US20240042701A1 - Control systems and methods for additive manufacturing - Google Patents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
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- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/171—Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects
- B29C64/182—Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects in parallel batches
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/205—Means for applying layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/264—Arrangements for irradiation
- B29C64/277—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
- B29C64/282—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] of the same type, e.g. using different energy levels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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Abstract
An additive manufacturing apparatus includes a first print module includes a first stage configured to hold a first component and a first radiant energy device. The resin support is configured to be positioned between the first stage and the first radiant energy device. A second print module includes a second stage configured to hold a second component and a second radiant energy device. The resin support is configured to be positioned between the second stage and the second radiant energy device. A control system is configured to translate the resin support based on a condition of the first print module and the second print module through the first print module and the second print module.
Description
- The present application claims priority to U.S. Provisional Patent Application Ser. No. 63/239,530, filed on Sep. 1, 2021, the contents of which of which are hereby incorporated by reference in their entirety.
- The present subject matter relates generally to additive manufacturing apparatuses, and more particularly to control systems and methods for various components of additive manufacturing apparatuses.
- Additive manufacturing is a process in which material is built up layer-by-layer to form a component. Stereolithography (SLA) is a type of additive manufacturing process, which employs a tank of radiant-energy curable photopolymer “resin” and a curing energy source such as a laser. Similarly, Digital Light Processing (DLP) three-dimensional (3D) printing employs a two-dimensional image projector to build components one layer at a time. For each layer, the energy source draws or flashes a radiation image of the cross section of the component onto the surface of the resin. Exposure to the radiation cures and solidifies the pattern in the resin and joins it to a previously cured layer.
- In some instances, additive manufacturing may be accomplished through a “tape casting” process. In this process, a resin is deposited onto a flexible radiotransparent resin support, such as a tape or foil, that is fed out from a supply reel to a build zone. Radiant energy is produced from a radiant energy device and directed through a window to cure the resin to a component that is supported by a stage in the build zone. Once the curing of the first layer is complete, the stage and the resin support are separated from one another. The resin support is then advanced and fresh resin is provided to the build zone. In turn, the first layer of the cured resin is placed onto the fresh resin and cured through the energy device to form an additional layer of the component. Subsequent layers are added to each previous layer until the component is completed.
- In some instances, it may be beneficial to implement an additive manufacturing apparatus that includes multiple print modules. In such instances, various components may be shared while others may be independently controlled. As such, a control system is needed for controlling the various components.
- A full and enabling disclosure of the present disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.
-
FIG. 1A is a schematic front view of an additive manufacturing apparatus in accordance with various aspects of the present disclosure; -
FIG. 1B is a schematic front view of an additive manufacturing apparatus in accordance with various aspects of the present disclosure; -
FIG. 2 is a front perspective view of a feed module in accordance with various aspects of the present disclosure; -
FIG. 3 is a rear perspective view of the feed module in accordance with various aspects of the present disclosure; -
FIG. 4 is a front perspective view of a take-up module in accordance with various aspects of the present disclosure; -
FIG. 5 is a rear perspective view of the take-up module in accordance with various aspects of the present disclosure; -
FIG. 6 is a schematic front view of an additive manufacturing apparatus in accordance with various aspects of the present disclosure; -
FIG. 7 depicts an exemplary control system for an additive manufacturing apparatus in accordance with various aspects of the present disclosure; -
FIG. 8 depicts an exemplary control system for an additive manufacturing apparatus in accordance with various aspects of the present disclosure; -
FIG. 9 is a method of operating the manufacturing apparatus in accordance with various aspects of the present disclosure; and -
FIG. 10 is a method of operating the manufacturing apparatus in accordance with various aspects of the present disclosure. - Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present disclosure.
- Reference will now be made in detail to present embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the present disclosure.
- As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify a location or importance of the individual components. The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intermediate components or features, unless otherwise specified herein. The terms “upstream” and “downstream” refer to the relative direction with respect to a resin support movement along the manufacturing apparatus. For example, “upstream” refers to the direction from which the resin support moves and “downstream” refers to the direction to which the resin support moves. The term “selectively” refers to a component's ability to operate in various states (e.g., an ON state and an OFF state) based on manual and/or automatic control of the component. As used herein, any two components that are “operably coupled” with one another may be capable of one-way two-way communication with one another. For example, a first component that is operably coupled with a second component may provide instructions to the second component from the first component and/or provide instructions to the first component from the second component. Additionally or alternatively, the first component may receive data from the second component, and/or the second component may receive data from the first component.
