer resin. However, upon formation of the initial layer L of the part P on the build surface106of the platform105, each layer L defines a new build surface BS (i.e., second build surface) upon which a subsequent layer L of the part P can be formed by curing the photopolymer resin R. In other words, the platform105defines an initial build surface106for curing an initial layer or base layer of the part P and each new layer L defines a build surface upon which a subsequent layer L is formed.

In some examples, the blade202includes significant thermal properties including heat-sink features (e.g., fins). In some examples, the blade202may include a phase-change heat pipe. In some implementations, the blade202may include resistive heating and/or a thermistor. In some examples, the blade202may be ferrous and a target of inductive heating through the basin200from a heat source located beneath the basin200. The thickness of the blade202may be very thin, thereby reducing requirements for the basin200to be completely surrounded by side walls208. That is, if the thickness of the blade202is relatively large, the blade202will displace a larger amount of liquid resin R while operating in the basin200. Thus, the large displacement of liquid resin R necessitates the need for the basin200to have side walls208that completely surround the basin200to constrain the liquid resin R.

In some examples, the blade202includes recoating features configured to distribute a thin layer of the liquid resin R along the bottom side of the printed part P after the part is separated from the flexible film layer204. Thus, the recoating features of the blade202ensure that the bottom side of the printed part P are evenly covered by the liquid resin R prior to a subsequent curing step. Incorporating recoating features into the blade202allows for low-depth liquid resin R printing. Optionally, the blade202may also include features for minimizing surface energy, such as coatings and/or surface textures that provide the blade202with a low surface energy to prevent the liquid resin R from collecting onto the blade202during low-depth liquid resin R printing.

FIG.2Aillustrates an example of the basin200wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin200. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer204corresponding one layer thickness. As used herein the first distance D1is configurable to any distance such that the bottom surface of the printed part P may be positioned at any distance from the flexible film layer. As such, increasing the first distance D1of the printed part from the flexible film layer thereby increases the thickness of the print layer L. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the flexible film layer204for forming a single printed layer L on the bottom surface of the printed part P. Moreover, the blade202is located at a first position at the first end203of the basin200.

FIG.2Billustrates an example of the basin200wherein a curing light220exposes the liquid resin R disposed between the printed part P and the flexible film layer204. As used herein (i.e., for all implementations), the term curing light may also interchangeably refer to an actinic radiation source. The actinic radiation source may produce electromagnetic radiation thereby producing photochemical reactions to solidify the liquid resin R disposed between the printed part P and the flexible film layer204. The curing light220cures the liquid resin R from the bottom side of the basin200through the print substrate206and the flexible film layer204, creating a new print layer L of the printed part P. The curing light220may be provided by any light source known by those skilled in the art of SLA printing.

FIG.2Cillustrates an example of the basin200wherein the liquid resin R disposed between the printed part P and the flexible film layer204is cured to form a new print layer L (i.e., second build surface). That is, the curing light220(FIG.2B) solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. Notably, the printed part P inFIG.2Cis larger than the printed part P inFIG.2Bby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer204such that a force must be applied to separate new print layer L and the flexible film layer204. Moreover, Stefan forces exist between the flexible film layer204and the print substrate206. As used herein the term Stefan forces may also include any fluid forces and/or vacuum forces between the flexible film layer and the print substrate. That is, the Stefan force between the flexible film layer204and the print substrate206prevent the printed part P from being lifted in the vertical direction away from the print substrate206. The Stefan force between the flexible film layer204and the print substrate206may be the result of a chemical bond and/or a fluidic bond from the inrush of viscous fluid (i.e., liquid resin R) into the widening gap beneath the printed part P.FIGS.2D-2Fillustrate various implementations to overcome the Stefan force between the flexible film layer204and the print substrate206. In particular, each example ofFIGS.2D-2Fmay be used independently of the other implementations of this disclosure, or in conjunction with the other implementations, to overcome the Stefan force.

FIG.2Dillustrates example configuration for overcoming the Stefan force between the print substrate206and the flexible film layer204. Here, forced air242is provided to the bottom side of the flexible film layer204at the first end203of the basin200and the second end205of the basin200. As such, the forced air242provided to the bottom of the flexible film layer204overcomes the Stefan force adhering the print substrate206to the flexible film layer204such that the flexible film layer204separates from the corners of the print substrate206.

FIG.2Eillustrates another example for overcoming the Stefan force between the print substrate206and the flexible film layer204. In this example, a horizontal buckling force FBmay be applied to the side wall208of the basin200to “buckle” the flexible film layer204. The buckling of the flexible film layer204causes the flexible film layer204to overcome the Stefan force between the print substrate206and the flexible film layer204. In some examples, the horizontal buckling force FBis applied directly to the side wall208to create the buckle motion of the flexible film layer204. Alternatively, the horizontal force FBmay be applied directly to the flexible film layer204rather than to the side wall208. In the example shown, the horizontal buckling force FBis only applied at the first end203of the basin, however, it is understood that the horizontal buckling force FBmay be applied additionally and/or alternatively to the second end205of the basin200.

FIG.2Fillustrates another example configuration for overcoming the Stefan force between the flexible film layer204and the print substrate206. Here, a poke actuation246may be applied to the bottom side of the flexible film layer204. The poke actuation246applies a force to the flexible film layer204that overcomes the Stefan force between the flexible film layer204and the print substrate206. The poke actuation246may be provided by a mechanical actuator or by any other actuator mechanism. In the example shown, the poke actuation246is only applied at the first end203of the basin, however, it is understood that the poke actuation246may be applied additionally and/or alternatively to the second end205of the basin200.

FIG.2G, illustrates an example of the basin200wherein the flexible film layer204, is lifted from the print substrate206by the data processing hardware115instructing the build platform105to move in the vertical direction away from the print substrate206. Here, the printed part P affixed to the build platform105and the flexible film layer204adhered to the printed part P are lifted in the vertical direction away from the print substrate206. That is, now that the flexible film layer204has overcome (or partially overcome) the Stefan force between the flexible film layer204and the print substrate206, the flexible film layer204may be lifted by the build platform105to separate from the print substrate206. Moving the build platform105, and thus the printed part P, allows sufficient room for the blade202to operate between the bottom surface of the printed part P and the print substrate206.

FIG.2Hillustrates an example of the basin200wherein the blade202translates from the first position (FIGS.2A-2G) to a second position. As the blade202(i.e., peeling mechanism) translates from the first position to the second position, a leading edge of the blade202contacts the top surface of the flexible film layer204, thereby inducing a peel front F. As used herein, the term “peel front” refers to the section of flexible film layer204actively “peeling” from the printed part P when the blade202(or similar mechanism in other implementations) is at a given position. The exact curvature of the flexible film layer204depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade202and the printed part P, and the stiffness, or other characteristics, of the flexible film layer204. Operating the blade202from the first position to the second position creates a separation force to separate the new layer L (i.e., second build surface) of the printed part P from the flexible film layer204. Notably, the blade202induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer204) while operating from the first position to the second position. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F), providing improved print quality of the printed part P.

FIG.2Iillustrates an example of the basin200wherein the blade202translates from the second position (FIG.2H) to a third position. As the blade202translates from the second position to the third position, the leading edge of the blade202remains in contact with the flexible film layer204. As such, the contact between blade202and the flexible film layer204induces a peeling force that peels the flexible film layer204from the printed part P. Translating the blade202from the second position to the third position continues creating the separation force to separate the new layer of the printed part P from the flexible film layer204. Notably, the blade202induces a high peel angle θPwhile operating from the second position to the third position. In some examples, the blade202induces the peeling force that peels the flexible film layer204from the printed part P when the blade202is at a first distance from the flexible film layer204. For example, the blade202may be at a first distance of without contacting the flexible film layer204. For example, the blade202may be at a first distance of 100 μm from the flexible film layer204during the peel. Whether the blade202contacts the flexible film layer204or is at the first distance from the flexible film layer204, the blade202reoxygenates the liquid resin R. Reoxygenation refers to providing oxygen into the flexible film layer204and/or the liquid resin R. Reoxygenation is required because, in some implementations, in order for the curing light220to cure the liquid resin R disposed between the printed part P and the flexible film layer204oxygen must be present. Notably, after curing a new print layer L the flexible film layer204and/or the liquid resin R may not have enough oxygen to form a subsequent new print layer L until the blade reoxygenates the liquid resin R.

FIG.2Jillustrates an example of the basin200wherein the blade202translates from the third position (FIG.2I) to a fourth position at the second end205of the basin200. As the blade202translates from the third position to the fourth position, the flexible film layer204separates completely from the printed part P (i.e., the flexible film layer204and the printed part P are no longer in contact, and the flexible film layer204re-laminates over the print substrate206due to tension of the flexible film layer204and/or Stefan force). Accordingly, the build platform105and the printed part P are now free to move in the vertical direction without causing movement of the flexible film layer204.

FIG.2Killustrates an example of the basin200, wherein the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer204, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer204(e.g., in a const-thickness printing setting, every layer shares the same thickness and D1is a constant. In an adaptive-thickness printing setting, each layer can have a different thickness and D1can be a variable). Notably, the printed part inFIG.2Kis larger than the printed part inFIG.2Aby the thickness of the previously printed print layer L. The process described above inFIGS.2A-2Kcan be repeated until all print layers are formed onto the printed part P and the print is complete.

In some examples, after the curing light220solidifies the print layer L of the printed part P, liquid resin R disposed near the flexible film layer204is at a first temperature and liquid resin R disposed at a further distance from the flexible film layer204is at a second temperature. Here, the first temperature is greater than the second temperature. In other examples, liquid resin R disposed near a rigid film substrate (not shown) is at the first temperature and liquid resin R disposed at a further distance from the rigid film substrate is at the second temperature. That is, as the liquid resin R cures to form the new print layer L and adheres to the flexible film layer204(or rigid film substrate) the surrounding liquid resin R heats to a higher temperature as compared to liquid resin R disposed at a further distance from the new print layer L. In these examples, the translation of the blade202from the first end203of the basin200to the second end205of the basin200reduces the temperature of the liquid resin R near the flexible film layer204(or rigid film substrate). In particular, the translation of the blade202causes the liquid resin R at the first temperature to mix with the liquid resin R at the second temperature thereby reducing the temperature of the liquid resin R disposed near the new print layer L. As such, the translation of the blade202provides a thermal regulation for the liquid resin R.

FIGS.3A-3Killustrate schematic views of an example basin300in which the peeling mechanism includes a blade and a roller, according to some examples. In the example ofFIGS.3A-3K, the basin300includes a top side blade301, a bottom side roller302, a flexible film layer304, a print substrate306, side walls308, and liquid resin R. The top side blade301is located on top of the flexible film layer304and the bottom side roller302is located below the flexible film layer304. In some examples, the top side blade301and/or the bottom side roller302extend across the entire width of the flexible film layer304(not shown). Alternatively, the top side blade301and/or the bottom side roller302may extend across a portion of the width of the flexible film layer304(not shown). The basin300also includes a first end303and a second end305. The side walls308are coupled to the flexible film layer304at the first end303and the second end305of the basin300, respectively, to allow the liquid resin R to be disposed within the basin300. The print substrate306may be a glass material that focuses a curing light320towards the printed part P. That is, the print substrate306may act as a window for the curing light320(FIG.3B). In each ofFIGS.3A-3K, the build platform105includes a printed part P affixed to the build platform105interacting with the basin300.

