Patent ID: 12214550

DESCRIPTION OF THE INVENTION

In the following discussion that addresses a number of embodiments and applications of the present invention, reference is made to the accompanying drawings that form a part thereof, where depictions are made, by way of illustration, of specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized, and changes may be made without departing from the scope of the invention. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements.

In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well known structures, components and/or functional or structural relationship thereof, etc., have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings.

Throughout the specification and claims, terms may have nuanced meanings suggested or implied in context beyond an explicitly stated meaning. Likewise, the phrase “in one embodiment/example” as used herein does not necessarily refer to the same embodiment and the phrase “in another embodiment/example” as used herein does not necessarily refer to a different embodiment. It is intended, for example, that claimed subject matter include combinations of example embodiments in whole or in part.

Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and or steps. Thus, such conditional language is not generally intended to imply that features, elements and or steps are in any way required for one or more embodiments, whether these features, elements and or steps are included or are to be performed in any particular embodiment.

The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present. The term “and or” means that “and” applies to some embodiments and “or” applies to some embodiments. Thus, A, B, and or C can be replaced with A, B, and C written in one sentence and A, B, or C written in another sentence. A, B, and or C means that some embodiments can include A and B, some embodiments can include A and C, some embodiments can include B and C, some embodiments can only include A, some embodiments can include only B, some embodiments can include only C, and some embodiments include A, B, and C. The term “and or” is used to avoid unnecessary redundancy. Similarly, terms, such as “a, an,” or “the,” again, may be understood to convey a singular usage or to convey a plural usage, depending at least in part upon context. In addition, the term “based on” may be understood as not necessarily intended to convey an exclusive set of factors and may, instead, allow for existence of additional factors not necessarily expressly described, again, depending at least in part on context.

While exemplary embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Thus, nothing in the foregoing description is intended to imply that any particular feature, characteristic, step, module, or block is necessary or indispensable. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions, and changes in the form of the methods and systems described herein may be made without departing from the spirit of the invention or inventions disclosed herein. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the appended claims.

As used in this disclosure, the term “comprise” and variations of the term, such as “comprising” and “comprises”, are not intended to exclude other additives, components, integers or steps. For purpose of description herein, the terms “upper”, “lower”, “left”, “right”, “front”, “rear”, “horizontal”, “vertical” and derivatives thereof shall relate to the invention as oriented in figures. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristic relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Turning now to the figures,FIG.1is an image of a 3D-printed objected1being separated from a prior art build platform2using a conventional tool3, which typically include sharp-edged scrapers or the like. As may be gleaned from this view, this prior art method of separating 3D-printed parts or objects from a prior art build platform is cumbersome, must be performed necessarily by hand or manually, and creates the issues that the present invention is designed to avoid.

Turning to the next set of figures,FIG.1A-FIG.1Billustrate a basic system and method in accordance with some exemplary embodiments of the present invention. From these views, system100is shown with a 3D-printed object101that has been printed or built onto a build platform that includes a build plate102in accordance with the present invention. As may be gleaned fromFIG.1A, and especially the subsequentFIG.1B, at least a portion of the build platform102is flexible. For example, and without limiting the scope of the present invention, a top surface of the build platform, such as a build plate102that is in contact with or onto which the 3D-printed object is printed on, is flexible or bendable. This flexibility allows at least a portion of the build platform102to bend in a manner such that a bottom surface of the 3D-printed object and a top surface of the build platform are separated or create a separation103. In this way, any forming material coupling the 3D-printed object to the surface of the build platform is decoupled from the build platform and thus the 3D-printed object separated from the build platform.

Rather than using a build platform that is completely rigid, for example using blocks of aluminum or very rigid inflexible plates of steel or ceramic that makes them impossible to bend, a flexible build plate201may be manufactured using multiple layers including less rigid materials. However, the flexibility element must be managed because too much flexibility in the build platform may introduce accuracy issues during the printing process. Accordingly, the present invention introduces a method of creating a build platform that offers both, rigidity during 3D printing, and flexibility during the separation process.