- The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
- Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately,” “generally,” and “substantially,” is not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or apparatus for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a ten percent margin.
- Moreover, the technology of the present application will be described in relation to exemplary embodiments. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Additionally, unless specifically identified otherwise, all embodiments described herein should be considered exemplary.
- Here and throughout the specification and claims, range limitations are combined and interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.
- As used herein, the term “and/or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition or assembly is described as containing components A, B, and/or C, the composition or assembly can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.
- The present disclosure is generally directed to an additive manufacturing apparatus that implements various manufacturing processes such that successive layers of material(s) are provided on each other to “build-up,” layer-by-layer, a three-dimensional component. The successive layers generally cure together to form a monolithic component which may have a variety of integral sub-components. Although additive manufacturing technology is described herein as enabling the fabrication of complex objects by building objects point-by-point, layer-by-layer, variations of the described additive manufacturing apparatus and technology are possible and within the scope of the present subject matter.
- The additive manufacturing apparatus can include a support plate, a window supported by the support plate, and a stage moveable relative to the window. The additive manufacturing apparatus can further include a resin that is deposited as a layer having a desired thickness onto a resin support (such as a foil, tape, vat, plate, etc.) that is fed out from a supply reel. A stage lowers onto the resin such that a working surface defined by one of a surface of the stage or a surface of the work in process component is positioned such that the working surface either is just touching the resin or compressing it between the resin support and the stage and defining a layer thickness. Radiant energy is used to cure the resin through the resin support. Once the curing of the first layer is complete, the stage is retracted, taking the cured material with it. The resin support is then advanced to expose a fresh clean section, ready for additional resin to be deposited in a subsequent, new cycle.
- In some instances, the additive manufacturing apparatus can include a first print module having a first stage configured to hold a first component and a first radiant energy device. The resin support is configured to be positioned between the first stage and the first radiant energy device. The additive manufacturing apparatus can also include a second print module having a second stage configured to hold a second component and a second radiant energy device. The resin support is configured to be positioned between the second stage and the second radiant energy device.
- A control system is configured to translate the resin support through the first print module and the second print module. The control system is configured to handle the synchronization of the multiple printing modules and the various other components of the apparatus. The synchronization of the multiple printing modules may lead to increased output of the apparatus due to the utilization of shared ancillary processes across the multiple print modules.
- Referring to the drawings wherein identical reference numerals denote the similar elements throughout the various views,
FIGS. 1A and 1B schematically illustrate an example of one type ofsuitable apparatus 10 for forming acomponent 12. Theapparatus 10 can include one or more of asupport plate 14, awindow 16, astage 18 that is movable relative to thewindow 16, and aradiant energy device 20, which, in combination, may be used to form any number (e.g., one or more) of additively manufacturedcomponents 12. - In the illustrated example of
FIG. 1A , theapparatus 10 includes afeed module 22, which may include afirst mandrel 22A, and a take-upmodule 24, which may include a take-upmandrel 24A, that are spaced-apart with aresin support 26 extending therebetween. A portion of theresin support 26 can be supported from underneath by thesupport plate 14. Suitable mechanical supports (frames, brackets, etc.) and/or alignment devices may be provided for themandrels support plate 14. Thefirst mandrel 22A and/or the take-upmandrel 24A can be configured to control the speed and direction of theresin support 26 such that the desired tension and speed is maintained in theresin support 26 through adrive system 28. By way of example and not limitation, thedrive system 28 can be configured as individual motors associated with thefirst mandrel 22A and/or the take-upmandrel 24A. Moreover, various components, such as motors, actuators, feedback sensors, and/or controls can be provided for driving themandrels resin support 26 tensioned between the alignedmandrels resin support 26 from thefirst mandrel 22A to the take-upmandrel 24A. - In various embodiments, the
window 16 is transparent and can be operably supported by thesupport plate 14. Further, thewindow 16 and thesupport plate 14 can be integrally formed such that one ormore windows 16 are integrated within thesupport plate 14, Likewise, theresin support 26 is also transparent or includes transparent portions. As used herein, the terms “transparent” and “radiotransparent” refer to a material that allows at least a portion of radiant energy of a selected wavelength to pass through. For example, the radiant energy that passes through thewindow 16 and theresin support 26 can be in the ultraviolet spectrum, the infrared spectrum, the visible spectrum, or any other practicable radiant energy. Non-limiting examples of transparent materials include polymers, glass, and crystalline minerals, such as sapphire or quartz. - The