FIG.3Aillustrates an example of the basin300wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin300. Here, the printed part P includes three distinct structures rather than a single structure as inFIG.2. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer304corresponding to one layer thickness. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the flexible film layer304for forming a single printed layer L on the bottom surface of the printed part P. Moreover, the top side blade301and the bottom side roller302are located at a first position at the first end303of the basin300. Optionally, at the first position the bottom side roller302may translate up or down in the vertical direction. In particular, moving the bottom side roller302in the downward vertical direction reduces will allow the flexible film layer304to lay flat on the print substrate306when the top side blade301and the bottom side roller302are located at the first position. Put another way, moving the bottom side roller302in the downward vertical direction reduces the curvature of the flexible film layer304thereby causing the flexible film layer304to lay flat on the print substrate306. In some examples, the data processing hardware115instructs the top side blade301and the bottom side roller302to operate in conjunction with each other. That is, as the top side blade301translates, the bottom side roller302translates with the top side blade301and vice versa. Alternatively, the data processing hardware115may instruct the top side blade301and the bottom side roller302to translate independently of each other.

FIG.3Billustrates an example of the basin300wherein a curing light320exposes the liquid resin R disposed between the printed part P and the flexible film layer304. The curing light320cures the liquid resin R from the bottom side of the basin300through the print substrate306and the flexible film layer304creating a new print layer L of the printed part P. The curing light320may be provided by any light source known by those skilled in the art of SLA printing.

FIG.3Cillustrates an example of the basin300wherein the liquid resin R disposed between the bottom surface of the printed part P and the flexible film layer304is cured to form a new print layer L (i.e., second build surface). That is, the curing light320(FIG.3B) solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. Notably, the printed part P inFIG.3Cis larger than the printed part P inFIG.3Bby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer304such that a force must be provided to separate new print layer L and the flexible film layer304. Moreover, Stefan forces exist between the flexible film layer304and the print substrate306. That is, the Stefan force between the flexible film layer304and the print substrate306prevent the printed part from being lifted in the vertical direction away from the print substrate306.FIGS.3D-3Fillustrate various implementations to overcome the Stefan force between the flexible film layer304and the print substrate306. In particular, each example ofFIGS.3D-3Fmay be used independently of the other implementations of this disclosure, or in conjunction with the other implementations, to overcome the Stefan force.

FIG.3Dillustrates an example for overcoming the Stefan force between the print substrate306and the flexible film layer304. Here, forced air342is provided to the bottom side of the flexible film layer304at the first end303of the basin300and the second end of305the basin300. As such, the forced air342provided to the bottom of the flexible film layer304overcomes the Stefan force adhering the print substrate306to the flexible film layer304such that the flexible film layer304separates from the corners of the print substrate306.

FIG.3Eillustrates another example for overcoming the Stefan force between the print substrate306and the flexible film layer304. In this example, a horizontal buckling force FBmay be provided to the side wall308of the basin300to “buckle” the flexible film layer304. The buckling of the flexible film layer304causes the flexible film layer304to overcome the Stefan force between the print substrate306and the flexible film layer304. In some examples, the horizontal buckling force FBis provided directly to the side wall308to create the buckle motion of the flexible film layer. Alternatively, the horizontal buckling force FBmay be provided directly to the flexible film layer304rather than to the side wall308. In the example shown, the horizontal buckling force FBis only provided at the first end303of the basin300, however, it is understood that the horizontal buckling force FBmay be provided additionally and/or alternatively to the second end305of the basin300.

FIG.3Fillustrates another example for overcoming the Stefan force between the flexible film layer304and the print substrate306. Here, a poke actuation346may be provided to the bottom side of the flexible film layer304. The poke actuation346applies a force to the flexible film layer304that overcomes the Stefan force between the flexible film layer304and the print substrate306. The poke actuation346may be provided by a mechanical actuator or by any other actuator mechanism. In the example shown, the poke actuation346is only provided at the first end303of the basin, however, it is understood that the poke actuation346may be provided additionally and/or alternatively to the second end305of the basin300.

FIG.3G, illustrates an example of the basin300wherein the flexible film layer304, is lifted from the print substrate306by the data processing hardware115instructing the build platform105to move in the vertical direction away from the print substrate306. Here, the printed part P, affixed to the build platform105, and the flexible film layer304adhered to the printed part Pare lifted in the vertical direction away from the print substrate306. That is, now that the flexible film layer304has overcome (or partially overcome) the Stefan force between the flexible film layer304and the print substrate306, the flexible film layer304may be lifted by the build platform105to separate from the print substrate306. Moving the build platform105, and thus the printed part P, allows sufficient room for the top side blade301and the bottom side roller302to operate between the bottom surface of the printed part P and the print substrate306.

FIG.3Hillustrates an example of the basin300wherein the top side blade301and the bottom side roller302(collectively referred to as the peeling mechanism) translate from the first position (FIGS.3A-3H) to a second position. As the top side blade301and the bottom side roller302translate from the first position to the second position, a leading edge of the top side blade301contacts the top surface of the flexible film layer304, thereby inducing a peel front F. The exact curvature of the flexible film layer304depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the flexible film layer304. Translating the top side blade301from the first position to the second position creates a separation force to separate the new layer L (i.e., second build surface) of the printed part P from the flexible film layer304. Notably, the top side blade301induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer304) while translating from the first position to the second position. The high peel angle θPminimizes the force applied to the printed part P (e.g., by localizing the peel front F), thereby providing improved print quality of the printed part P.

Additionally, as the top side blade301translates from the first position to the second position, the bottom side roller302translates from the first position to the second position. The bottom side roller302is configured to support the flexible film layer304as the top side blade301propagates the peel. In particular, a trailing edge of the bottom side roller302supports the bottom of the flexible film layer304to increase the peel angle θPand localize the peel front F. Accordingly, the bottom side roller302further minimizes the force applied on the printed part P as the top side blade301peels the flexible film layer304from the printed part P by increasing the peel angle θP.

The bottom side roller302allows the printed parts P to be supported from beneath the flexible film layer304thereby allowing high peel forces between the top side blade301and the flexible film layer304without transferring the high peel forces to the printed part. Moreover, the bottom side roller302protects the flexible film layer304by supporting the bottom side of the flexible film layer304thereby maintaining a consistent peel angle θPthroughout the entire peel. Thus, by maintaining the consistent peel angle θP, the flexible film layer304peels from the printed part P with zero Gaussian curvature. In contrast, by simply lifting the printed part P to separate the printed part P from the flexible film layer304without the top side blade301and/or bottom side roller302, the flexible film layer304forms a conical shape curvature that may damage the flexible film layer304. In addition to supporting the bottom surface of the printed part P, the combination of the top side blade301with the bottom side roller302dictates the curvature and the peel angle θPof the flexible film layer304as the top side blade301and the bottom side roller302traverse the build area.

FIG.3Iillustrates an example of the basin300wherein the top side blade301and the bottom side roller302translate from the second position (FIG.3H) to a third position. As the top side blade301and the bottom side roller302translate from the second position to the third position, the leading edge of the top side blade301remains in contact with the flexible film layer304. As such, the contact between top side blade301and the flexible film layer304induces a peeling force that peels the flexible film layer304from the printed part P. Translating the top side blade301from the second position to the third position continues creating the separation force to separate the new layer L of the printed part P from the flexible film layer304. Notably, the top side blade301and the bottom side roller302induces a high peel angle θPwhile translating from the second position to the third position.

FIG.3Jillustrates an example of the basin300wherein the top side blade301and the bottom side roller302translate from the third position (FIG.3I) to a fourth position at the second end305of the basin300. As the top side blade301and the bottom side roller translate from the third position to the fourth position, the flexible film layer304separates completely from the printed part P (i.e., the flexible film layer304and the printed part P are no longer in contact). Accordingly, the build platform105and the printed part P are now free to move in the vertical direction without causing movement of the flexible film layer304.

FIG.3Killustrates an example of the basin300, wherein the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer304, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer304. Notably, the printed part inFIG.3Kis larger than the printed part inFIG.3Aby the thickness of the previously printed layer. Here, the top side blade301and bottom side roller302translate from the fourth position (FIG.3J) to the first position before the build platform105lowers the printed part P to the first distance D1from the flexible film layer304. Optionally, the top side blade301and bottom side roller302may remain in the fourth position (FIG.3J) as the build platform105lowers the printed part P to the first distance D1from the flexible film layer304. The process described above inFIGS.3A-3Kcan be repeated until all print layers are formed onto the printed part P and the print is complete.

An additional extension of this implementation involves the phenomenon of “squish,” where the printed parts P are traditionally brought to a distance of one layer thickness away from the print substrate306to entrap a layer of uncured liquid resin R between the flexible film layer304and the bottom surface of the printed part P. In a typical stereolithography process, the printed parts P are lowered toward the print substrate306over a much greater depth of the resin R than the thickness of the subsequent new print layer L, necessitating the displacement of a volume of viscous liquid resin R. This displacement imparts a significant force to the printed parts P, which may be undesirable. By including the second trailing bottom side roller302behind the top side blade301, or by reversing the motion of the mechanism from the second end305to the first end303of the basin300, it is possible to push the flexible film layer304up to laminate it to the bottom surface of the printed part P with a thin layer L of the liquid resin R in a gradual process known as line squish. Thus, the forces associated with displacing the excess fluid are imparted on the bottom side roller302and not by the bottom surface of the printed part P, greatly reducing or even eliminating the need to perform a typical “squish” maneuver.

In some examples, after the curing light320solidifies the print layer L of the printed part P, liquid resin R disposed near the flexible film layer304is at a first temperature and liquid resin R disposed at a further distance from the flexible film layer304is at a second temperature. Here, the first temperature is greater than the second temperature. In other examples, liquid resin R disposed near a rigid film substrate (not shown) is at the first temperature and liquid resin R disposed at a further distance from the rigid film substrate is at the second temperature. That is, as the liquid resin R cures to form the new print layer L and adheres to the flexible film layer304(or rigid film substrate) the surrounding liquid resin R heats to a higher temperature as compared to liquid resin R disposed at a further distance from the new print layer L. In these examples, the translation of the top side blade301and bottom side roller302from the first end303of the basin300to the second end305of the basin300reduces the temperature of the liquid resin R near the flexible film layer304(or rigid film substrate). In particular, the translation of the top side blade301and bottom sider roller302causes the liquid resin R at the first temperature to mix with the liquid resin R at the second temperature thereby reducing the temperature of the liquid resin R disposed near the new print layer L. As such, the translation of the top side blade301and bottom side roller302provides a thermal regulation for the liquid resin R.

FIGS.4A-4Killustrate schematic views of an example basin400in which the peeling mechanism includes a vacuum nozzle, according to some examples. In the example ofFIGS.4A-4K, the basin400includes a vacuum nozzle402, a flexible film layer404, a print substrate406, side walls408, and liquid resin R. The basin400also includes a first end403and a second end405. The vacuum nozzle402is located on the bottom side of the flexible film layer404and includes an outer chamber402,402aand an inner chamber402,402b. The outer chamber402ais configured to provide structural support for the vacuum nozzle402. The inner chamber402bis configured to pull a vacuum against the flexible film layer404(e.g., to depressurize a region between the flexible film layer404and the vacuum nozzle402). That is, the vacuum of the inner chamber402bpulls via the vacuum the bottom side of the flexible film layer404towards the top side of the vacuum nozzle402to draw the flexible film layer404away from the printed part P. Optionally, the basin400may have a bottom side roller302(FIG.3) to further support the flexible film layer404(not shown). In some examples, the vacuum nozzle402and/or the bottom side roller302(FIG.3) extend across the entire width of the flexible film layer404. Alternatively, the vacuum nozzle402and/or the bottom side roller302(FIG.3) may extend across a portion of the width of the flexible film layer404.

The side walls408are coupled to the flexible film layer404at the first end403and the second end405of the basin400, respectively, to allow the liquid resin R to be disposed within the basin400. The print substrate406may be a glass material that focuses a curing light420towards the printed part P. That is, the print substrate406may act as a window for the curing light420(FIG.4B). In each ofFIGS.4A-4K, the build platform105includes a printed part P affixed to the build platform105interacting with the basin400.

FIG.4Aillustrates an example of the basin400wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin400. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer404corresponding to one layer thickness. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the flexible film layer404for forming a single printed layer L on the bottom surface of the printed part P. Moreover, the vacuum nozzle402is located at a first position at the first end403of the basin400.

