Abstract: A method for producing a component layer-by-layer includes: providing two or more resin handling assemblies, each including a resin support which has at least a portion which is transparent, each resin support defining a build surface located in a build zone of the respective assembly; executing a build cycle, including: depositing on each build surface radiant-energy-curable resin, the resin on each build surface being a unique material combination; positioning a stage relative to one of the build surfaces to define a layer increment; selectively curing the resin using applied radiant energy so as to define a cross-sectional layer of the component; separating the component from the build surface; cleaning at least one of the component and the stage; and repeating the cycle, for a plurality of layers, wherein at least one of the layers is cured in each of the build zone. Apparatus is described for carrying out the method.

Abstract: An additive manufacturing apparatus is disclosed. The apparatus includes a build surface, at least a portion of which is transparent. The apparatus includes a first material depositor operable to deposit a curable resin to form a deposited resin layer on the build surface. A first sensing device is configured to measure the thickness of the deposited resin layer; and wherein the at least one sensing device is configured to generate a signal indicative of the thickness of the deposited resin layer. The first sensing device can be connected to a computer such that the additive manufacturing apparatus is configured to control the thickness of the deposited resin layer. The thickness of the deposited resin layer can be controlled such that it varies from side to side. The thickness can also be controlled such that it varies with time.

Abstract: An additive manufacturing apparatus is disclosed. The apparatus includes a build surface, at least a portion of which is transparent. The apparatus includes a first material depositor operable to deposit a curable resin to form a deposited resin layer on the build surface. A first sensing device is configured to measure the thickness of the deposited resin layer; and wherein the at least one sensing device is configured to generate a signal indicative of the thickness of the deposited resin layer. The first sensing device can be connected to a computer such that the additive manufacturing apparatus is configured to control the thickness of the deposited resin layer. The thickness of the deposited resin layer can be controlled such that it varies from side to side, i.e. across the width of the deposited resin layer in the transverse direction along the x-axis. The thickness can also be controlled such that it varies with time, i.e., in the machine direction along the y-axis.

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

Abstract: A method for producing a component layer-by-layer includes: providing two or more resin handling assemblies, each including a resin support which has at least a portion which is transparent, each resin support defining a build surface located in a build zone of the respective assembly; executing a build cycle, including: depositing on each build surface radiant-energy-curable resin, the resin on each build surface being a unique material combination; positioning a stage relative to one of the build surfaces to define a layer increment; selectively curing the resin using applied radiant energy so as to define a cross-sectional layer of the component; separating the component from the build surface; cleaning at least one of the component and the stage; and repeating the cycle, for a plurality of layers, wherein at least one of the layers is cured in each of the build zone. Apparatus is described for carrying out the method.

Abstract: A method for producing a component layer-by-layer includes: providing two or more resin handling assemblies, each including a resin support which has at least a portion which is transparent, each resin support defining a build surface located in a build zone of the respective assembly; executing a build cycle, including: depositing on each build surface radiant-energy-curable resin, the resin on each build surface being a unique material combination; positioning a stage relative to one of the build surfaces to define a layer increment; selectively curing the resin using applied radiant energy so as to define a cross-sectional layer of the component; separating the component from the build surface; cleaning at least one of the component and the stage; and repeating the cycle, for a plurality of layers, wherein at least one of the layers is cured in each of the build zone. Apparatus is described for carrying out the method.

Abstract: A method for forming a part layer by layer using an additive manufacturing apparatus. The additive manufacturing apparatus includes a resin support, a stage, a measuring system, and an actuator configured to change the relative position of the stage and the resin support. The method includes the steps of: performing an additive manufacturing cycle including the following steps: depositing an uncured layer of resin; moving the stage to a target location; curing the uncured layer of resin; and moving the stage away from the target location; repeating the additive manufacturing cycle; performing a measuring process wherein the measuring process includes the following steps: using the measuring system to take a measurement indicative of an actual position of a structure; comparing the actual position of the structure to an expected position of the structure to determine an error; and using the error to modify the target location.

Abstract: An additive manufacturing apparatus configured to produce a component layer by layer. The manufacturing apparatus includes a support structure, a stage that is positioned opposite the support structure. The stage is configured to hold a stacked arrangement of one or more cured layers of a resin. The apparatus also includes one or more actuators operable to move the stage away from the support structure, and a radiant energy apparatus is positioned opposite the stage such that the support structure is positioned between the radiant energy apparatus and the stage. The radiant energy apparatus is operable to generate and project radiant energy through the support structure on the resin in a predetermined pattern. a foil separation device that includes at least one holddown device is configured such that the foil contacts the at least one holddown device as the stage is moved away from the support structure.

Abstract: A method is provided for controlling an additive manufacturing process in which a layer of resin is deposited on a build surface and selectively cured via selective application of radiant energy so as to define the geometry of a cross-sectional layer of the component, such that uncured resin remaining on the build surface after curing defines a negative structure of the layer being cured. The method includes: using an imaging apparatus to produce an image of the negative structure; evaluating the image of the negative structure and controlling at least one aspect of the additive manufacturing process with reference to the image of the negative structure.