resin support 26 extends between thefeed module 22 and the take-upmodule 24 and defines a “resin surface” 30, which is shown as being planar, but could alternatively be arcuate (depending on the shape of the support plate 14). In some instances, theresin surface 30 may be defined by theresin support 26 and be positioned to face thestage 18 with thewindow 16 on an opposing side of theresin support 26 from thestage 18. For purposes of convenient description, theresin surface 30 may be considered to be oriented parallel to an X-Y plane of theapparatus 10, and a direction perpendicular to the X-Y plane is denoted as a Z-axis direction (X, Y, and Z being three mutually perpendicular directions). As used herein, the X-axis refers to the machine direction along the length of theresin support 26. As used herein, the Y-axis refers to the transverse direction across the width of theresin support 26 and generally perpendicular to the machine direction. As used herein, the Z-axis refers to the stage direction that can be defined as the direction of movement of thestage 18 relative to thewindow 16. - The
resin surface 30 may be configured to be “non-stick,” that is, resistant to adhesion of a cured resin R. The non-stick properties may be embodied by a combination of variables such as the chemistry of theresin support 26, its surface finish, and/or applied coatings. For instance, a permanent or semi-permanent non-stick coating may be applied. One non-limiting example of a suitable coating is polytetrafluoroethylene (“PTFE”). In some examples, all or a portion of theresin surface 30 may incorporate a controlled roughness or surface texture (e.g. protrusions, dimples, grooves, ridges, etc.) with nonstick properties. Additionally or alternatively, theresin support 26 may be made in whole or in part from an oxygen-permeable material. - For reference purposes, an area or volume immediately surrounding the location of the
resin support 26 and thewindow 16 or transparent portion defined by thesupport plate 14 may be defined as a “build zone,” labeled 32. - In some instances, a
deposition assembly 34 may be positioned along theresin support 26. In the illustrated embodiment, thematerial deposition assembly 34 includes avessel 36 and areservoir 40. Aconduit 38 extends from thevessel 36 to direct resin from thevessel 36 to thereservoir 40. Theconduit 38 may be positioned along a bottom portion of thevessel 36 such that the resin R may be gravity fed from thevessel 36 to theconduit 38, which may generally prevent the introduction of air to the resin R as the air is transferred into and/or through theconduit 38. In some instances, a filter may be positioned upstream, downstream, and/or within theconduit 38 with respect to the flow of resin from thevessel 36 to thereservoir 40. In such instances, the resin may be gravity fed through the filter prior to entering thereservoir 40 to catch various agglomerates, partially cured resin pieces, and/or other foreign objects that may affect the resin once it is thinned out on theresin support 26 or may affect the quality of thecomponent 12. - The
reservoir 40 may include any assembly to control the thickness of the resin R applied to thefoil resin support 26, as thefoil resin support 26 passes under and/or through thereservoir 40. Thereservoir 40 may be configured to maintain a first amount volume of the resin R and define a thickness of the resin R on thefoil resin support 26 as thefoil resin support 26 is translated in an X-axis direction. Thevessel 36 may be positioned above thereservoir 40 in a Z-axis direction, or in any other position, and configured to maintain a second amount volume of the resin R. In various embodiments, when the first amount volume of the resin R deviates from a predefined range, additional resin R is supplied from thevessel 36 to thereservoir 40. - In the illustrated example of
FIG. 1B , theresin support 26 may be in the form of avat 42 that is configured to isolate debris that could contaminate the build from usable resin R. Thevat 42 may include a floor 44 and aperimeter wall 46. Theperimeter wall 46 extends from the floor 44. Inner surfaces of the floor 44 and theperimeter wall 46 define areceptacle 48 for receiving the resin R. - A drive system may be provided for moving the
vat 42 relative to thestage 18 parallel to the X-direction between abuild zone 32 and a position at least partially external to thebuild zone 32. However, it will be appreciated that, in other embodiments, theresin support 26 may be stationary without departing from the scope of the present disclosure. - Referring back to
FIGS. 1A and 1B , the resin R includes any radiant-energy curable material, which is capable of adhering or binding together the filler (if used) in the cured state. As used herein, the term “radiant-energy curable” refers to any material which solidifies or partially solidifies in response to the application of radiant energy of a particular frequency and energy level. For example, the resin R may include a photopolymer resin containing photo-initiator compounds functioning to trigger a polymerization reaction, causing the resin R to change from a liquid (or powdered) state to a solid state. Alternatively, the resin R may include a material that contains a solvent that may be evaporated out by the application of radiant energy. The uncured resin R may be provided in solid (e.g. granular) or liquid form, including a paste or slurry. - Furthermore, the resin R can have a relatively high viscosity resin that will not “slump” or run off during the build process. The composition of the resin R may be selected as desired to suit a particular application. Mixtures of different compositions may be used. The resin R may be selected to have the ability to out-gas or burn off during further processing, such as a sintering process.