FIG.4Billustrates an example of the basin400wherein a curing light420exposes the liquid resin R disposed between the printed part P and the flexible film layer404. The curing light420cures the liquid resin R from the bottom side of the basin400through the print substrate406and the flexible film layer404creating a new print layer L of the printed part P. The curing light420may be provided by any light source known by those skilled in the art of SLA printing.

FIG.4Cillustrates an example of the basin400wherein the liquid resin R disposed between the bottom surface of the printed part P and the flexible film layer404is cured to form a new print layer L. That is, the curing light420(FIG.4B) solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. Notably, the printed part P inFIG.4Cis larger than the printed part P inFIG.4Bby the size of the new print layer L. The new print layer L (i.e., second build surface) of the printed part P adheres to the flexible film layer404such that a force must be provided to separate new print layer L and the flexible film layer404. Moreover, Stefan forces exist between the flexible film layer404and the print substrate406. That is, the Stefan force between the flexible film layer404and the print substrate406prevent the printed part from being lifted in the vertical direction away from the print substrate406.FIGS.4D-4Fillustrate various implementations to overcome the Stefan force between the flexible film layer404and the print substrate406. In particular, each example ofFIGS.4D-4Fmay be used independently of the other implementations of this disclosure, or in conjunction with the other implementations, to overcome the Stefan force.

FIG.4Dillustrates an example for overcoming the Stefan force between the print substrate406and the flexible film layer404. Here, forced air442is provided to the bottom side of the flexible film layer404at the first end403of the basin400and the second end of405the basin400. As such, the forced air442provided to the bottom of the flexible film layer404overcomes the Stefan force adhering the print substrate406to the flexible film layer404such that the flexible film layer404separates from the corners of the print substrate406.

FIG.4Eillustrates another example for overcoming the Stefan force between the print substrate406and the flexible film layer404. A horizontal buckling force FB may be provided to the side wall408of the basin400to “buckle” the flexible film layer404. The buckling of the flexible film layer404causes the flexible film layer404to overcome the Stefan force between the print substrate406and the flexible film layer404. In some examples, the horizontal buckling force FBis provided directly to the side wall408to create the buckle motion of the flexible film layer. Alternatively, the horizontal buckling force FBmay be provided directly to the flexible film layer404rather than to the side wall408. In the example shown, the horizontal buckling force FBis only provided at the first end403of the basin400, however, it is understood that the horizontal buckling force FBmay be provided additionally and/or alternatively to the second end405of the basin400.

FIG.4Fillustrates another example for overcoming the Stefan force between the flexible film layer404and the print substrate406. Here, a poke actuation446may be provided to the bottom side of the flexible film layer404. The poke actuation446applies a force to the flexible film layer404that overcomes the Stefan force between the flexible film layer404and the print substrate406. The poke actuation446may be provided by a mechanical actuator or by any other actuator mechanism. In the example shown, the poke actuation446is only provided at the first end403of the basin, however, it is understood that the poke actuation446may be provided additionally and/or alternatively to the second end405of the basin400.

FIG.4G, illustrates an example of the basin400wherein the flexible film layer404, is lifted from the print substrate406by the data processing hardware115instructing the build platform105to move in the vertical direction away from the print substrate406. Here, the printed part P affixed to the build platform105and the flexible film layer404adhered to the printed part P are lifted in the vertical direction away from a first part position (FIG.4A) to a second part position away from the print substrate406. That is, now that the flexible film layer404has overcome (or partially overcome) the Stefan force between the flexible film layer404and the print substrate406, the flexible film layer404may be lifted by the build platform105to separate from the print substrate406. Moving the build platform105, and thus the printed part P, allows sufficient room for the vacuum nozzle402to operate between the bottom surface of the printed part P and the print substrate406.

FIG.4Hillustrates an example of the basin400wherein the vacuum nozzle402translates from the first position (FIGS.4A-4G) on a first side of the printed part to a second position. As the vacuum nozzle402translates from the first position to the second position, vacuum of the vacuum nozzle402pulls the flexible film layer404down towards the vacuum nozzle402. Accordingly, as the vacuum nozzle402(i.e., peeling mechanism) pulls the flexible film layer404down towards the leading edge of the vacuum nozzle402inducing a peel front F. The exact curvature of the flexible film layer404depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the flexible film layer404. Notably, the vacuum nozzle402induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer404) while translating from the first position to the second position. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P.

FIG.4Iillustrates an example of the basin400wherein the vacuum nozzle402translates from the second position (FIG.4H) to a third position. As the vacuum nozzle402translates from the second position to the third position, the vacuum nozzle402continues to pull the vacuum pulling the flexible film layer404towards the top of the vacuum nozzle402. As such, the vacuum between vacuum nozzle402and the flexible film layer404induces a peeling force that peels the flexible film layer404from the printed part P. Translating the vacuum nozzle402from the second position to the third position continues creating the separation force to separate the new layer of the printed part P from the flexible film layer404. Notably, the vacuum nozzle402induces a high peel angle θPwhile translating from the second position to the third position.

FIG.4Jillustrates an example of the basin400wherein the vacuum nozzle402translates from the third position (FIG.4I) to a fourth position on a second side of the printed part P at the second end405of the basin400. As the vacuum nozzle402translates from the third position to the fourth position, the flexible film layer404separates completely from the printed part P (i.e., the flexible film layer404and the printed part P are no longer in contact). As such, the flexible film layer404re-laminates over the print substrate406due to tension of the flexible film layer404and/or the vacuum nozzle402pulling the flexible film layer404(e.g., via vacuum applied to the bottom side of the flexible film layer404) away from the printed part P and towards the print substrate406. Accordingly, the build platform105and the printed part P are now free to move in the vertical direction without causing movement of the flexible film layer404.

FIG.4Killustrates an example of the basin400, wherein the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer404, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer404. Notably, the printed part inFIG.4Kis larger than the printed part inFIG.4Aby the thickness of the previously printed layer. The process described above inFIGS.4A-4Kcan be repeated until all print layers are formed onto the printed part P and the print is complete.

In some examples, after the curing light420solidifies the print layer L of the printed part P, liquid resin R disposed near the flexible film layer404is at a first temperature and liquid resin R disposed at a further distance from the flexible film layer404is at a second temperature. Here, the first temperature is greater than the second temperature. In other examples, liquid resin R disposed near a rigid film substrate (not shown) is at the first temperature and liquid resin R disposed at a further distance from the rigid film substrate is at the second temperature. That is, as the liquid resin R cures to form the new print layer L and adheres to the flexible film layer404(or rigid film substrate) the surrounding liquid resin R heats to a higher temperature as compared to liquid resin R disposed at a further distance from the new print layer L. In these examples, the translation of the vacuum nozzle402from the first end403of the basin400to the second end405of the basin400reduces the temperature of the liquid resin R near the flexible film layer404(or rigid film substrate). In particular, the translation of the vacuum nozzle402causes the liquid resin R at the first temperature to mix with the liquid resin R at the second temperature thereby reducing the temperature of the liquid resin R disposed near the new print layer L. As such, the translation of the vacuum nozzle402provides a thermal regulation for the liquid resin R.

FIGS.5A-5Gillustrate schematic views of an example basin500that includes a deformable substrate, according to some examples. In the example ofFIGS.5A-5G, the basin500includes a roller502, a deformable print substrate504side walls508, and liquid resin R. The deformable print substrate504may be any deformable substrate including foam, plastic, a volume of gel, encapsulated liquid, or any other deformable transparent medium. The deformable print substrate504may be translucent allowing light to pass through the deformable print substrate504. That is, the deformable print substrate504may act as a window for the curing light520. In each ofFIGS.5A-5G, the build platform105includes a printed part P affixed to the build platform105interacting with the basin500.

FIG.5Aillustrates an example of the basin500wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin500. Here, the printed part P includes three distinct structures rather than a single structure as inFIG.2. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the deformable print substrate504corresponding to one layer thickness. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the deformable print substrate504for forming a single printed layer L on the bottom surface of the printed part P. Moreover, the roller502may be located at or near the deformable print substrate504at the first end503of the basin500, and may extend across the entire width of the deformable print substrate504or a portion of the width of the deformable print substrate504.

FIG.5Billustrates an example of the basin500wherein a curing light520exposes the liquid resin R disposed between the printed part P and the deformable print substrate504. The curing light520cures the liquid resin R from the bottom side of the basin500through the deformable print substrate504creating a new print layer L of the printed part P. The curing light520may be provided by any light source known by those skilled in the art of SLA printing.

FIG.5Cillustrates an example of the basin500wherein the liquid resin R disposed between the printed part P and the deformable print substrate504is cured to form a new print layer L. That is, the curing light520(FIG.5B) solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. Notably, the printed part P inFIG.5Cis larger than the printed part P inFIG.5Bby the size of the new print layer L. The new print layer L of the printed part P adheres to the deformable print substrate504such that a force must be provided to separate new print layer L and the deformable print substrate504. Optionally, the data processing hardware may instruct the build platform105to raise the printed part P creating tension on the deformable print substrate.

FIG.5D, illustrates an example of the basin500wherein the data processing hardware115(FIG.1) instructs the roller502to move from the first position at the first end of the basin to a second position. At the second position, the roller502induces a peel front F by deforming the deformable print substrate504. The exact curvature of the deformable print substrate504depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the deformable print substrate504. Operating the roller502from the first position to the second position creates a separation force to separate the new layer of the printed part P from the deformable print substrate. Notably, the roller502induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the deformable print substrate504) while operating from the first position to the second position. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P. Moreover, at the second position the roller502localizes the peel front F to the pocket created by the roller502deforming the deformable print substrate.

FIG.5Eillustrates an example of the basin500wherein the roller502translates from the second position (FIG.5D) to a third position. As the roller502operates from the second position to the third position, the previously deformed material (i.e., to the right of the roller502) remains separated from the printed part.FIG.5Eis for illustrative purpose only, and in actual practice, the previously deformed material will return to its original shape/height after the roller502moves over. The roller502continues to contact the deformable print substrate504inducing a print front with a high peel angle θP. Accordingly, the roller502only applies a small amount of force onto the printed part P to separate the deformable print substrate504and the printed part P.

FIG.5Fillustrates an example of the basin500wherein the roller502translates from the third position (FIG.5E) to a fourth position. As the roller502translates from the third position to the fourth position, the previously deformed material (i.e., to the right of the roller502) remains separated from the printed part P. The roller502continues to contact the deformable print substrate504inducing a print front with a high peel angle θP. Accordingly, the roller502only applies a small amount of force onto the printed part P to separate the deformable print substrate504and the printed part P.

FIG.5Gillustrates an example of the basin500wherein the roller502fourth position (FIG.5F) to a fifth position at the second end505of the basin500. As the roller502translates from the fourth position to the fifth position, the deformable print substrate504separates completely from the printed part P (i.e., the deformable print substrate504and the printed part P are no longer in contact). Accordingly, the build platform105and the printed part P are now free to move in the vertical direction without causing movement of the deformable print substrate504. Here, the data processing hardware may instruct the build platform105to position the printed part the one layer thickness from the deformable print substrate for another print cycle.

Alternatively, the deformable print substrate504peels at or about the one layer thickness away from the printed part P. Put another way, after the roller502completes the peel of the deformable print substrate504and the printed part, the deformable print substrate504is spaced the first distance D1equal to one layer thickness away from the printed part P. That is because the roller502acting on the deformable print substrate504localizes the peel and keeps the deformable print substrate504in close proximity to the printed part P. Therefore, because the deformable print substrate504is already one layer thickness from the printed part P (i.e., spaced by the first distance D1) the build platform105is not required to lower the printed part P into the liquid resin R performing the “squish” movement. Not performing the squish movement (i.e., lowering the printed part P in the vertical direction into the liquid resin R) prevents the printed part P from incurring additional forces from displacing the liquid resin R as the printed part P is lowered towards the printed part P. The process described above inFIGS.5A-5Gcan be repeated until all print layers are formed onto the printed part P and the print is complete.

