Abstract: An additive manufacturing apparatus can include a stage configured to hold one or more cured layers of resin that form a component. A radiant energy device can be operable to generate and project radiant energy in a patterned image. An actuator can be configured to change a relative position of the stage relative to the radiant energy device. A reclamation system can be downstream of the stage and can be configured to remove at least a portion of the resin from a resin support. The reclamation system can include a first collection structure configured to accept a resin support therethrough along a resin support movement direction. A first scraper is positioned within the first collection structure. The first scraper has an elongation axis that is offset from the resin support movement direction by an offset angle that is less than 90 degrees.

Abstract: A reclamation system for an additive manufacturing apparatus can include a collection structure configured to remove at least a portion of the resin from a foil. A containment vessel can be configured to retain the resin removed from the foil. A drain can direct the resin from the containment vessel to a reservoir.

Abstract: An additive manufacturing apparatus can include a stage configured to hold a component formed by one or more layers of resin. A support plate can be positioned above the stage. A radiant energy device can be positioned above the stage. The radiant energy device can be operable to generate and project energy in a predetermined pattern. A feed module can be configured to operably couple with a first end portion of a resin support and can be positioned upstream of the stage. A take-up module can be configured to operably couple with a second end portion of the resin support and can be positioned downstream of the stage.

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 includes a feed module and a take-up module that are configured to operably couple with a foil. A stage is configured to hold one or more cured layers of a resin that form a component. A radiant energy device is positioned opposite to the at least one stage. The radiant energy device is operable to generate and project radiant energy in a predetermined pattern. An actuator is configured to change a relative position of the at least one stage and the foil. An accumulator is positioned between the feed module and the take-up module. The accumulator is configured to retain an intermediate portion of the foil to allow a first portion of the foil upstream of the accumulator to move at a first speed and a second portion of the foil downstream of the accumulator to move at a second speed during a defined time period.

Abstract: An additive manufacturing apparatus includes a stage configured to hold a component. A radiant energy device is operable to generate and project radiant energy in a patterned image. An actuator is configured to change a relative position of the stage relative to the radiant energy device. A resin management system includes a material deposition assembly upstream configured to deposit a resin on a resin support. The material deposition assembly includes a reservoir configured to retain a first volume of the resin and define a thickness of the resin on the resin support as the resin support is translated in an X-axis direction. The material deposition assembly further includes a vessel positioned above the reservoir in a Z-axis direction and configured to store a second volume of the resin. In addition, the material deposition assembly includes a conduit configured to direct the resin from the vessel to the reservoir.

Abstract: An additive manufacturing apparatus includes a support plate including a window. A stage is configured to hold one or more cured layers of the resin to form a component. A radiant energy device positioned on an opposite side of the support plate from the stage and operable to generate and project radiant energy in a patterned image through the window. An actuator is operably coupled with the stage and is configured to move the stage between a curing position and a removal position. The curing position can be offset from the removal position.

Abstract: A method is provided for casting a component. Accordingly, a casting core is provided within a cavity of a component mold. The casting core defines an inner component shape and includes a core wall. The core wall defines a core outer surface and a core inner surface disposed opposite the core outer surface. The core inner surface defines a core cavity. The casting core also includes a removal facilitation feature. The component is cast within the cavity of the component mold with the casting core positioned therein. The cast component is removed from the component mold and the casting core is removed from the cast component.

Abstract: An additive manufacturing apparatus is provided herein that includes a resin support configured to support a resin. A support plate includes a window. A stage is configured to hold one or more cured layers of the resin to form a component. Each cured layer is formed with the stage in a respective cure position. A radiant energy device is positioned on an opposite side of the resin support from the stage and is operable to generate and project radiant energy in a patterned image through the window. An actuator is operably coupled with the stage and is configured to move the stage in a Z-axis direction to place the stage in a removal position. The component contacts one of the resin support or the resin supported by the resin support in the removal position.