Turning now to the next figure,FIG.2-FIG.3illustrate a system and method in accordance with some exemplary embodiments of the present invention. More specifically,FIG.2-FIG.3depict build platform200, which is formed by a sandwiched multi-layer structure that is configured for creating localized tilting/movement/peeling/deformation underneath the 3D-printed objects. Build platform200may be at least partially flexible and may include: a flexible layer201providing a top surface of the build platform; and a rigid layer203situated below and coupled to the flexible layer so that applying a force on the flexible layer bends at least a portion of the flexible layer without bending the rigid layer. Moreover, in this embodiment, a middle layer202may comprise of a thin flexible material such as silicon, foam, or velcro. The top layer201may be a sheet of a rigid material which has some flexibility such as carbon fiber sheets.

Accordingly, in some exemplary embodiments, a build platform200for a stereolithographic printer, may include a flexible layer201having a printable surface201afor building 3D-printed objects on the printable surface201aof the flexible layer201. Moreover, to ensure stability during printing and to structurally support flexible layer201, build platform200may include a rigid layer203coupled to the flexible layer so that applying a force on the flexible layer deforms a localized portion of the printable surface without deforming the rigid layer. In some exemplary embodiments, flexible layer201comprises a carbon fiber layer that serves as the printable surface201aof the flexible layer201.

The rigid layer203may comprise aluminum or steel, or both, and is typically a sturdy layer that provides stability and support for the forces necessary for building the 3D-printed objects on the printable surface201aof the flexible layer201. As shown inFIG.2andFIG.3, build platform200may further include a middle layer202that is sandwiched between the flexible layer and rigid layer. In some exemplary embodiments, the middle layer202comprises a silicon layer. In some exemplary embodiments, the middle layer202comprises a foam layer. In some exemplary embodiments, the middle layer202comprises a Velcro layer.

After the 3D printing process is completed, the area underneath the 3D-printed object is pressed down and the part comes off very easily. As shown in the following figure,FIG.3illustrates this method that may be performed by a system employing build platform200in accordance with the present invention. Method300creates a local peeling of the build plate that is enough to initiate a propagation of the gap301between the 3D-printed object and build platform200, resulting in separating the 3D-printed object completely. This avoids having to use tools that can damage the 3D-printed part or hurt the user handling the manual separation.

Turning now to the next set of figures,FIG.4illustrates build platform in accordance with some exemplary embodiments of the present invention. More specificallyFIG.4illustrates a block diagram of a stereolithographic printer400. In this exemplary embodiment, a 3D printer—for example a stereolithographic printer—is configured to facilitate separation of the 3D-printed objects from a build platform.

Printer400may include a light source401, reservoir tank402for storing a forming material, and a build platform403. The build platform403in accordance with the present invention, may comprise of: a flexible build plate404for providing a top surface of the build platform on which 3D-printed objects are built; and a build assembly405situated below and coupled to the build plate404to provide structural stability and so that applying a force on the build plate404bends at least a portion of the flexible build plate404without bending the build assembly405; an actuator406coupled to the build platform403; and a controller407in communication with the actuator406, the controller407configured to activate the actuator406and apply a force on the flexible build plate404to bend at least a portion of the build plate404so as to create a gap adapted to separate a 3D-printed object created on the build platform. In exemplary embodiments, a sensor408may be coupled to the base assembly405and adapted to detect whether the removable build plate404is coupled on the base assembly405.FIG.4Ais an image of a build platform in accordance with some exemplary embodiments of the present invention.

In some exemplary embodiments, instead of actuator406, other means of bending or changing a stiffness or rigidity of the build plate may be employed. For example, and without limiting the scope of the present invention, instead of actuator406, system400may employ a vibration module that includes a vibration motor coupled to build plate404of build platform403such that when activated by controller407, the vibration motor will cause build plate404to vibrate cause a 3D-printed object to detach therefrom due to vibration.