FIGS.6A-6Fillustrate schematic views of an example basin600in that includes tensioners, according to some examples. In the example ofFIGS.6A-6F, the basin600includes capstans602, a flexible film layer604, side walls608, tensioners614, a platform612, and liquid resin R. The capstans602are configured to support the flexible film layer604and are located on the bottom side of the flexible film layer604and on top of the platform612. The capstans602are rotatable about the X-axis in either direction. The capstans602are located at the first end603of the basin600and the second end605of the basin600. The side walls608are coupled to the flexible film layer604at the first end603and the second end605of the basin600, respectively, to allow the liquid resin R to be disposed within the basin600. Tensioners614may be located within the side walls608and coupled to the flexible film layer604. The tensioners614are configured to control the tension of the flexible film layer604by moving inwards towards the center of the basin600(e.g., to loosen tension) and moving outwards from the center of the basin600(e.g., to increase tension). In some examples, one of the tensioners614is fixed (i.e., does not move or increase/reduce tension) and the other one of the tensioners614controls the tension of the flexible film layer604. The tensioners614may apply tension by springs, vacuum, a mechanical actuator, and/or magnets. As the tensioners614increase and loosen tension on the flexible film layer604, the capstans602rotate about the X-axis allowing the flexible film layer604to move across the capstans602. In each ofFIGS.6A-6F, the build platform105includes a printed part P affixed to the build platform105interacting with the basin600.

FIG.6Aillustrates an example of the basin600wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin600. Here, the printed part P includes three distinct structures rather than a single structure as inFIG.2. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer604corresponding to one layer thickness. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the flexible film layer604for forming a single printed layer L on the bottom surface of the printed part P. Moreover, the tensioners614increase tension on the flexible film layer604by moving outward from the center of the basin600. Applying tension to the flexible film layer604causes the flexible film layer604to lay flat thereby increasing the transparency of the flexible film layer604. Increasing the flatness and/or transparency of the flexible film layer reduces defects caused in the printed part caused by any imperfections in the flexible film layer as a curing light620cures the liquid resin R through the flexible film layer604.

FIG.6Billustrates an example of the basin600wherein the curing light620exposes the liquid resin R disposed between the printed part P and the flexible film layer604. The curing light620cures the liquid resin R disposed between the printed part P and the flexible film layer604is cured to form a new part layer L. That is, the curing light620solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. Optionally, the light source of the curing light620may be located beneath the platform612. The curing light620may be provided by any light source known by those skilled in the art of SLA printing.

FIG.6Cillustrates an example of the basin600wherein the tensioners reduce tension on the flexible film layer604. That is, the curing light620(FIG.6B) solidifies the liquid resin R onto the surface of the printed part P becoming the new print layer L of the printed part P. Notably, the printed part P inFIG.6Cis larger than the printed part P inFIG.6Bby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer604such that a force must be applied to separate new print layer L and the flexible film layer604.

Moreover, the tensioners614reduce tension on the flexible film layer604(i.e., by moving inwards towards the center of the basin600) providing extra film length for the flexible film layer604. Thus, the data processing hardware115(FIG.1) instructs the build platform105to lift the printed part P in the vertical direction away from the platform612. Reducing tension on the flexible film layer604allows the build platform105to raise the printed part P to apply a force between the flexible film layer604and the printed part P.

FIG.6Dillustrates an example of the basin600wherein the flexible film layer604peels from the printed part P. That is, the data processing hardware115instructs the build platform105to move in the vertical direction further away from the platform612inducing a peel front F. Here, the printed part P affixed to the build platform105and the flexible film layer604adhered to the printed part P are lifted in the vertical direction away from the platform612. Thus, the build platform105and the printed part P is at a position further away from the platform612as compared toFIG.6C. The exact curvature of the flexible film layer604depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the flexible film layer604. Notably, the reducing the tension and further raising the build platform105induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer604) on both sides of the flexible film layer604. Here, the peeling process initiates on both the first end603and the second end605of the basin and converging in the center of the basin. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P. Optionally, the build platform105and the printed part P may not move further away from the platform612and the tensioners614move to an intermediate position within the side walls608. As such, the retraction of the tensioners614(not shown) provides tension on the flexible film layer604to peel from the printed part P. In some examples, the build platform105and the printed part P may move further away from the platform612and the tensioners move to the intermediate position within the side walls608.

FIG.6Eillustrates an example of the basin600wherein the flexible film layer604fully separates from the printed part. That is, the printed part P is now free to move in the vertical direction causing movement of the flexible film layer604. After the flexible film layer604completely separates from t the printed part, the tensioners increase tension on the flexible film layer604causing the flexible film layer604to flatten out.

FIG.6Fillustrates an example of the basin600, wherein the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer604, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer604. Notably, the printed part inFIG.6Fis larger than the printed part inFIG.6Aby the thickness of the previously printed print layer L. The process described above inFIGS.6A-6Fcan be repeated until all print layers are formed onto the printed part P and the print is complete.

FIGS.7A-7Fillustrate schematic views of an example basin700that includes tensioners, according to some examples. In the example ofFIGS.7A-7F, the basin700includes capstans702, a flexible film layer704, a print substrate706, side walls708, tensioners714, a platform712, and liquid resin R. The capstans702are configured to support the flexible film layer704and are located on the bottom side of the flexible film layer704and on top of the platform712. The capstans702are rotatable about the X-axis in either direction. The capstans702are located at the first end703of the basin700and the second end705of the basin700. The side walls708are coupled to the flexible film layer704at the first end703and the second end705of the basin, respectively, to allow the liquid resin R to be disposed within the basin700. The print substrate706is configured to provide reinforcement to the flexible film layer704. That is, the print substrate706is a rigid material that include mechanical stability, repeatability, and high tolerance to higher squish pressures while maintaining planarity that the flexible film layer704does not. Thus, by supporting the flexible film layer704with the print substrate706, the flexible film layer704is able to benefit from these advantages. The print substrate706may be a glass material that focuses a curing light720towards the printed part P. That is, the print substrate706may act as a window for the curing light720(FIG.7B).

Tensioners714may be located within the side walls708and coupled to the flexible film layer704. The tensioners714are configured to control the tension of the flexible film layer704by moving inwards towards the center of the basin700(e.g., to loosen tension) and moving outwards from the center of the basin700(e.g., to increase tension). In some examples, one of the tensioners714is fixed (i.e., does not move or increase/reduce tension) and the other one of the tensioners714controls the tension of the flexible film layer704. The tensioners714may apply tension by springs, vacuum, a mechanical actuator, and/or magnets. As the tensioners714increase and loosen tension on the flexible film layer704, the capstans702rotate about the X-axis allowing the flexible film layer704to move across the capstans702. In each ofFIGS.7A-7F, the build platform105includes a printed part P affixed to the build platform105interacting with the basin700.

FIG.7Aillustrates an example of the basin700wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin700. Here, the printed part P includes three distinct structures rather than a single structure as inFIG.2. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer704corresponding to one layer thickness. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the flexible film layer704for forming a single printed layer L on the bottom surface of the printed part P. Moreover, the tensioners714increase tension on the flexible film layer704by moving outward from the center of the basin700. Applying tension to the flexible film layer704causes the flexible film layer704to lay flat on the print substrate706thereby increasing the transparency of the flexible film layer704. Increasing the flatness and/or transparency of the flexible film layer704reduces defects caused in the printed part caused by any imperfections in the flexible film layer as a curing light720cures the liquid resin R through the flexible film layer704.

FIG.7Billustrates an example of the basin700wherein the curing light720exposes the liquid resin R disposed between the printed part P and the flexible film layer704. The curing light720cures the liquid resin R disposed between the printed part P and the flexible film layer704is cured to form a new part layer L. That is, the curing light720solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. Optionally, the light source of the curing light720may be located beneath the platform712. The curing light720may be provided by any light source known by those skilled in the art of SLA printing.

FIG.7Cillustrates an example of the basin700wherein the tensioners reduce tension on the flexible film layer704. That is, the curing light720(FIG.7B) solidifies the liquid resin R onto the surface of the printed part P becoming the new print layer L of the printed part P. Notably, the printed part P inFIG.7Cis larger than the printed part P inFIG.7Bby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer704such that a force must be applied to separate new print layer L and the flexible film layer704.

Moreover, the tensioners714reduce tension on the flexible film layer704(i.e., by moving inwards towards the center of the basin700) providing extra film length for the flexible film layer704. Thus, the data processing hardware115(FIG.1) instructs the build platform105to lift the printed part P in the vertical direction away from the platform712. Reducing tension on the flexible film layer704allows the build platform105to raise the printed part P to apply a force between the flexible film layer704and the printed part P.

FIG.7Dillustrates an example of the basin700wherein the flexible film layer704peels from the printed part P. That is, the data processing hardware115instructs the build platform105to move in the vertical direction further away from the print substrate706inducing a peel front F. Here, the printed part P affixed to the build platform105and the flexible film layer704adhered to the printed part P are lifted in the vertical direction away from the print substrate706. The exact curvature of the flexible film layer704depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the flexible film layer704. Notably, the reducing the tension and raising the build platform105induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer704) on both sides of the flexible film layer704. Here, the peeling process initiates on both the first end703and the second end705of the basin and converging in the center of the basin. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P. Optionally, the build platform105and the printed part P may not move further away from the platform712and the tensioners714move to an intermediate position within the side walls708. As such, the retraction of the tensioners714(not shown) provides tension on the flexible film layer704to peel from the printed part P. In some examples, the build platform105and the printed part P may move further away from the platform712and the tensioners move to the intermediate position within the side walls708.

FIG.7Eillustrates an example of the basin700wherein the flexible film layer704fully separates from the printed part. That is, the printed part P is now free to move in the vertical direction without causing movement of the flexible film layer704. After the flexible film layer704completely separates from t the printed part, the tensioners increase tension on the flexible film layer704causing the flexible film layer704to lay flat on the print substrate706.

FIG.7Fillustrates an example of the basin700, wherein the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer704, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer704. Notably, the printed part inFIG.7Fis larger than the printed part inFIG.7Aby the thickness of the previously printed print layer L. The process described above inFIGS.7A-7Fcan be repeated until all print layers are formed onto the printed part P and the print is complete.

FIG.8Aillustrates a perspective view of an example of a basin800,800athat includes a scroll tank. The basin800aincludes a flexible film layer804, a print substrate806, and side walls808. The flexible film layer804is coupled to a plank812on each end of the flexible film layer804. The plank812of the flexible film layer mechanically couples with tension adjusters814disposed on the side walls808. That is, the plank812of the flexible film layer804may be rotated and mechanically couple with any of the tensioner adjusters814. By rotating the plank812into the various tensioner adjusters814, the tension of the flexible film layer804is adjusted by the curvature of the flexible film layer.

The side walls808are coupled to the print substrate806. The print substrate806may be a glass material that focuses a curing light towards a printed part. That is, the print substrate806may act as a window for a curing light. The print substrate806is located beneath the flexible film layer804and provides support for the flexible film layer. The side walls808may include height adjusters818that adjusts the support that the print substrate806provides the flexible film layer804and thereby adjusting the tension of the flexible film layer804.

The tension (i.e., internal bending stresses) of the flexible film layer804force the flexible film layer to conform to the rigid print substrate806while still allowing the flexible film layer to be lifted off the print substrate806. In particular, the internal bending stresses causes the flexible film layer804to naturally relax into a continuous curved shape, but the print substrate806interferes with the flexible film layer804such that the flexible film layer804presses flat against the print substrate806(e.g., laminate against the print substrate806). By rotating the plank812to couple with one of the tension adjusters814the internal bending stress of the flexible film layer804may increase or decrease. Increasing or decreasing the internal bending stress of the flexible film layer804controls the natural curvature of the flexible film layer804and a flatness between the flexible film layer804and the print substrate806. The curvature of the scrolled ends of the flexible film layer804allows the entire flat area of the flexible film layer to rise the vertical direction without imparting horizontal forces as the radius of the curvature of the flexible film layers decreases. Thus, the flexible film layer804may be lifted from the print substrate806with very low force applied.