- Additionally or alternatively, the resin R may be selected to be a viscosity reducible composition. These compositions reduce in viscosity when a shear stress is applied or when they are heated. For example, the resin R may be selected to be shear-thinning such that the resin R exhibits reduced viscosity as an amount of stress applied to the resin R increases. Additionally or alternatively, the resin R may be selected to reduce in viscosity as the resin R is heated.
- The resin R may incorporate a filler. The filler may be pre-mixed with resin R, then loaded into the
deposition assembly 34. Alternatively, the filler may be mixed with the resin R on theapparatus 10. The filler includes particles, which are conventionally defined as “a very small bit of matter.” The filler may include any material that is chemically and physically compatible with the selected resin R. The particles may be regular or irregular in shape, may be uniform or non-uniform in size, and may have variable aspect ratios. For example, the particles may take the form of powder, of small spheres or granules, or may be shaped like small rods or fibers. - The composition of the filler, including its chemistry and microstructure, may be selected as desired to suit a particular application. For example, the filler may be metallic, ceramic, polymeric, and/or organic. Other examples of potential fillers include diamond, silicon, and graphite. Mixtures of different compositions may be used. In some examples, the filler composition may be selected for its electrical or electromagnetic properties, e.g. it may specifically be an electrical insulator, a dielectric material, an electrical conductor, and/or magnetic.
- The filler may be “fusible,” meaning it is capable of consolidation into a mass upon application of sufficient energy. For example, fusibility is a characteristic of many available powders including but not limited to polymeric, ceramic, glass, and metallic. The proportion of filler to resin R may be selected to suit a particular application. Generally, any amount of filler may be used so long as the combined material is capable of flowing and being leveled, and there is sufficient resin R to hold together the particles of the filler in the cured state.
- In some embodiments, a
reclamation system 50 may be configured to remove at least a portion of the resin R that remains on thefoil resin support 26 after thefoil resin support 26 is removed from abuild zone 32. For example, thereclamation system 50 may include a collection structure, such as a wiper assembly, a blade assembly, and/or any other removal assembly. - With further reference to
FIGS. 1A and 1B , thestage 18 is capable of being oriented parallel to theresin surface 30. Various devices may be provided for moving thestage 18 relative to thewindow 16 parallel to the Z-axis direction. For example, as illustrated inFIGS. 1A and 1B , the movement may be provided through anactuator assembly 52 that may be coupled with astatic support 54. In some embodiments, theactuator assembly 52 may include avertical actuator 56 between thestage 18 and thestatic support 54 that allows for movement of thestage 18 in a first, vertical direction (e.g., along the Z-axis direction). Theactuator assembly 52 may additionally or alternatively include alateral actuator 58 between thestage 18 and thevertical actuator 56 and/or thestatic support 54 that allows for movement in a second, horizontal direction (e.g., along the X-axis direction and/or the Y-axis direction). In some embodiments, thevertical actuator 56 may be operably coupled with thelateral actuator 58 such that thestage 18 andvertical actuator 56 move along thelateral actuator 58 simultaneously. Theactuator assembly 52 may include any device practicable of moving thestage 18 in the first and/or second direction, such as ballscrew electric actuators, linear electric actuators, pneumatic cylinders, hydraulic cylinders, delta drives, belt systems, or any other practicable device. - The
radiant energy device 20 may be configured as any device or combination of devices operable to generate and project radiant energy at the resin R in a suitable pattern and with a suitable energy level and other operating characteristics to cure the resin R during the build process. For example, as shown inFIGS. 1A and 1B , theradiant energy device 20 may include a projector 60, which may generally refer to any device operable to generate a radiant energy image of suitable energy level and other operating characteristics to cure the resin R. As used herein, the term “patterned image” refers to a projection of radiant energy including an array of one or more individual pixels. Non-limiting examples of patterned image devices include a DLP projector or another digital micromirror device, a two-dimensional array of LEDs, a two-dimensional array of lasers, and/or optically addressed light valves. In the illustrated example, the projector 60 includes aradiant energy source 62 such as a UV lamp, animage forming apparatus 64 operable to receive asource beam 66 from theradiant energy source 62 and generate apatterned image 68 to be projected onto the surface of the resin R, and optionally focusingoptics 70, such as one or more lenses. - The