Similarly, in another embodiment, instead of actuator406, a module set to apply an electric charge to build plate404may be employed. In such embodiment, build plate404may include a piezoelectric material that changes its rigidity or stiffness when the electric charge is applied to it. In this way, for example and without limiting the scope of the present invention, instead of actuator406, system400may employ a module configured to send an electric charge to build plate404of build platform403such that when activated by controller407, the module will send the electric charge to the build plate and cause build plate404to change its rigidity causing a 3D-printed object to detach therefrom due to the change in stiffness or rigidity of the build plate.

FIG.5illustrates build platform in accordance with some exemplary embodiments of the present invention. More specifically,FIG.5depicts build platform500, which utilizes similar principles by employing a mechanism to tilt/move/peel the build platform underneath the 3D-printed object in order to facilitate separation of the 3D-printed object from the build platform. In this exemplary embodiment, build platform500comprises of a flexible layer501providing a top surface of the build platform; a rigid layer503situated below and coupled to the flexible layer501so that applying a force on the flexible layer501bends at least a portion of the flexible layer501without bending the rigid layer503. Moreover, in this embodiment, a middle layer502amay comprise of a special separation between the flexible layer and the rigid layer. The separation may be facilitated by way of spring elements502that couple the flexible layer501to the rigid layer503and create the special separation502abetween the two layers. In exemplary embodiments, the flexible layer may be bendable by means of separating the flexible layer into two components501aand501b, that ware coupled together with a hinge mechanism or a means that allows the two components501aand501bto pivot about an axis. In this way, the flexible layer on the top may be split into two sections by application of a force, thereby bending the top surface of the build platform. Because on spring elements502are situated at terminal ends of the build platform500, pressing down on the build platform will tilt or bend a portion of the build platform to create a gap505that propagates and separates the 3D-printed object.FIG.5A-FIG.5Cillustrate a method that may be performed by system500in accordance with the present invention. As may be gleaned from these views, a force F applied on either spring element causes the bend or split in the top surface of the build plate.

FIG.6illustrates build platform in accordance with some exemplary embodiments of the present invention.FIG.6A-FIG.6Billustrate a method that may be performed by system600in accordance with the present invention. More specifically, build platform600is shown comprising a flexible layer601, coupled to a rigid layer602by way of securing components601aand601b. Furthermore, an actuator603may be situated below the flexible layer601in order to bend at least a portion of the flexible layer and create a gap adapted to separate a 3D-printed object created on the build platform600.

This embodiment employs an actuator to bend the flexible layer upward in order to separate the 3D-printed object as shown inFIG.6A-FIG.6B. The force is applied on the underside side of the flexible layer using a button or a spring-loaded system and when the user wants to separate the parts, the button may be pressed, the flexible layer may bend, and the 3D-printed object separates. The flexible layer may be coupled to terminal ends of the build platform to have the ability to fully bend.

FIG.7illustrates build platform in accordance with some exemplary embodiments of the present invention.FIG.7A-FIG.7Billustrate a method that may be performed by system700in accordance with the present invention. In this embodiment, the force is applied from the side to make the flexible layer bend and separate the 3D-printed object. The flexible layer may be preferably restricted or coupled to one side only and should have the ability to move sideways. More specifically, build platform700is shown comprising a flexible layer701, coupled to a rigid layer702by way of at least one securing component701asituated at one terminal end of the build platform701. Furthermore, an actuator703may be situated so that a force enacted by activating the actuator703is applied on one of the sides, typically opposite of the side secured by securing component701a. When the actuator is activated, the flexible layer701is bent to form a gap505that facilitates a separation of 3D-printed object101off of the build platform700.

FIG.8illustrates a flow chart of a method in accordance with some exemplary embodiments of the present invention. More specifically, this figure shows method800, which may include the steps of: (801) creating a 3D-printed object on a flexible build platform; (802) applying a force to a portion of the flexible build platform to bend at least a portion of the flexible build platform; and (803) separating the 3D-printed object from the flexible build platform.