FIG.8Billustrates a perspective view of an example of a basin800,800bthat includes a scroll tank. The basin800bincludes a flexible film layer804, side walls808, and compliant walls816. The flexible film layer804is attached at each end to side walls808creating a curvature in the flexible film layer804(i.e., scroll tank design). That is, the internal bending stresses of the flexible film layer804may be utilized to force the flexible film layer804to conform to the rigid print substrate while still allowing the flexible film layer804to be lifted off the printed substrate. The compliant walls816may be thermoformed walls coupled to the top of the flexible film layer804and coupled to the side walls808. In some examples, the compliant walls816are pleated side walls thermoformed as a single parts with the active printing area. In other examples, the compliant walls816include foam material that allow for compliance within the compliant walls816. The compliant walls816are highly compliant and may further control internal stresses of the flexible film layer804. That is, as the flexible film layer804is raised and lowered, the compliant walls816expand or contract thereby decreasing or increasing internal stresses on the flexible film layer804respectively.

FIGS.8C-8Hillustrate schematic views of an example basin800that includes a scroll tank design, according to some examples. In the example ofFIGS.8C-8H, the basin800includes a flexible film layer804, a print substrate806, side walls808, and liquid resin R. The side walls808are coupled to planks812of the flexible film layer804at the first end803and the second end805respectively to allow the liquid resin R to be disposed within the basin800. Moreover, the planks812of the flexible film layer804are coupled to the side walls808such that a curvature is induced into the flexible film layer804. The print substrate806interferes with the curvature of the flexible film layer804causing the flexible film layer804to lay flat on top of the print substrate806. The print substrate806may be a glass material that focuses a curing light820towards the printed part P. That is, the print substrate806may act as a window for the curing light820.

FIG.8Cillustrates an example of the basin800wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin800. Here, the printed part P includes three distinct structures rather than a single structure as inFIG.2. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer804corresponding to one layer thickness. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the flexible film layer804for forming a single printed layer L on the bottom surface of the printed part P.

FIG.8Dillustrates an example of the basin800wherein the curing light820exposes the liquid resin R disposed between the printed part P and the flexible film layer804. The curing light820cures the liquid resin R disposed between the printed part P and the flexible film layer804is cured to form a new part layer L. That is, the curing light820solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. The curing light820may be provided by any light source known by those skilled in the art of SLA printing.

FIG.8Eillustrates an example of the basin800wherein the printed part P cures to the flexible film layer804. That is, the curing light820(FIG.8D) solidifies the liquid resin R onto the surface of the printed part P becoming the new print layer L of the printed part P. Notably, the printed part P inFIG.8Eis larger than the printed part P inFIG.8Dby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer804such that a force must be applied to separate new print layer L and the flexible film layer804.

FIG.8Fillustrates an example of the basin800wherein the flexible film layer804peels from the printed part P. That is, the data processing hardware115instructs the build platform105to move in the vertical direction away from the print substrate806inducing a peel front F. Here, the printed part P affixed to the build platform105and the flexible film layer804adhered to the printed part P are lifted in the vertical direction away from the print substrate806. The exact curvature of the flexible film layer804depends on several factors including, but not limited to, geometry of the printed part P, and the stiffness, or other characteristics, of the flexible film layer804. Notably, raising the build platform105induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer804) on both sides of the flexible film layer804. Here, the peeling process initiates on both the first end803and the second end805of the basin and converging in the center of the basin. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P. Here, the tension on the flexible film layer804remains constant as the plank812remains in the same position of the side wall808.

FIG.8Gillustrates an example of the basin800wherein the flexible film layer804fully separates from the printed part. That is, the printed part P is now free to move in the vertical direction without causing movement of the flexible film layer804. After the flexible film layer804completely separates from t the printed part, internal stresses of the flexible film layer804causes the flexible film layer804to return to the print substrate806laying flat.

FIG.8Hillustrates an example of the basin800, wherein the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer804, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer804. Notably, the printed part inFIG.8His larger than the printed part inFIG.8Cby the thickness of the previously printed layer. The process described above inFIGS.8C-8Hcan be repeated until all print layers are formed onto the printed part P and the print is complete.

FIGS.9A-9Fillustrate schematic views of an example basin900, according to some examples. In the example ofFIGS.9A-9F, the basin900includes capstan rings902, a flexible film layer904, a print substrate906, side walls908, air ports942, a platform912, and liquid resin R. The capstan rings902are configured to support the flexible film layer904and are located on the bottom side of the flexible film layer904and on top of the platform912. The surface of the capstan rings902may be configured to rotate about the X-axis in either direction. The capstan rings902are located at the first end903of the basin900and the second end905of the basin900. The side walls908are coupled to the flexible film layer904at the first end903and the second end905of the basin, respectively, to allow the liquid resin R to be disposed within the basin900. The print substrate906may be a glass material that focuses a curing light920towards the printed part P. That is, the print substrate906may act as a window for the curing light920(FIG.9B).

The air ports942may pull a vacuum downwards through the platform912towards the bottom of the basin900(e.g., depressurizing the region between the flexible film layer904and the print substrate906). The vacuum provides a force that pulls the flexible film layer904to lay flat on the print substrate906. The capstan rings902located at the first end903and second end905of the basin900, interfere with the flexible film layer904inducing a contour into the flexible film layer904. In each ofFIGS.9A-9F, the build platform105includes a printed part P affixed to the build platform105interacting with the basin900.

FIG.9Aillustrates an example of the basin900wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin900. Here, the printed part P includes three distinct structures rather than a single structure as inFIG.2. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer904corresponding to one layer thickness. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the flexible film layer904for forming a single printed layer L on the bottom surface of the printed part P. Moreover, the air ports942pull vacuum causing the flexible film layer904to lay flat on the print substrate906. Increasing the flatness and/or transparency of the flexible film layer904reduces defects caused in the printed part caused by any imperfections in the flexible film layer as a curing light920cures the liquid resin R through the flexible film layer904.

FIG.9Billustrates an example of the basin900wherein the curing light920exposes the liquid resin R disposed between the printed part P and the flexible film layer904. The curing light920cures the liquid resin R from the bottom side of the basin900through the print substrate906and the flexible film layer904creating a new print layer L of the printed part P. Optionally, the light source of the curing light920may be located beneath the platform912. The curing light920may be provided by any light source known by those skilled in the art of SLA printing. Here, the air ports942continue to pull vacuum holding the flexible film layer904flat against the print substrate906while the curing light920cures the liquid resin R.

FIG.9Cillustrates an example of the basin900wherein the liquid resin R disposed between the printed part P and the flexible film layer904is cured to form a new part layer L. That is, the curing light920(FIG.9B) solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. Notably, the printed part P inFIG.9Cis larger than the printed part P inFIG.9Bby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer904such that a force must be applied to separate new print layer L and the flexible film layer904. Notably, the air ports942terminate the vacuum force pulled against the flexible film layer904. Thus, the build platform105may now raise the printed part P and the flexible film layer904together.

FIG.9Dillustrates an example of the basin900wherein the build platform105lifts the printed part P and the flexible film layer from the print substrate906. Here, the flexible film layer904may overcome Stefan forces adhering the flexible film layer904and the print substrate906together. In particular, the data processing hardware115instructs the build platform105to move in the vertical direction away from the platform912and the print substrate906inducing a peel front F.

FIG.9Eillustrates an example of the basin900wherein the flexible film layer904peels from the printed part P. That is, the data processing hardware115instructs the build platform105to move in the vertical direction further away from the platform912inducing a peel front F. Here, the printed part P affixed to the build platform105and the flexible film layer904adhered to the printed part Pare lifted in the vertical direction away from the platform912. The exact curvature of the flexible film layer904depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the flexible film layer904. Notably, raising the build platform105induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer904) on both sides of the flexible film layer904. Here, the peeling process initiates on both the first end903and the second end905of the basin and converging in the center of the basin. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P.

FIG.9Fillustrates an example of the basin900wherein the flexible film layer904fully separates from the printed part. After the flexible film layer904fully separates from the printed part P, the air ports942pull vacuum downward again pulling the flexible film layer904to lay flat against the print substrate906. Moreover, the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer904, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer904. Notably, the printed part inFIG.9Fis larger than the printed part inFIG.9Aby the thickness of the previously printed layer. The process described above inFIGS.9A-9Fcan be repeated until all print layers are formed onto the printed part P and the print is complete.

FIGS.10A-10Dillustrate schematic views of an example basin1000, according to some examples. In the example ofFIGS.10A-10D, the basin1000includes a flexible film layer1004, a print substrate1006, side walls1008, air ports1042, a platform1012, and liquid resin R. The side walls1008are configured to induce a curvature into the flexible film layer1004. The side walls1008are coupled to the flexible film layer1004at the first end1003and the second end1005of the basin1000, respectively, to allow the liquid resin R to be disposed within the basin1000. Moreover, the flexible film layer1004is coupled to the side walls1008at a height substantially higher than the print substrate1006. Thus, as the flexible film layer1004lays flat on the print substrate1006, the flexible film layer1004defines a curvature at the first end1003and the second end1005of the basin1000. The print substrate1006may be a glass material that focuses a curing light1020towards the printed part P. That is, the print substrate1006may act as a window for the curing light1020.

The air ports1042may pull a vacuum downwards through the platform1012towards the bottom of the basin1000(e.g., depressurize the region between the flexible film layer1004and the platform1012/print substrate1006). The vacuum provides a force that pulls the flexible film layer1004to lay flat on the print substrate1006. The side walls10008located at the first end1003and second end1005of the basin1000, interfere with the flexible film layer1004inducing a contour into the flexible film layer1004. In each ofFIGS.10A-10D, the build platform105includes a printed part P affixed to the build platform105interacting with the basin1000.

FIG.10Aillustrates an example of the basin1000wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin1000. Here, the printed part P includes three distinct structures rather than a single structure as inFIG.2. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer1004corresponding to one layer thickness. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the flexible film layer1004for forming a single printed layer L one the bottom surface of the printed part P. Moreover, the air ports1042pull vacuum causing the flexible film layer1004to lay flat on the print substrate1006. Increasing the flatness and/or transparency of the flexible film layer1004reduces defects caused in the printed part caused by any imperfections in the flexible film layer as a curing light1020cures the liquid resin R through the flexible film layer1004.

FIG.10Billustrates an example of the basin1000wherein the curing light1020exposes the liquid resin R disposed between the printed part P and the flexible film layer1004. The curing light1020cures the liquid resin R from the bottom side of the basin1000through the print substrate1006and the flexible film layer1004creating a new print layer L of the printed part P. Optionally, the light source of the curing light1020may be located beneath the platform1012. The curing light1020may be provided by any light source known by those skilled in the art of SLA printing. Here, the air ports1042continue to pull vacuum holding the flexible film layer1004flat against the print substrate1006while the curing light1020cures the liquid resin R.

FIG.10Cillustrates an example of the basin1000wherein the liquid resin R disposed between the printed part P and the flexible film layer1004is cured to form a new part layer L. That is, the curing light1020(FIG.10B) solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. Notably, the printed part P inFIG.10Cis larger than the printed part P inFIG.10Bby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer1004such that a force must be applied to separate new print layer L and the flexible film layer1004. Notably, the air ports1042terminate the vacuum force pulled against the flexible film layer1004. Thus, the build platform105may now raise the printed part P and the flexible film layer1004together.