image forming apparatus 64 may include one or more mirrors, prisms, and/or lenses and is provided with suitable actuators, and arranged so that thesource beam 66 from theradiant energy source 62 can be transformed into apixelated image 68 in an X-Y plane coincident with the surface of the resin R. In the illustrated example, theimage forming apparatus 64 may be a digital micro-mirror device. - The projector 60 may incorporate additional components, such as actuators, mirrors, etc. configured to selectively move the
image forming apparatus 64 or another part of the projector 60 with the effect of rastering or shifting the location of the patternedimage 68 on theresin surface 30. Stated another way, the patternedimage 68 may be moved away from a nominal or starting location. - In addition to other types of
radiant energy devices 20, theradiant energy device 20 may include a “scanned beam apparatus” used herein to refer generally to any device operable to generate a radiant energy beam of suitable energy level and other operating characteristics to cure the resin R and to scan the beam over the surface of the resin R in a desired pattern. For example, the scanned beam apparatus can include aradiant energy source 62 and a beam steering apparatus. Theradiant energy source 62 may include any device operable to generate a beam of suitable power and other operating characteristics to cure the resin R. Non-limiting examples of suitableradiant energy sources 62 include lasers or electron beam guns. - In some instances, the
apparatus 10 may include amaterial retention assembly 72 that may be configured to retain theresin support 26 in a predefined position along thesupport plate 14. In some instances, thematerial retention assembly 72 can include one or morepneumatic actuation zones 72 a with eachpneumatic actuation zone 72 a configured to selectively interact with theresin support 26 by producing a force on a surface of theresin support 26 opposite the resin R. - The one or more
pneumatic actuation zones 72 a may apply a negative pressure on a first surface of theresin support 26 that is opposite to the resin R, or a second side of theresin support 26, to produce a suction or vacuum on theresin support 26. The negative pressure may retain theresin support 26 in a desired position long thesupport plate 14. The one or morepneumatic actuation zones 72 a may also apply a positive pressure on the first surface of theresin support 26 that is opposite to the resin R, or a second side of theresin support 26, to produce a pushing force on theresin support 26. The positive pressure may release theresin support 26 from a module of theapparatus 10, such as thewindow 16, thematerial retention assembly 72, etc. As used herein, a “negative” pressure is any pressure that is less than an ambient pressure proximate to one or morepneumatic actuation zones 72 a such that fluid may be drawn into the one or morepneumatic actuation zones 72 a. Conversely, a “positive” pressure is any pressure that is greater than an ambient pressure proximate to one or morepneumatic actuation zones 72 a such that fluid may be exhausted from the one or morepneumatic actuation zones 72 a. Further, a “neutral” pressure is any pressure that is generally equal to an ambient pressure proximate to one or morepneumatic actuation zones 72 a. - In some examples, the
pneumatic actuation zones 72 a may be fluidly coupled with apneumatic assembly 72 b through various hoses and one or more ports. Thepneumatic assembly 72 b may include any device capable of providing a vacuum/suction and/or pushing a fluid, such as air or a process gas (e.g., nitrogen or argon), through the one or morepneumatic actuation zones 72 a. For instance, thepneumatic assembly 72 b may include a pressurized fluid source that includes a compressor and/or a blower. Thepneumatic assembly 72 b may additionally or alternatively include any assembly capable of altering a pressure, such as a venturi vacuum pump. In some embodiments, one or more valves and/or switches may be coupled with thepneumatic assembly 72 b and the one or morepneumatic actuation zones 72 a. The one or more valves and/or switches are configured to regulate a pressure to each of the one or morepneumatic actuation zones 72 a. - In some embodiments, the
