Abstract: A 3D printing system and method for mitigating the force needed to separate a transparent printing membrane from a most-recently photocured layer of resin on a sample secured to a platform. The membrane is coupled to an actuator and a pivot joint adapted to rotate the membrane into the resin, and the platform is coupled to a vertical stage adapted to translate the platform downward. Through simultaneous activation of the actuator and the vertical stage, the membrane is progressively peeled away from the sample. The system and method are suitable for various membrane-based 3D printing technologies including large-area projection micro stereolithography (P?SL).

Abstract: The speed and control over layer thickness in multi-layer 3-D printing is enhanced when producing a sample layer by projecting an image of the layer from light engine onto an optically clear membrane in contact with a printing material to prepare a sample layer in contact with the membrane, followed by moving the sample away from the membrane to separate the two, then moving the sample back toward the membrane to a point where the distance between the membrane and sample, as measured by a laser displacement sensor, is equal to the thickness of the next layer. While the sample moves back toward the membrane a dual-roller spreader or rotary roller spreader oscillates on the membrane to simultaneously to drive away printing material and flatten the membrane. A bubble scrapper is employed to remove bubbles from the printing material as they form.