After the printed part P adheres to the print substrate1006, the flexible film layer1004may overcome Stefan forces adhering the flexible film layer1004and the print substrate1006together. In particular, the data processing hardware115instructs the build platform105to move in the vertical direction away from the platform1012and the print substrate1006inducing a peel front F. That is, the data processing hardware115instructs the build platform105to move in the vertical direction further away from the platform1012inducing a peel front F. Here, the printed part P affixed to the build platform105and the flexible film layer1004adhered to the printed part Pare lifted in the vertical direction away from the platform1012. The exact curvature of the flexible film layer1004depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the flexible film layer1004. Notably, lifting the build platform105induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer1004) on both sides of the flexible film layer1004. Here, the peeling process initiates on both the first end1003and the second end1005of the basin and converging in the center of the basin. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P.

FIG.10Dillustrates an example of the basin1000wherein the flexible film layer1004fully separates from the printed part. That is, the printed part P is now free to move in the vertical direction without causing movement of the flexible film layer1004. After the flexible film layer1004completely separates from the printed part, the air ports1042pull vacuum inducing the flexible film layer1004to lay flat on the print substrate1006again. Moreover, the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer1004, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer1004to cure the next layer of liquid resin R onto the printed part P. Notably, the printed part inFIG.10Dis larger than the printed part inFIG.10Aby the thickness of the previously printed layer. The process described above inFIGS.10A-10Dcan be repeated until all print layers are formed onto the printed part P and the print is complete.

FIGS.11A-11Fillustrate schematic views of an example basin1100that includes a scroll tank design, according to some examples. In the example ofFIGS.11A-11F, the basin1100includes a flexible film layer1104, a print substrate1106, side walls1108, air ports1142, and liquid resin R. The side walls1108are coupled to planks1112of the flexible film layer1104at the first end1103and the second end1105of the basin1100, respectively, to allow the liquid resin R to be disposed within the basin1100. Moreover, the planks1112of the flexible film layer1104are coupled to the side walls1108such that a curvature is induced into the flexible film layer1104. The print substrate1106interferes with the curvature of the flexible film layer1104causing the flexible film layer1104to lay flat on top of the print substrate1106. The print substrate1106may be a glass material that focuses a curing light1120towards the printed part P. That is, the print substrate1106may act as a window for the curing light420. The print substrate1106includes air ports1142that pull a vacuum downwards towards the bottom of the basin1100(e.g., depressurize the region between the flexible film layer1104and the print substrate1106). The vacuum in the air ports1142provides a suction that pulls that flexible film layer1104to lay flat on the print substrate1106.

FIG.11Aillustrates an example of the basin1100wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin1100. Here, the printed part P includes three distinct structures rather than a single structure as inFIG.2. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer1104corresponding to one layer thickness. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the flexible film layer1104for forming a single printed layer L on the bottom surface of the printed part P. Here, the air ports1142pull a vacuum to pull the flexible film layer1104downwards towards the print substrate1106.

FIG.11Billustrates an example of the basin1100wherein the curing light1120exposes the liquid resin R disposed between the printed part P and the flexible film layer1104. The curing light1120cures the liquid resin R disposed between the printed part P and the flexible film layer804is cured to form a new part layer L. That is, the curing light820solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. The curing light1120may be provided by any light source known by those skilled in the art of SLA printing.

FIG.11Cillustrates an example of the basin1100wherein the printed part P cures to the flexible film layer1104. That is, the curing light1120(FIG.11D) solidifies the liquid resin R onto the surface of the printed part P becoming the new print layer L of the printed part P. Notably, the printed part P inFIG.11Eis larger than the printed part P inFIG.11Dby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer1104such that a force must be applied to separate new print layer L and the flexible film layer1104. Thus, the air ports1142are closed off allowing removing the vacuum force holding the flexible film layer1104onto the print substrate1106.

FIG.11Dillustrates an example of the basin1100wherein the flexible film layer1104peels from the printed part P. That is, the data processing hardware115instructs the build platform105to move in the vertical direction away from the print substrate1106inducing a peel front F. Here, the printed part P affixed to the build platform105and the flexible film layer1104adhered to the printed part P are lifted in the vertical direction away from the print substrate1106. The exact curvature of the flexible film layer1104depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the flexible film layer1104. Notably, raising the build platform105induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer1104) on both sides of the flexible film layer1104. Here, the peeling process initiates on both the first end1103and the second end1105of the basin and converging in the center of the basin. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P. Here, the tension on the flexible film layer1104remains constant as the plank1112remains in the same position of the side wall1108.

FIG.11Eillustrates an example of the basin1100wherein the flexible film layer1104fully separates from the printed part. That is, the printed part P is now free to move in the vertical direction without causing movement of the flexible film layer1104. After the flexible film layer1104completely separates from t the printed part, internal stresses of the flexible film layer1104causes the flexible film layer1104to return to the print substrate1106laying flat.

FIG.11Fillustrates an example of the basin1100, wherein the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer1104, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer1104. Notably, the printed part inFIG.11Fis larger than the printed part inFIG.11Aby the thickness of the previously printed layer. The process described above inFIGS.11A-11Fcan be repeated until all print layers are formed onto the printed part P and the print is complete.

FIGS.12A-12Fillustrate schematic views of an example basin1200, according to some examples. In the example ofFIGS.12A-12F, the basin1200includes blocks1202, a flexible film layer1204, a print substrate1206, side walls1208, and liquid resin R. The blocks1202are configured to support the flexible film layer1204and are located on the bottom side of the flexible film layer1204. The blocks1202are located at the first end1203of the basin1200and the second end1205of the basin1200. In the example shown, the blocks1202are triangular in shape, however, it is understood that the blocks1202may include any geometric shape. In some examples, the blocks1202define a gap between the blocks1202and the print substrate1206. The side walls1208are coupled to the flexible film layer1204at the first end1203and the second end1205of the basin1200, respectively, to allow the liquid resin R to be disposed within the basin1200. The print substrate1206may be a glass material that focuses a curing light1220towards the printed part P. That is, the print substrate1206may act as a window for the curing light1220. The blocks1202located at the first end1203and second end1205of the basin1200, interfere with the flexible film layer1204inducing a contour into the flexible film layer1204. In each ofFIGS.12A-12K, the build platform105includes a printed part P affixed to the build platform105interacting with the basin1200.

FIG.12Aillustrates an example of the basin1200wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin1200. Here, the printed part P includes three distinct structures rather than a single structure as inFIG.2. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer1204corresponding to one layer thickness. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the flexible film layer1204for forming a single printed layer L on the bottom surface of the printed part P.

FIG.12Billustrates an example of the basin1200wherein the curing light1220exposes the liquid resin R disposed between the printed part P and the flexible film layer1204. The curing light1220cures the liquid resin R from the bottom side of the basin1200through the print substrate1206and the flexible film layer1204creating a new print layer L of the printed part P. Optionally, the light source of the curing light1220may be located beneath the print substrate1206. The curing light1220may be provided by any light source known by those skilled in the art of SLA printing.

FIG.12Cillustrates an example of the basin1200wherein the liquid resin R disposed between the printed part P and the flexible film layer1204is cured to form a new part layer L. That is, the curing light1220(FIG.12B) solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. Notably, the printed part P inFIG.12Cis larger than the printed part P inFIG.12Bby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer1204such that a force must be applied to separate new print layer L and the flexible film layer1204. Moreover, the basin1200include forced air1242provided to the bottom side of the flexible film layer1204. The forced air1242is provided between the blocks1202and the print substrate1206on the first end1203and the second end1205of the basin, thus pressurizing the region. Accordingly, the forced air1242overcomes the Stefan force between the flexible film layer1204and the print substrate1206. Thus, the build platform105may now raise the printed part P and the flexible film layer1204together.

FIG.12Dillustrates an example of the basin1200wherein the build platform105lifts the printed part P and the flexible film layer from the print substrate1206. Here, the flexible film layer1204may overcome Stefan forces adhering the flexible film layer1204and the print substrate1206together. In particular, the data processing hardware115instructs the build platform105to move in the vertical direction away from the print substrate1206inducing a peel front F. Here, the printed part P affixed to the build platform105and the flexible film layer1204adhered to the printed part Pare lifted in the vertical direction away from the print substrate1206. The exact curvature of the flexible film layer1204depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the flexible film layer1204. Notably, raising the build platform105induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer1204) on both sides of the flexible film layer1204. Here, the peeling process initiates on both the first end1203and the second end1205of the basin and converging in the center of the basin. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P.

FIG.12Eillustrates an example of the basin1200wherein the flexible film layer1204fully separates from the printed part. After the flexible film layer1204fully separates from the printed part P, flexible film layer1204returns back to laying flat on the print substrate1206. In some examples, the flexible film layer1204returns back to laying flat on the print substrate1206due to depressurizing the region between the flexible film layer1204and the print substrate1206. Alternatively, the flexible film layer1204returns back to the laying flat on the print substrate due to the elastic force of the flexible film layer1204(e.g., due to the tensioning of the film) without any assistance of depressurization. That is to say, while forced air is used to pressurize the region between the flexible film layer1204and the print substrate1206after/concurrently with printing a layer, no active pressurization/depressurization occurs after the printed layer is fully separate from the flexible film layer1204, and the inherent properties of the flexible film layer1204(e.g., elastic force or tension) re-laminates the flexible film layer1204over the print substrate.

FIG.12Fillustrates an example of the basin1200wherein the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer1204, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer1204. Notably, the printed part inFIG.12Fis larger than the printed part inFIG.12Aby the thickness of the previously printed layer. The process described above inFIGS.12A-12Fcan be repeated until all print layers are formed onto the printed part P and the print is complete.

FIGS.13A-13Eillustrate schematic views of an example basin1300, according to some examples. In the example ofFIGS.13A-13E, the basin1300includes a flexible film layer1304, a print substrate1306, side walls1308, and liquid resin R. The side walls1308are coupled to the flexible film layer1304at the first end1303and the second end1305of the basin, respectively, to allow the liquid resin R to be disposed within the basin1300. The print substrate1306may be a glass material that focuses a curing light1320towards the printed part P. That is, the print substrate1306may act as a window for the curing light1320. The print substrate1306includes a textured surface1306,1306a(e.g., a surface that is not smooth and has particular pattern such as bumps). The textured surface1306aof the print substrate1306is configured to reduce the surface area between the print substrate1306and the flexible film layer1304. That is, only the textured part of the textured surface1306acomes into contact with the flexible film layer1304, thus reducing the contacting surface area between the flexible film layer1304and the print substrate1306. The reduced surface area reduces Stefan forces adhering the flexible film layer1304and the print substrate1306together. In each ofFIGS.13A-13E, the build platform105includes a printed part P affixed to the build platform105interacting with the basin1300.

FIG.13Aillustrates an example of the basin1300wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin1300. Here, the printed part P includes three distinct structures rather than a single structure as inFIG.2. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer1304corresponding to one layer thickness. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the flexible film layer1304for forming a single printed layer L on the bottom surface of the printed part P.

FIG.13Billustrates an example of the basin1300wherein the curing light1320exposes the liquid resin R disposed between the printed part P and the flexible film layer1304. The curing light1320cures the liquid resin R from the bottom side of the basin1300through the print substrate1306and the flexible film layer1304creating a new print layer L of the printed part P. Optionally, the light source of the curing light1320may be located beneath the print substrate1306. The curing light1320may be provided by any light source known by those skilled in the art of SLA printing.

The curing light1320solidifies the liquid resin R onto the surface of the printed part P becoming the new print layer L of the printed part P. Notably, the printed part P inFIG.13Bis larger than the printed part P inFIG.13Aby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer1304such that a force must be applied to separate new print layer L and the flexible film layer1304.

Moreover, flexible film layer1304and the print substrate1306are adhered together by Stefan forces. Notably, the Stefan forces adhering the flexible film layer1304to the print substrate1306is reduced because the surface area between the flexible film layer1304and the print substrate1306is reduced by the textured surface1306a. The reduced surface area (and thereby reduced Stefan force) allows the flexible film layer1304to be lifted from the print substrate1306with a limited force applied. Thus, the build platform105may now raise the printed part P and the flexible film layer1304together.