pneumatic actuation zone 72 a includes one ormore apertures 72 c of any size and shape for interacting with theresin support 26. For instance, theapertures 72 c may be any number and combination of holes, slits, or other geometric shapes defined by any module of theadditive manufacturing apparatus 10, such as a portion of thesupport plate 14. Additionally, or alternatively, theapertures 72 c may be defined by a portion of thesupport plate 14 being formed from a porous material, or through any other assembly in which a fluid may be moved from a first side of thesupport plate 14 to a second side of thesupport plate 14 to interact with theresin support 26. - In some examples, the
pneumatic actuation zone 72 a may be defined by aplenum 72 d. Theplenum 72 d may be of any size and may be similar or varied from the shape of any remainingplenum 72 d. In some instances, a gasket may be positioned about a rim of theplenum 72 d. Additionally or alternatively, thematerial retention assembly 72 may include one or more clamps that compressively maintain theresin support 26 along thesupport plate 14. - With further reference to
FIGS. 1A and 1B , aviscosity modification assembly 74 may be integrated within thesupport plate 14 and/or otherwise operably coupled with theresin support 26. Theviscosity modification assembly 74 may be configured to apply a shearing stress to the resin R to alter (e.g., reduce) a viscosity of the resin R. Additionally or alternatively, theviscosity modification assembly 74 may be configured to heat the resin R to alter the viscosity of the resin R. - In some embodiments, the
viscosity modification assembly 74 may be configured to mechanically vibrate one or more parts of theadditive manufacturing apparatus 10 to create a shearing stress on the resin R. For example, theviscosity modification assembly 74 may include amovement device 74 a (e.g., a transducer) that is operably coupled with thesupport plate 14. Themovement device 74 a may be configured to vibrate at least a portion of thesupport plate 14 or any other module of theapparatus 10 that is then transferred to the resin R. Additionally and/or alternatively, themovement device 74 a may be configured to convert electrical energy to ultrasonic mechanical pressure waves that are transferred to the resin R. For instance, themovement device 74 a may be in the form of an ultrasonic vibrating device, such as one utilizing a piezoelectric transducer. In other embodiments, theviscosity modification assembly 74, in addition to or in lieu of the transducer, may include, alone or in conjunction with one or the other, a fluid, an acoustic, a motor (e.g., offset cam), a reciprocating piston, or anyother movement device 74 a. - With further reference to
FIGS. 1A and 1B , in various embodiments, in various embodiments, agasket 76 may be positioned between thewindow 16 and thesupport plate 14 to isolate movement of each of thewindow 16 and thesupport plate 14 from one another. In various examples, thegasket 76 may be formed from a motion attenuating material, such as any of a wide variety of resilient elastomers including, but not limited to, materials containing natural rubber and silicone. - The
apparatus 10 may include and/or be operably coupled with acomputing system 78. Thecomputing system 78 inFIGS. 1A and 1B is a generalized representation of the hardware and software that may be implemented to control the operation of theapparatus 10, including some or all of thestage 18, thedrive system 28, theradiant energy device 20, theactuator assembly 52, thematerial retention assembly 72, theviscosity modification assembly 74, actuators, and the various parts of theapparatus 10 described herein. Thecomputing system 78 may be embodied, for example, by software running on one or more processors embodied in one or more devices such as a programmable logic controller (“PLC”) or a microcomputer. Such processors may be coupled to process sensors and operating modules, for example, through wired or wireless connections. The same processor or processors may be used to retrieve and analyze sensor data, for statistical analysis, and for feedback control. Numerous aspects of theapparatus 10 may be subject to closed-loop control. - Optionally, the modules of the
apparatus 10 may be surrounded by ahousing 80, which may be used to provide a shielding or inert gas (e.g., a “process gas”) atmosphere usinggas ports 82. Optionally, pressure within thehousing 80 could be maintained at a desired level greater than or less than atmospheric. Optionally, thehousing 80 could be temperature and/or humidity controlled. Optionally, ventilation of thehousing 80 could be controlled based on factors such as a time interval, temperature, humidity, and/or chemical species concentration. In some embodiments, thehousing 80 can be maintained at a pressure that is different than an atmospheric pressure. - Referring to