Turning now to the next set of figures,FIG.9andFIG.10illustrate build platforms in accordance with some exemplary embodiments of the present invention. More specifically, these figures show exemplary embodiments in accordance with some aspects of the invention that involve a build platform for a stereolithographic printer that includes an alignment module. The build platform may comprise a removable build plate having a build surface for building 3D-printed objects on the build platform, a base assembly removably coupled to the removable build plate, and a magnetic alignment module adapted to magnetically move the removable build plate along a surface of the base assembly such that the removable build plate automatically self-aligns along a boundary of the base assembly and magnetically couples to the base assembly.

To these ends, a build platform such as build platform900, may include several layers, as shown in each figure. InFIG.9, build platform900is shown with four basic layers or portions of the build platform. For example, a carbon fiber layer901may be suitable for a build plate of the build platform. Layer902may be a composite layer that is integral with or is adhered to layer901, and which is embedded with magnets. Layer903may be an aluminum plate that forms a top layer or surface of a build assembly to which the build plate (layers901and902) is magnetically coupled to. Like layer902, layer903may comprise embedded magnets or magnetic components. Layer904forms a rigid layer or structure for the base assembly of the build platform900. This layer may comprise aluminum or steel, or a similarly suitable hard but light-weight material.

InFIG.10, build platform900is shown with five layers or portions of the build platform. For example, a spring steel layer910may be suitable for a build plate of the build platform. Layer911may be a composite layer that is integral with or is adhered to layer910, and which is embedded with magnets. Layer912may include a rubber layer or the like. Layer913may include aluminum plate that forms a top layer or surface of a build assembly to which the build plate is magnetically coupled to. Like layer910, layer913may comprise embedded magnets or magnetic components. Layer914forms a rigid layer or structure for the base assembly of the build platform900. This layer may comprise aluminum or steel, or a similarly suitable hard but light-weight material.

In exemplary embodiments, build plate surfaces may include carbon fiber or spring steel. To improve accuracy and reliability of 3D prints, sanded and or textured versions of both these materials may be employed as well.FIG.11A-11Bare images of two types of build platforms in accordance with some exemplary embodiments of the present invention.FIG.11Ashows an aluminum base assembly above a sanded carbon fiber build plate.FIG.11Bshows an aluminum base assembly above a carbon fiber build plate, wherein the carbon fiber surface has been machine-grooved.FIG.12A-12Bare images of two other types of build platforms in accordance with some exemplary embodiments of the present invention.FIG.12Ashows a smooth aluminum base assembly above a smooth carbon fiber build plate.FIG.12Bshows a sanded aluminum base assembly above a sanded spring steel build plate.

As will be described in more detail below, in some embodiments of the present invention, there are important objectives for a removable build plate, including but not limited to auto-alignment, sealability, and easy removal.

Turning to the next figure,FIG.13illustrates a build platform in accordance with some exemplary embodiments of the present invention in which an alignment module is employed. What makes a removable build plate in accordance with at least one embodiment of the present invention unique is the configuration and use of an alignment module adapted to auto-align, in addition to specifically securing the build plate to a base assembly of the build platform. The auto-alignment capability ensures the build plate is lined up against the platform properly, since if the plate is mis-aligned, this could result in a damaged resin tank, and/or failed prints.

As shown inFIG.13, a build platform1300in accordance with the present invention, may comprise a removable build plate1301having a build surface1303for building 3D-printed objects on the build platform; a base assembly1302removably coupled to the removable build plate1301; and an alignment module1304adapted to magnetically move the removable build plate along a surface1306of the base assembly1302such that the removable build plate1301automatically self-aligns along a boundary of the base assembly1302and magnetically couples to the base assembly1302.

In some exemplary embodiments, a set of magnets are disposed on corresponding substrates1305and1306of the removable build plate1301and the base assembly1302, respectively.FIG.14illustrates a layer or substrate employed by alignment module1304on which a plurality of magnets is dispose in accordance with some exemplary embodiments of the present invention.