FIG.13Cillustrates an example of the basin1300wherein the build platform105lifts the printed part P and the flexible film layer from the print substrate1306. Here, the flexible film layer1304may overcome Stefan forces adhering the flexible film layer1304and the print substrate1306together. In particular, the data processing hardware115instructs the build platform105to move in the vertical direction away from the print substrate1306inducing a peel front F. Here, the printed part P affixed to the build platform105and the flexible film layer1304adhered to the printed part P are lifted in the vertical direction away from the print substrate1306. The exact curvature of the flexible film layer1304depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the flexible film layer1304. Notably, raising the build platform105induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer1304) on both sides of the flexible film layer1304. Here, the peeling process initiates on both the first end1303and the second end1305of the basin and converging in the center of the basin. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P.

FIG.13Dillustrates an example of the basin1300wherein the flexible film layer1304fully separates from the printed part. After the flexible film layer1304fully separates from the printed part P, flexible film layer1304returns back to laying flat on the textured surface1306aof the print substrate1306.

FIG.13Eillustrates an example of the basin1300wherein the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer1304, commonly referred to as a “squish” move.

The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer1304. Notably, the printed part inFIG.13Eis larger than the printed part inFIG.13Aby the thickness of the previously printed layer. The process described above inFIGS.13A-13Ecan be repeated until all print layers are formed onto the printed part P and the print is complete.

FIGS.14A-14Fillustrate schematic views of an example basin1400, according to some examples. In the example ofFIGS.14A-14F, the basin1400includes a flexible film layer1404, a print substrate1406, a platform1412, side walls1408, and liquid resin R. The side walls1408are coupled to the flexible film layer1404at the first end1403and the second end1405of the basin, respectively, to allow the liquid resin R to be disposed within the basin1400. The side walls1408are configured to support the bottom side of the flexible film layer1404. In particular, the flexible film layer1404sits atop of a ledge of the side walls1408such that the side walls1408, when raised or lowered, can lift and lower the flexible film layer1404. The print substrate1406may be a glass material that focuses a curing light1420towards the printed part P. That is, the print substrate1406may act as a window for the curing light1420. In each ofFIGS.14A-14F, the build platform105includes a printed part P affixed to the build platform105interacting with the basin1400.

FIG.14Aillustrates an example of the basin1400wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin1400. Here, the printed part P includes three distinct structures rather than a single structure as inFIG.2. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer1404corresponding to one layer thickness. The one layer thickness refers to the amount of liquid resin R disposed between the printed part P and the flexible film layer1404for forming a single printed layer L on the bottom surface of the printed part P.

FIG.14Billustrates an example of the basin1400wherein the curing light1420exposes the liquid resin R disposed between the printed part P and the flexible film layer1404. The curing light1420cures the liquid resin R from the bottom side of the basin1400through the print substrate1406and the flexible film layer1404creating a new print layer L of the printed part P. Optionally, the light source of the curing light1420may be located beneath the print substrate1406. The curing light1420may be provided by any light source known by those skilled in the art of SLA printing.

FIG.14Cillustrates an example of the basin1400wherein the liquid resin R disposed between the printed part P and the flexible film layer1204is cured to form a new part layer L. That is, the curing light1420(FIG.14B) solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. Notably, the printed part P inFIG.14Cis larger than the printed part P inFIG.14Bby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer1404such that a force must be applied to separate new print layer L and the flexible film layer1404. Moreover, the side walls1408, located at the first end1403and the second end1405of the basin1400may be lifted to overcome Stefan forces between the flexible film layer1404and the print substrate1406. The side walls1408may be lifted by any actuation method such as pneumatic, mechanical actuation, hydraulic actuation, etc. After the flexible film layer1404overcomes, or partially overcomes, the Stefan forces adhering the flexible film layer1404to the print substrate1406, the build platform105may lift the printed part P and the flexible film layer1404from the print substrate1406.

FIG.14Dillustrates an example of the basin1400wherein the build platform105lifts the printed part P and the flexible film layer from the print substrate1406. Here, the flexible film layer1404may overcome Stefan forces adhering the flexible film layer1404and the print substrate1406together. In particular, the data processing hardware115instructs the build platform105to move in the vertical direction away from the print substrate1406inducing a peel front F. Here, the printed part P affixed to the build platform105and the flexible film layer1404adhered to the printed part P are lifted in the vertical direction away from the print substrate1406. The exact curvature of the flexible film layer1404depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the flexible film layer1404. Notably, raising the build platform105induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer1404) on both sides of the flexible film layer1404. Here, the peeling process initiates on both the first end1403and the second end1405of the basin and converging in the center of the basin. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P.

FIG.14Eillustrates an example of the basin1400wherein the flexible film layer1404fully separates from the printed part. After the flexible film layer1404fully separates from the printed part P, flexible film layer1404returns back to laying flat on the print substrate1406. Here, the flexible film layer1404may return back to the print substrate1406because the side walls1408are returned back to a resting (i.e., non-actuated state).

FIG.14Fillustrates an example of the basin1400wherein the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer1404, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer1404. Notably, the printed part inFIG.14Fis larger than the printed part inFIG.14Aby the thickness of the previously printed layer. The process described above inFIGS.14A-14Fcan be repeated until all print layers are formed onto the printed part P and the print is complete.

FIGS.15A-15Fillustrate schematic views of an example basin1500, according to some examples. In the example ofFIGS.15A-15F, the basin1500includes a flexible film layer1504, a print substrate1506, side walls1508, and liquid resin R. The side walls1508are coupled to the flexible film layer1504at the first end1503and the second end1505of the basin, respectively, to allow the liquid resin R to be disposed within the basin1500. The side walls1508are configured to support the bottom side of the flexible film layer1504. The flexible film layer1504is attached to the bottom of the basin1500. In some examples, the flexible film layer1504is tensioned to laminate over the bottom of the basin1500and the print substrate1506such that the top surface of the flexible film layer1504remains flat for the printing process. The print substrate1506may be a glass material that focuses a curing light1520towards the printed part P. That is, the print substrate1506may act as a window for the curing light1520. In each ofFIGS.15A-15F, the build platform105includes a printed part P affixed to the build platform105interacting with the basin1500.

FIG.15Aillustrates an example of the basin1500wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin1500. Here, the printed part P includes three distinct structures rather than a single structure as inFIG.2. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer1504corresponding to one layer thickness. The one layer thickness refers to the amount of liquid resin R disposed between the printed part P and the flexible film layer1504for forming a single printed layer L on the bottom surface of the printed part P.

FIG.15Billustrates an example of the basin1500wherein the curing light1520exposes the liquid resin R disposed between the printed part P and the flexible film layer1504. The curing light1520cures the liquid resin R from the bottom side of the basin1500through the print substrate1506and the flexible film layer1504creating a new print layer L of the printed part P. Optionally, the light source of the curing light1520may be located beneath the print substrate1506. The curing light1520may be provided by any light source known by those skilled in the art of SLA printing.

FIG.15Cillustrates an example of the basin1500wherein the liquid resin R disposed between the printed part P and the flexible film layer1504is cured to form a new part layer L. That is, the curing light1520(FIG.15B) solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. Notably, the printed part P inFIG.15Cis larger than the printed part P inFIG.15Bby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer1504such that a force must be applied to separate new print layer L and the flexible film layer1504. After the flexible film layer1504overcomes, or partially overcomes, the Stefan forces adhering the flexible film layer1504to the print substrate1506, the build platform105may lift the printed part P and the flexible film layer1504from the print substrate1506.

FIG.15Dillustrates an example of the basin1500wherein the build platform105lifts the printed part P and the flexible film layer from the print substrate1506. Here, the flexible film layer1504may overcome Stefan forces adhering the flexible film layer1504and the print substrate1506together. In particular, the data processing hardware115instructs the build platform105to move in the vertical direction away from the print substrate1506inducing a peel front F. Here, the printed part P affixed to the build platform105and the flexible film layer1504adhered to the printed part P are lifted in the vertical direction away from the print substrate1506. The exact curvature of the flexible film layer1504depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the flexible film layer1504. Notably, raising the build platform105induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer1504) on both sides of the flexible film layer1504. Here, the peeling process initiates on both the first end1503and the second end1505of the basin and converging in the center of the basin. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P.

FIG.15Eillustrates an example of the basin1500wherein the flexible film layer1504fully separates from the printed part and has returned to re-laminate the print substrate1504. In some examples, the flexible film layer1504returns to its initial position (e.g., laying flat on the print substrate1504) solely due to the tension of the flexible film layer1504. The flexible film layer1504may be stretched over the print substrate1504to form a flat print surface (e.g., the peripheral of the flexible film layer1504is affixed to the side walls1508). The elastic force exerted by the flexible film layer1504inFIG.15Dcauses the flexible film layer1504to return to its initial position and re-laminates the print substrate1506. InFIGS.15D-15E, as the build platform105travels upwards in the z-direction, the flexible film layer1504experiences both a “pulling-up” force due to the adhesion between the flexible film layer1504and the newly formed layer L, and a “pull-down” force due to the elasticity and the tendency of the flexible film layer to return to its initial position. As the build platform105continues to travel upward in z-direction, the pull-down force increases (e.g., due to the transformation of the flexible film layer1504) while the pull-up force decreases (e.g., due to the gradual separation of the flexible film layer1504and the part L). At a threshold point, the flexible film layer1504fully separates from the printed part, and returns to its initial position to re-laminate the print substrate1506. Comparing to a system where a blade, roller, pressurization or depressurization is used to assist the peeling of the parts, the process shown inFIGS.15D-15Eis simpler and relies exclusively on the inherent tensioning of the flexible film layer1504for peeling. The distance the build platform105is required to travel to complete the peel is at least a function of the internal properties of the flexible film layer1504, such as the size of the film, the material of the film, and/or the elasticity of the film, and can be set before printing starts.

FIG.15Fillustrates an example of the basin1500wherein the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer1504, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer1504. Notably, the printed part inFIG.15Fis larger than the printed part inFIG.15Aby the thickness of the previously printed layer. The process described above inFIGS.15A-15Fcan be repeated until all print layers are formed onto the printed part P and the print is complete.

FIGS.16A-16Fillustrate schematic views of an example basin1600, according to some examples. The peeling process illustrated inFIGS.16A-16Fis similar to that inFIGS.15A-15F, but uses pressurization for assisted-peeling.

InFIG.16C, after the new layer L has been printed and as the build platform105moves upward in the z-direction (or before the build platform105starts to move upward in the z-direction) the region between the flexible film layer1604and the print substrate1606is inflated to assisted the separation of the flexible film layer1604and the printed part L and the print substrate1606. Comparing to basin1200as illustrated in

FIGS.12A-12F, the basin1600does not have additional blocks (e.g., blocks1202) for defining the air channels. Instead, holes are directly located on the bottom of the print substrate1606. AlthoughFIG.16Cshows the pressurization happening before the build platform105lifts in the z-direction, in other examples, the pressurization process can happen simultaneously with or after the build platform105first starts to lift in the z-direction.

FIGS.17A-17Fillustrate schematic views of an example basin1700, according to some examples. The peeling process illustrated inFIGS.17A-17Fis similar to that inFIGS.16A-16F, but additionally uses depressurization to re-laminate the flexible film layer1704over the print substrate1706.

InFIG.17D, as the build platform105travels upward in the z-direction (or after the build platform105has come to a stop), to assist peeling of the flexible film layer1704from the newly printed layer L, and to return the flexible film layer1704to the initial position, the region between the flexible film layer1704and the print substrate1706is depressurized. As a result, the pressure differential as well the elasticity of the flexible film layer1704force the flexible film layer1704to return to its initial position to re-laminate over the print substrate1706. In some implementations, the step of pressurization (e.g., as illustrated inFIG.17C) is omitted, and only depressurization is used for peeling. In some examples, the depressurization process illustrated inFIG.17Dor the pressurization process illustrated inFIG.17Cmay happen prior to, simultaneously with, or after the build platform105first starts to lift in the z-direction.