FIGS. 2 and 3 , exemplary perspective views of thefeed module 22 including afirst plate 84 are illustrated in accordance with exemplary embodiments of the present disclosure. As illustrated, thefeed mandrel 22A can be anchored to thefirst plate 84 and may support and rotate a feed roll 86 (FIG. 6 ) of the resin support 26 (FIG. 6 ). In various embodiments, thefeed mandrel 22A includes afront portion 88 on afirst side 90 of thefirst plate 84 and arear portion 92 on a second, opposingside 94 of thefirst plate 84. In some instances, abearing 96 may be positioned along thefront portion 88, therear portion 92, and/or between the front andrear portions - The
front portion 88 of thefeed mandrel 22A may include acylindrical portion 98 that is configured to accept thefeed roll 86 of theresin support 26 thereabout. In various instances, theresin support 26 may be operably coupled to a first spool 100 (FIG. 6 )(e.g., e.g., cardboard spool, polymeric spool, paper-based spool, metallic spool, composite spool, elastomeric spool, etc.), and thefirst spool 100 may be positioned about thefeed mandrel 22A. - A
stop 102 may be positioned between thecylindrical portion 98 and thefirst plate 84. As such, when theresin support 26 is wrapped about thefeed mandrel 22A, thestop 102 defines afirst distance d 1 between an inner edge of theresin support 26 and thefirst plate 84. In some examples, thefeed mandrel 22A may be configured to move between a disengaged position and an engaged position. In operation, thefeed mandrel 22A may be placed in the disengaged position to allow thefirst spool 100, and theresin support 26 wound thereabout, to be slid along thefeed mandrel 22A to a position in which an end portion of thefirst spool 100 is in contact or close proximity to thestop 102. Once thefirst spool 100 is positioned about thefeed mandrel 22A, thefeed mandrel 22A may be placed in the engaged position causing thefirst spool 100, and, consequently, thefeed roll 86 of theresin support 26 to rotate with thefeed mandrel 22A. - In some embodiments, the drive system 28 (
FIG. 1A ) may include afeed actuation assembly 104 be operably coupled with therear portion 92 of thefeed mandrel 22A. Thefeed actuation assembly 104 may be configured as one or more motors, actuators, brakes (mechanical and/or electrical), or any other device that may rotate thefeed mandrel 22A. Further, as illustrated inFIG. 3 , thefeed actuation assembly 104 may include atransmission 106 in the form of a belt system, a gear system, and/or any other practicable system. - With further reference to
FIGS. 2 and 3 , one ormore rollers tension sensor 110, such as a load cell, may be anchored to thefirst side 90 of thefirst plate 84. For example, a pair ofrollers feed mandrel 22A in the Z-axis direction. In some instances, the pair ofrollers rotation 112 that is generally parallel to an axis ofrotation 114 of thefeed mandrel 22A. - The
tension sensor 110 may be positioned between the pair ofrollers feed mandrel 22A in the Z-axis direction. Thetension sensor 110 may be configured as a force transducer that converts a tension or torque provided by theresin support 26 onto the load cell into an electrical signal that can be measured by thecomputing system 78 to determine a tension of theresin support 26. In some embodiments, theresin support 26 may be provided from thefeed mandrel 22A around thefirst roller 108A, thetension sensor 110, and, subsequently, thesecond roller 108B. - As illustrated in
FIG. 2 , acover 116 may be anchored to thefirst side 90 of thefirst plate 84. In various instances, thecover 116 may be configured to prevent any resin that might drip from dripping onto the feed roll 86 (FIG. 6 ) and/or any other module of theapparatus 10. Additionally or alternatively, thecover 116 may also prevent damage to various modules of theapparatus 10 while loading thefeed roll 86 onto and/or off of theapparatus 10. - Referring still to
FIGS. 2 and 3 , in some embodiments, afirst position sensor 118 may be operably coupled with thefirst plate 84 and configured to contact theresin support 26. Thefirst position sensor 118, and/or any other sensor, may be capable of monitoring a movement (e.g., a linear distance) of theresin support 26 and may be positioned at any point within thefeed module 22 or any other location upstream of thebuild stage 18. In several embodiments, thefirst position sensor 118 may be configured as a mechanical, optical, on-axis magnetic, and/or off-axis magnetic, may be an absolute encoder, an incremental encoder, and/or any other type of practicable encoder. Moreover, thefirst position sensor 118 may be any other type of practicable sensor without separating from the scope of the present disclosure. - The