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 includes a feed module and a take-up module that are configured to operably couple with a foil. A stage is configured to hold one or more cured layers of a resin that form a component. A radiant energy device is positioned opposite to the at least one stage. The radiant energy device is operable to generate and project radiant energy in a predetermined pattern. An actuator is configured to change a relative position of the at least one stage and the foil. An accumulator is positioned between the feed module and the take-up module. The accumulator is configured to retain an intermediate portion of the foil to allow a first portion of the foil upstream of the accumulator to move at a first speed and a second portion of the foil downstream of the accumulator to move at a second speed during a defined time period.

Abstract: An additive manufacturing apparatus includes a stage configured to hold a component. A radiant energy device is operable to generate and project radiant energy in a patterned image. An actuator is configured to change a relative position of the stage relative to the radiant energy device. A resin management system includes a material deposition assembly upstream configured to deposit a resin on a resin support. The material deposition assembly includes a reservoir configured to retain a first volume of the resin and define a thickness of the resin on the resin support as the resin support is translated in an X-axis direction. The material deposition assembly further includes a vessel positioned above the reservoir in a Z-axis direction and configured to store a second volume of the resin. In addition, the material deposition assembly includes a conduit configured to direct the resin from the vessel to the reservoir.

Abstract: A method is provided for casting a component. Accordingly, a casting core is provided within a cavity of a component mold. The casting core defines an inner component shape and includes a core wall. The core wall defines a core outer surface and a core inner surface disposed opposite the core outer surface. The core inner surface defines a core cavity. The casting core also includes a removal facilitation feature. The component is cast within the cavity of the component mold with the casting core positioned therein. The cast component is removed from the component mold and the casting core is removed from the cast component.

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 apparatus includes a support plate and a foil supporting an uncured layer of a resin. A stage is configured to hold a component of one or more cured layers of the resin. One or more actuators is operable to move the stage away from the support plate in a Z-axis direction. A radiant energy device is positioned opposite the stage such that the support plate is positioned between the radiant energy device and the stage. A foil interaction device includes a first pneumatic actuation zone and a second pneumatic actuation zone. Each of the first and second pneumatic actuation zones is configured to apply a force on a surface of the foil. The first and second pneumatic actuation zones are fluidly separable and configured to apply varied pressures relative to one another to the surface of the foil.

Abstract: An intermediate investment casting mold includes at least a shell and a core. The shell has an outer surface and an inner surface, with the inner surface defining an interior for the shell. The core is located in the interior of the shell and is at least partially spaced from the inner surface of the shell. A void can be defined as the space between the core and the inner surface. The intermediate investment casting mold can include a plurality of anchors.

Abstract: An additive manufacturing apparatus includes a resin support configured to support a first resin and a second resin. A support plate includes a window. A stage is configured to hold one or more cured layers of the resin to form a component positioned opposite the support plate. A radiant energy device is positioned on an opposite side of the resin support from the stage and is operable to generate and project radiant energy in a patterned image through the window. An actuator assembly is configured to move the stage in a Z-axis direction and in a Y-axis direction.

Abstract: An additive manufacturing apparatus includes a support plate and a foil supporting an uncured layer of a resin. A stage is configured to hold a component of one or more cured layers of the resin. One or more actuators is operable to move the stage away from the support plate in a Z-axis direction. A radiant energy device is positioned opposite the stage such that the support plate is positioned between the radiant energy device and the stage. A foil interaction device includes a first pneumatic actuation zone and a second pneumatic actuation zone. Each of the first and second pneumatic actuation zones is configured to apply a force on a surface of the foil. The first and second pneumatic actuation zones are fluidly separable and configured to apply varied pressures relative to one another to the surface of the foil.

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 functionally graded component layer-by-layer includes: depositing radiant-energy-curable resin on a build surface defined by a resin support, the resin containing filler including at least two groups of particles with different physical properties; allowing the filler to settle such that the groups of particles separate from each other, defining at least two regions within the resin; positioning a stage relative to the build surface so as to define a layer increment in the resin; selectively curing the resin using an radiant energy applied in a specific pattern so as to define the geometry of a cross-sectional layer of the component; moving the build surface and the stage relatively apart so as to separate the component from the build surface; repeating at least the steps of positioning and selectively curing for a plurality of layers, until the component is complete.