Abstract: A method for producing a component from two or more sub-components includes the steps of: producing each of the sub-components using an additive manufacturing process in which a resin, which is radiant-energy-curable, is partially cured using a selective application of radiant energy, wherein each sub-component includes a joint surface in which the resin is partially cured which is cured to a lesser degree than the remainder of the respective sub-component, so as to leave the joint surfaces in a condition suitable for bonding; assembling the sub-components with their respective joint surfaces in mutual contact; and performing a secondary cure of the partially-cured resin at the joint surfaces using an application of radiant energy, so as to further cure the partially-cured resin and bond the sub-components to each other, thereby forming the component.

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

Abstract: A method for producing a component from two or more sub-components includes the steps of: producing each of the sub-components using an additive manufacturing process in which a resin, which is radiant-energy-curable, is partially cured using a selective application of radiant energy, wherein each sub-component includes a joint surface in which the resin is partially cured which is cured to a lesser degree than the remainder of the respective sub-component, so as to leave the joint surfaces in a condition suitable for bonding; assembling the sub-components with their respective joint surfaces in mutual contact; and performing a secondary cure of the partially-cured resin at the joint surfaces using an application of radiant energy, so as to further cure the partially-cured resin and bond the sub-components to each other, thereby forming the component.

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

Abstract: An additive manufacturing apparatus configured to produce a component layer by layer. The manufacturing apparatus includes a support structure, a stage that is positioned opposite the support structure. The stage is configured to hold a stacked arrangement of one or more cured layers of a resin. The apparatus also includes one or more actuators operable to move the stage away from the support structure, and a radiant energy apparatus is positioned opposite the stage such that the support structure is positioned between the radiant energy apparatus and the stage. The radiant energy apparatus is operable to generate and project radiant energy through the support structure on the resin in a predetermined pattern. a foil separation device that includes at least one holddown device is configured such that the foil contacts the at least one holddown device as the stage is moved away from the support structure.

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

Abstract: An additive manufacturing apparatus is disclosed. The apparatus includes a build surface, at least a portion of which is transparent. The apparatus includes a first material depositor operable to deposit a curable resin to form a deposited resin layer on the build surface. A first sensing device is configured to measure the thickness of the deposited resin layer; and wherein the at least one sensing device is configured to generate a signal indicative of the thickness of the deposited resin layer. The first sensing device can be connected to a computer such that the additive manufacturing apparatus is configured to control the thickness of the deposited resin layer. The thickness of the deposited resin layer can be controlled such that it varies from side to side, i.e. across the width of the deposited resin layer in the transverse direction along the x-axis. The thickness can also be controlled such that it varies with time, i.e., in the machine direction along the y-axis.

Abstract: A method for forming a part layer by layer using an additive manufacturing apparatus. The additive manufacturing apparatus includes a resin support, a stage, a measuring system, and an actuator configured to change the relative position of the stage and the resin support. The method includes the steps of: performing an additive manufacturing cycle including the following steps: depositing an uncured layer of resin; moving the stage to a target location; curing the uncured layer of resin; and moving the stage away from the target location; repeating the additive manufacturing cycle; performing a measuring process wherein the measuring process includes the following steps: using the measuring system to take a measurement indicative of an actual position of a structure; comparing the actual position of the structure to an expected position of the structure to determine an error; and using the error to modify the target location.

Abstract: A method is provided for controlling an additive manufacturing process in which a layer of resin is deposited on a build surface and selectively cured via selective application of radiant energy so as to define the geometry of a cross-sectional layer of the component, such that uncured resin remaining on the build surface after curing defines a negative structure of the layer being cured. The method includes: using an imaging apparatus to produce an image of the negative structure; evaluating the image of the negative structure and controlling at least one aspect of the additive manufacturing process with reference to the image of the negative structure.

Abstract: A method for producing a component layer-by-layer includes: providing two or more resin handling assemblies, each including a resin support which has at least a portion which is transparent, each resin support defining a build surface located in a build zone of the respective assembly; executing a build cycle, including: depositing on each build surface radiant-energy-curable resin, the resin on each build surface being a unique material combination; positioning a stage relative to one of the build surfaces to define a layer increment; selectively curing the resin using applied radiant energy so as to define a cross-sectional layer of the component; separating the component from the build surface; cleaning at least one of the component and the stage; and repeating the cycle, for a plurality of layers, wherein at least one of the layers is cured in each of the build zone. Apparatus is described for carrying out the method.

Abstract: A method for producing a component from two or more sub-components includes the steps of: producing each of the sub-components using an additive manufacturing process in which a resin, which is radiant-energy-curable, is partially cured using a selective application of radiant energy, wherein each sub-component includes a joint surface in which the resin is partially cured which is cured to a lesser degree than the remainder of the respective sub-component, so as to leave the joint surfaces in a condition suitable for bonding; assembling the sub-components with their respective joint surfaces in mutual contact; and performing a secondary cure of the partially-cured resin at the joint surfaces using an application of radiant energy, so as to further cure the partially-cured resin and bond the sub-components to each other, thereby forming the component.