For example, and without limiting the scope of the present invention, a substrate1305may be attached or adhered to a surface of build plate1301, underneath printable surface1303and embed a plurality of magnets inside or within the substrate1305. In exemplary embodiments, a first configuration of magnets are disposed on a surface of the removable build plate—for example on a substrate1305—such that a first set of magnets1306,1307,1308,1309,1310, and1311—are distributed along a perimetrical boundary1312of the surface of the substrate, and a second set of the magnets are distributed in two clusters1313and1314along a center region of the surface or substrate1305, the center region divided by a centric boundary1315. In this configuration, and as shown, magnets1306,1308, and1309, for example, may have a first polarity (a north polarity for example) and magnets1307,1310, may have the opposite polarity (a south polarity for example). When coupled against a second surface of the alignment module, such as substrate1306, the interaction of the alternate polarities guide the removable build plate into an aligned position on a surface of the base assembly1302.

Accordingly, a second configuration of magnets disposed on a surface or substrate1306of the base assembly correspond to but have opposite polarity to each of the first configuration of magnets disposed on the surface or substrate1305of the removable build plate.

FIG.15illustrates a layer or substrate1305aemployed by an alignment module on which a plurality of magnets is dispose in accordance with some exemplary embodiments of the present invention. In this configuration, a plurality of magnets is spaced apart such that another boundary1316surrounds the two central magnet clusters separated by the central boundary1315. As with the embodiment shown inFIG.14, a corresponding plate with a complimentary configuration of magnets disposed on a surface or substrate of the base assembly will correspond to but have opposite polarity to each of the first configuration of magnets disposed on the surface or substrate1305aof the removable build plate.

FIG.15Aillustrates a substrate or layer1305bemployed by an alignment module on which a plurality of magnets is dispose in accordance with some exemplary embodiments of the present invention. Layer1305bmay comprise of a plurality of cavities or apertures in which a plurality of magnets or magnetic components may be disposed on layer1505b. In some exemplary embodiments, the magnets are configured as shown with a first plurality or set of magnets disposed along an outer or perimetrical boundary1512that generally follows the perimeter of layer1305b. A second plurality or set of magnets may be disposed within two separate boundaries1513and1514, wherein each group of magnets forms a cluster of magnets within each of these two boundaries. A third plurality or set of magnets may be disposed along a central boundary1515which runs along a center region of the layer1305b. In the shown embodiment, the first set of magnets disposed along the outer or perimetrical boundary1512include a set of two magnets at each of the corners1501, and a plurality of magnets along the entire lengths of the perimetrical boundary1512at locations1502,1503,1504,1505,1506, and1507; as well as along the shorter lengths of the perimetrical boundary1512at locations1508, and1509. Notably: the corner magnets1501are the same polarity magnets; magnets at locations1502and1504, which are opposite to magnets at location1505and1507, are same polarity, just as magnets located at1503and1506; similarly, magnets located at oppose sides of the shorter length of layer1305b, at1508and1509, are magnets positioned so that they have the same polarity as well. The second set of magnets in clusters or within boundaries1513and1514, have the same polarity pattern. The third set of magnets within boundary1515have the same polarity as those in regions1503and1506. This configuration allows the build plate to automatically self-align; as such, a build plate with this configuration of magnets (and a complementary set of magnets on the base assembly with the same configuration but opposite polarity) is adapted to magnetically move the removable build plate along a top surface of the base assembly such that the removable build plate automatically self-aligns along a boundary of the base assembly and magnetically couples to the top surface of the base assembly.

In some exemplary embodiments, a build platform1300for a stereolithographic printer, may comprise: a removable build plate1301having a flexible build surface1303for building 3D-printed objects on the build platform1300; a base assembly1302removably coupled to the removable build plate1301; and an alignment module1304, comprising: a first configuration of magnets disposed on a surface1305of the removable build plate such that a first set of magnets are distributed along a perimetrical edge of the surface, and a second set of the magnets are distributed in two clusters along a center region of the surface; and a second configuration of magnets disposed on a surface of the base assembly that correspond to but have opposite polarity to each of the first configuration of magnets disposed on the surface of the removable build plate; wherein the magnetic alignment module is adapted to magnetically move the removable build plate along a top surface of the base assembly such that the removable build plate automatically self-aligns along a boundary of the base assembly and magnetically couples to the top surface of the base assembly.