FIGS.18A-18Fillustrate schematic views of an example basin1800, according to some examples. In the example ofFIGS.18A-18F, the basin1800includes a flexible film layer1804, a print substrate1806, side walls1808, and liquid resin R. The side walls1808are coupled to the flexible film layer1804at the first end1803and the second end1805of the basin, respectively, to allow the liquid resin R to be disposed within the basin1800. The side walls1808are configured to support the bottom side of the flexible film layer1804. The flexible film layer1804is attached to the bottom of the basin1800. In some examples, the flexible film layer1804is tensioned to laminate over the bottom of the basin1800and the print substrate1806such that the top surface of the flexible film layer1804remains flat for the printing process. The print substrate1806may be a glass material that focuses a curing light1820towards the printed part P. That is, the print substrate1806may act as a window for the curing light1820. In each ofFIGS.18A-18F, the build platform105includes a printed part P affixed to the build platform105interacting with the basin1800. The mechanical raisers1807are configured to raise portions of the flexible film layer1804upward in the z-direction. The mechanical raisers1807can extend across the width of the basin1800, or are localized to “poke” selected regions of the flexible film layer1804.

FIG.18Cillustrates an example of the basin1800wherein the liquid resin R disposed between the printed part P and the flexible film layer1804is cured to form a new part layer L. That is, the curing light1820(FIG.18B) solidifies the liquid resin R onto the bottom surface of the printed part P to form the new print layer L of the printed part P. Notably, the printed part P inFIG.18Cis larger than the printed part P inFIG.18Bby the size of the new print layer L. The new print layer L of the printed part P adheres to the flexible film layer1804such that a force must be applied to separate new print layer L and the flexible film layer1804. Moreover, the mechanical raisers1807may be lifted to overcome Stefan forces between the flexible film layer1804and the print substrate1806. The mechanical raisers1807may be lifted by any actuation method such as pneumatic, mechanical actuation, hydraulic actuation, etc. After the flexible film layer1804overcomes, or partially overcomes, the Stefan forces adhering the flexible film layer1804to the print substrate1806, the build platform105may lift the printed part P and the flexible film layer1804from the print substrate1806.

FIG.18Eillustrates an example of the basin1800wherein the flexible film layer1804fully separates from the printed part and has returned to re-laminate the print substrate1804. In some examples, the flexible film layer1804returns to its initial position (e.g., laying flat on the print substrate1806) as or after the mechanical raisers1807move downward in the z-direction.

Although the aforementioned description and related figures illustrate distinctive peeling systems and processes, in practice, any number of the illustrated peeling systems and processes can be combined to improve peeling efficiency. For example, the mechanical raiser based peeling system illustrated inFIGS.18A-18Emay be combined with the blade202inFIGS.2A-2K, and/or with the pressurization/depressurization assisted peeling inFIGS.16A-16F,FIGS.17A-17F.

FIGS.19A-19Jillustrate schematic views of an example basin1900, according to some examples. In the example ofFIGS.19A-19J, the basin1900includes a flexible film layer1904, a print substrate1906, side walls1908, and liquid resin R. The side walls1908are coupled to the flexible film layer1904at the first end1903and the second end1905of the basin, respectively, to allow the liquid resin R to be disposed within the basin1900. The print substrate1906includes a textured surface1906,1906a(e.g., a surface that is not smooth and has particular pattern such as a sinusoidal texture). The textured surface1906aof the print substrate1906is configured to reduce the surface area between the print substrate1906and the flexible film layer1904. That is, only the textured part of the textured surface1906acomes into contact with the flexible film layer1904, thus reducing the contacting surface area between the flexible film layer1304and the print substrate1906. In some embodiments, texture1906is introduced to print substrate1904to allow sufficient air flow between the film1902and the print substrate1904, mitigating the formation of low-pressure regions as the part lifts with the build platform. The texture1906can be designed as described below to produce minimal optical artifacts, lensing of the light, local optically coupled zones, blurring, etc., in order to maintain accurate prints. The reduced surface area reduces Stefan forces adhering the flexible film layer1904and the print substrate1906together. In each ofFIGS.13A-13E, the build platform105includes a printed part P affixed to the build platform105interacting with the basin1900.

In some implementations, the textured surface1906ais produced by injection molding the pattern directly into the print substrate1906, cutting the pattern (e.g., milling) directly into the print substrate1906, etching the pattern into the print substrate1906(e.g., HF glass etching), applying a film that contains geometric texture onto the print substrate1906or the LCD screen (e.g., UV roll to roll embossing, roll to roll hot embossing). Alternatively, the textured surface1906acan be formed directly into a separate film and then casting the film between the print substrate1906and the flexible film layer1904, or applying the film directly onto an LCD screen. In some implementations, the textured surface1906ais directly cast onto the print substrate1906or to an LCD screen. The textured surface1906amay be made using rubbery or elastomer material to provide compliance.

In some implementations, the flexible film layer1904has limited contact area with the textured surface1906a(e.g., the flexible film layer1904rests on top of individual peaks of the textured surface1906a). This can cause parts of the print area to have a different amount of optical coupling, causing power variation. To mitigate this effect, textured surface1906acan have a high frequency pattern to the bottom of the print surface (e.g., stochastic texture), or increasing surface hardness of texture to help reduce surface are contact.

FIG.19Aillustrates an example of the basin1900wherein data processing hardware115instructs the build platform105to position the printed part P at a first vertical position in the basin1900. At the first vertical position, the bottom surface of the printed part P is positioned a first distance D1from the flexible film layer1904corresponding to one layer thickness. The one layer thickness refers to the depth of liquid resin R disposed between the printed part P and the flexible film layer1904for forming a single printed layer L on the bottom surface of the printed part P. The flexible film layer1904is highly tensioned and laminates the curing plane.FIG.19Billustrates a perspective view of the print substrate1906that includes the textured surface1906a.

FIG.19Cillustrates an example of the basin1900wherein the curing light1920exposes the liquid resin R disposed between the printed part P and the flexible film layer1904. The curing light1920cures the liquid resin R from the bottom side of the basin1300through the print substrate1906and the flexible film layer1304creating a new print layer L of the printed part P. Optionally, the data processing hardware115may operate the print substrate1906while the curing light1920exposes the liquid resin R. That is, the print substrate1906oscillates from a first sinusoidal position1906,1906a1(denoted by the solid line) and a second sinusoidal position1906,1906a2. The operation of the print substrate1906during the curing process is configured to reduce any optical artifacts of the print substrate1906(e.g., bumps, folds, etc.). The textured surface1906acan be designed as described below to produce minimal optical artifacts, lensing of the light, local optically coupled zones, blurring, etc., in order to maintain accurate prints.

As shown inFIGS.19D and19E, the operation frequency of the print substrate1906may influence light distortions of the curing light1920. In the example shown, the print substrate1906operates at a high frequency inFIG.19Dand a lower frequency inFIG.19E. As such, the high frequency creates multiple distortions in the textured surface1906aof the print substrates1906thereby distorting the light through the print substrate1906. The arrows in19D illustrate the distorted light flow from the curing light1920through the print substrate1906. In contrast, the low frequency operation of the print substrate1906reduces distortions in the print substrate1906such that the curing light1920passes through the print substrate with minimal light distortions. Accordingly, operating the print substrate1906lower frequency may reduce light distortion and thereby increase print quality of the printed part P.

FIG.19Fillustrates an example of the basin1900wherein the build platform105lifts the printed part P and the flexible film layer from the print substrate1906. Here, the flexible film layer1904may overcome Stefan forces adhering the flexible film layer1904and the print substrate1906together. In particular, the data processing hardware115instructs the build platform105to move in the vertical direction away from the print substrate1906inducing a peel front F. Here, the printed part P affixed to the build platform105and the flexible film layer1904adhered to the printed part P are lifted in the vertical direction away from the print substrate1906. The exact curvature of the flexible film layer1904depends on several factors including, but not limited to, geometry of the printed part P, geometric relationship between the blade and the printed part P, and the stiffness, or other characteristics, of the flexible film layer1904. Notably, raising the build platform105induces a high peel angle θP(i.e., angle between the new print layer L of the printed part P and the flexible film layer1904) on both sides of the flexible film layer1304. Here, the peeling process initiates on both the first end1903and the second end1905of the basin and converging in the center of the basin. During the peeling process, the printed part P sticks to and lifts the film1904in the z-direction. As a result, a low-pressure region forms between the flexible film layer1904and the print substrate1906, causing high peel force and unpredictable peeling result. The high peel angle θPreduces the force applied to the printed part P (e.g., by localizing the peel front F) providing increased print quality of the printed part P.

FIG.19Gillustrates an example of the basin1900wherein the flexible film layer1904fully separates from the printed part. After the flexible film layer1904fully separates from the printed part P, flexible film layer1904returns back to laying flat on the textured surface1906aof the print substrate1906.

FIG.19Hillustrates an example of the basin1900wherein the data processing hardware115instructs the build platform105to lower the printed part P in the vertical direction towards the flexible film layer1904, commonly referred to as a “squish” move. The build platform105lowers the printed part P such that the bottom surface of the new print layer L of the printed part P is spaced the first distance D1equal to one layer thickness from the flexible film layer1904. Notably, the printed part inFIG.13His larger than the printed part inFIG.19Aby the thickness of the previously printed layer.

FIG.19Ishows the force experienced by the build platform during the peeling cycle when the flexible film layer1904is highly tensioned and laminates the print substrate1906—a sudden increase in force is experienced by the build platform105.FIG.19J, on the other hand, shows the force experience by the build platform105when the flexible film layer1904is allowed to freely move over the print substrate1906—a smaller magnitude of force is experienced by the build platform105(with a maximum peel force around 17 N), and the increase of force is slower and smoother.

In some implementations, the textured surface1906ahas a low frequency geometric pattern (e.g., shallow2D sine waves) to allow minimal optical distortion while providing airflow. The pattern should be much larger than the expected pixel size in order to minimize optical distortions. Varying the amplitude and period of the pattern allows one to tune the optical lensing that occurs as well as the air flow that is allowed through the system. This pattern can be applied in a grid (rectangular, hex, parallelogram, etc.) or randomly spaced throughout the print substrate1906. Additional features such as vents or holes can be added outside of the printing area to reduce air flow restriction outside of the printing build area.

A high frequency, stochastic texture can be added to the interface of the flexible film layer1904and the print substrate1906. This texture can be adhered to either the print substrate1906(e.g., glass surface of LCD screen) or used as the bottom layer of a laminate stack in flexible film layer1904. This texture can be formed by coating or embossing a film during the roll-to-roll film processing. Examples include matte films, anti-Newton ring (ANR) films, etc.

In some implementations, the textured surface1906acan be moved during the exposure period (e.g., moving film with the texture) to attenuate any optical effects. The preferred motion is half of a texture period in the X and Y directions, and the period of the motion would be shorter than the exposure period.

If the texture's position in XY is known as well as its optical effect, the exposed image can correct for the distortion. A number of calibration routines such as multipoint can be used to achieve this.

In some embodiments, texture geometry can be variable across the printing region to compensate for known and consistent distortions in the optical system. Optimized textures in the center or edges of the print region could blur a seam line or correct for field curvature.

Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Further, though advantages of the present invention are indicated, it should be appreciated that not every example of the technology described herein will include every described advantage. Some implementations may not implement any features described as advantageous herein and in some instances one or more of the described features may be implemented to achieve further implementations. Accordingly, the foregoing description and drawings are by way of example only.

Various aspects of the present disclosure may be used alone, in combination, or in a variety of arrangements not specifically discussed in the implementations described in the foregoing and is therefore not limited in its application to the details and arrangement of components set forth in the foregoing description or illustrated in the drawings. For example, aspects described in one example may be combined in any manner with aspects described in other implementations.

Use of ordinal terms such as “first,” “second,” “third,” etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.

Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.