FIG.16illustrates a top view of a base assembly for a build platform in accordance with some exemplary embodiments of the present invention. More specifically, this figure shows base assembly1600, which includes a top surface1601adapted to receive a build plate. In exemplary embodiments of the present invention, such as the embodiment shown in this view, base assembly1600includes a raised edge1602adapted to register with and facilitate alignment of a removable build plate on the surface1601of the base assembly1600. The edge1602may be a gradually rising edge that runs around a portion of a perimeter of the base assembly or perimeter of the surface1601.

FIG.17illustrates a side view of base assembly1600, from which it may be appreciated that raised edge1602is gradual along opposite sides of the base assembly. Typically, the edge is planar along a length of the base assembly in order to provide a backing or support for the build plate that is slid in place when coupled to the base assembly1600.

FIG.18illustrates a top view of base assembly1600, showing a removable build plate1604moving or sliding into an aligned position on a surface1601of the base assembly1600, in accordance with some exemplary embodiments of the present invention. The magnetic forces of the magnets guide or magnetically move the removable build plate1604along the top surface1601of the base assembly1600such that the removable build plate1604automatically self-aligns along a boundary (in exemplary embodiments the boundary aligns with raised edge1602) of the base assembly and magnetically couples to the top surface1601of the base assembly1600.

In some exemplary embodiments, removable build plate1604includes a tab1605extending from the flexible surface of removable build plate1604. Tab1605facilitates manual placement or removal of the removable build plate1604on the base assembly1600. In some exemplary embodiments, as will be discussed further below, the base assembly1600may further include a recessed edge along a side surface of the base assembly to facilitate manual placement or removal of the removable build plate.

Turning to the next set of figures,FIG.19illustrates a front view of a base assembly1900in accordance with some exemplary embodiments of the present invention;FIG.20illustrates a side view thereof; andFIG.21illustrates a side view of the base assembly1900, showing a recessed edge1902that facilitates removal of a removable build plate1904, when it is positioned on the top surface1903of the base assembly1901. From these views, it may be appreciated that the recessed edge1902creates a crevasse202that allows a user to easily lift the removable build plate1904from the top surface1903of the base assembly1901.

FIG.22illustrates a top view of a build plate including a protruding edge or tab to facilitate placement or removal, in accordance with some exemplary embodiments of the present invention. In this view an alternative position for a tab such as at2202is shown. In this embodiment, the removable build plate2200includes a flexible printable surface2201from which a tab2202extends from. Tab2202facilitates manual placement or removal of the removable build plate2200on a base assembly. As indicated in other shown embodiments, tab2202may be positioned along any length of the removable build plate2200.

FIG.23-25are images of a build platform in accordance with some exemplary embodiments of the present invention. More specifically,FIG.23shows an image of a disassembled build platform2300comprising an alignment module2303that includes an electromagnet housed inside the base assembly2304. A build plate2302and a platform lid2301are shown decoupled from the base assembly2304. A plurality of electromagnets2305are shown disposed in an interior of the base assembly2304, wherein the plurality of electromagnets2305will conduct an attractive force through the surface of the base assembly2304in order to automatically self-align the build plate2302along a boundary of the base assembly2304and magnetically couple build plate2302to the top surface of the base assembly2304. In some exemplary embodiments, the removable build plate2302includes a ferromagnetic surface that magnetically couples to the surface of the base assembly. In other exemplary embodiments, build plate2302includes a substrate with magnets embedded therein.

In some exemplary embodiments, the build platform may further include a sensor coupled to the base assembly2304that is adapted to detect whether the removable build plate2302is coupled on the base assembly2304.

Turning now t the next set of figures,FIG.26-FIG.28illustrate a build plate for a build platform to which a seal has been applied, in accordance with some exemplary embodiments of the present invention. Because forming material such as resin can get between layers of materials, and especially get between the platform and build plate, with no chance to remove during the wash cycles, a seal may be desirable. One type of sealing mechanism that may be employed is a face seal, in which a layer of, for example and without limiting the scope of the present invention, rubber, (ie., Neoprene, Silicone etc.), is applied. In some exemplary embodiments, a flat durable material with minimum thickness is preferred.

In some exemplary embodiments, as shown inFIG.26, a sealing surface2603is used to cover a layer2602that is embedded with magnets or magnetic components of build plate2600, so that the sealing surface2603sandwiches layer2602between it and printing surface2601. In some exemplary embodiments, as shown inFIG.27, on the base assembly2700, a second sealing surface2701may be secured to seal a layer2702that is embedded with magnets or magnetic the base assembly2700.

Another type of sealing mechanism is an edge seal.FIG.28illustrates a build plate for a build platform to which a seal has been applied along an edge of the build platform, in accordance with some exemplary embodiments of the present invention. Build platform2800includes a surface2802which is surrounded by a sealing surface covering an edge2801of the removable build plate that creates a seal between the removable build plate and the base assembly. Because the idea is to keep the surface of the build plate flat, employing the seal may require a build plate surface structure that accommodates the seal.

For example,FIG.28A-FIG.28Billustrate cross-sectional views of exemplary embodiments of the present invention wherein a build plate for a build platform employs a sealing material2803along an edge (FIG.28A) and along the top surface (FIG.28A) of the build plate2800.

InFIG.28A, an exemplary cross-section of a first embodiment is shown along line segment A-A (seeFIG.28) whereby surface2802of build platform2800includes a sealing component2803that sits on edge2801athat has a surface that is recessed or lower than the surface2802of the build plate2800. Between this recessed edge2801aand the higher surface2802, a sealing component2803may be disposed. The sealing component2803may comprise of a softer material, such as but not limited to silicone component, a synthetic rubber and fluoropolymer elastomer such as Viton®, a ethylene propylene diene monomer (EPDM) rubber, or other types of similar materials may be used.

In another embodiment, as shownFIG.28B—a cross-section along line segment A-A (seeFIG.28)—it is the surface2802of build platform2800that is recessed or lower with reference to a surface of edge2801and which is filled with the sealing component2803. That is, in this embodiment, the sealing material2803is disposed on the top of the recessed surface2802. Notably, in either embodiments ofFIG.28AorFIG.28B, a flat planar surface is achieved.

Since the build plate is removable and may require cleaning from time to time, it may be desirable to alert users to make sure the building platform is coupled to the removable build plate. As such, as shown inFIG.29, a build platform2900may be labeled2903for ease of use, in accordance with some exemplary embodiments of the present invention. In this shown embodiment. Build platform2900includes a base assembly2901that employs a recessed edge2902.

Finally turning to the last set of figures,FIG.30illustrates another build platform in accordance with some exemplary embodiments of the present invention. In this embodiment, a build platform3000may include a first flat surface3002of preferably an impermeable material, and a second flat surface3001of a similarly flat impermeable material that can be used as a printing surface; the second flat surface3002may be secured to a base assembly3003of a build platform. The flat impermeable material for surface3001and3002may be for example, and without limiting the scope of the present invention, tempered glass. When an object is printed on surface3001, surface3001may be removed from surface3002. Because surface3001is flexible, a separation(s)3004between the printed objected and the flexible surface is created, and the printed object will be easily peeled therefrom, as shown inFIG.30A-FIG.30B. For example, affixing an upper tempered glass sheet to an aluminum base on the print platform using epoxy and allow it to cure. It is important that the tempered glass be made to be as flat as possible as it cures. The second piece of tempered glass may be placed onto the first piece of tempered glass so that their two coated faces touched one another, creating the required suction force to keep the second glass piece fixed while print is performed. After successful printing, the top layer of tempered glass will easily peel off of the lower layer of tempered glass, and the part is easily removed from the glass by flexing it by hand.

A system and method for facilitating separation of 3D-printed objects from build platforms has been described. The foregoing description of the various exemplary embodiments of the invention has been presented for the purposes of illustration and disclosure. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching without departing from the spirit of the invention.