feed module 22 may further include a feedroll proximity sensor 120 that may be configured to detect a distance d f r (FIG. 6 ) between the feedroll proximity sensor 120 and thefeed roll 86 of theresin support 26. As theresin support 26 is translated from thefeed module 22 to the take-upmodule 24, the distance between the feedroll proximity sensor 120 and thefeed roll 86 of theresin support 26 increases as a radius of thefeed roll 86 is reduced. This change in distance may be provided to thecomputing system 78, which in turn, may be used to calculate a radius of thefeed roll 86. - Referring to
FIGS. 4 and 5 , respective front and rear perspective views of the take-upmodule 24 including asecond plate 122 are illustrated in accordance with exemplary embodiments of the present disclosure. As illustrated, the take-upmandrel 24A may be anchored to thesecond plate 122 and configured to support a take-up roll 124 (FIG. 6 ) of theresin support 26. - In various embodiments, the take-up
mandrel 24A includes afront portion 126 on afirst side 128 of thesecond plate 122 and arear portion 130 on a second, opposingside 132 of thesecond plate 122. In some instances, abearing 134 may be positioned along thefront portion 126, therear portion 130, and/or between the first andsecond portions mandrel 24A. - The
front portion 126 of the take-upmandrel 24A may include acylindrical portion 136 that is configured to accept the take-up roll 124 of theresin support 26 thereabout. In various instances, theresin support 26 may be operably coupled to a second spool 138 (FIG. 6 )(e.g., cardboard spool, polymeric spool, paper-based spool, metallic spool, composite spool, elastomeric spool, etc.). Thesecond spool 138 may be positioned about the take-upmandrel 24A. - A
stop 140 may be positioned between thecylindrical portion 136 and thesecond plate 122. As such, theresin support 26 is wrapped about the take-upmandrel 24A, thestop 140 defines asecond distance d 2 between the inner edge of theresin support 26 and thesecond plate 122. In some examples, the take-upmandrel 24A may be configured to move between a disengaged position and an engaged position. In operation, the take-upmandrel 24A may be placed in the disengaged position to allow thesecond spool 138 to be slid along the take-upmandrel 24A to a position in which an end portion of thesecond spool 138 is in contact or close proximity to thestop 140. Once thesecond spool 138 is positioned about the take-upmandrel 24A, the take-upmandrel 24A may be placed in the engaged position causing thesecond spool 138, and, consequently, the take-up roll 124 of theresin support 26 to rotate with the take-upmandrel 24A. - Similar to the
feed module 22, asecond actuation assembly 142 may be operably coupled with therear portion 130 of the take-upmandrel 24A and extends from thesecond plate 122. Thesecond actuation assembly 142 may be configured as one or more motors, actuators, or any other device that may rotate the take-upmandrel 24A. Further, as illustrated inFIG. 5 , thesecond actuation assembly 142 may include atransmission 144 in the form of a belt system, a gear system, and/or any other practicable system. Moreover, thefeed actuation assembly 104 and thesecond actuation assembly 142 may be operably coupled with feedback sensors and/or controls that can be provided for driving themandrels resin support 26 tensioned between themandrels resin support 26 from thefeed mandrel 22A to the take-upmandrel 24A. - With further reference to
FIGS. 4 and 5 , one or more rollers may be anchored to thefirst side 128 of thesecond plate 122. For example, a set of threerollers second plate 122. In some instances, eachroller rotation 148 that is generally parallel to an axis ofrotation 150 of the take-upmandrel 24A. - The
second plate 122 may further support thereclamation system 50, which may be configured to remove at least a portion of resin R that remains on theresin support 26 after theresin support 26 is removed from a build zone 32 (FIG. 1A ). For example, thereclamation system 50 may include a wiper assembly, a blade assembly, and/or any other removal assembly for collecting the resin R that is removed from theresin support 26. - Referring still to
FIGS. 4 and 5 , in some embodiments, in addition to or instead of thefirst position sensor 118 upstream of the build stage 18 (FIG. 1A ), the apparatus 10 (FIG. 1A ) may include asecond position sensor 152 downstream of thebuild stage 18. Thesecond position sensor 152, and/or any other sensor, may be capable of monitoring a movement (e.g., a linear distance) of theresin support 26 and may be positioned at any point within the take-upmodule 24 or any other location downstream of thebuild stage 18. In various embodiments, thesecond position sensor 152 may be used for redundancy and verification of thedrive system 28. Additionally or alternatively, thecomputing system 78 can compare the difference of motion between thefirst position sensor 118 and thesecond position sensor 152 to determine whether thedrive system 28 is stretching/over tensioning theresin support 26. - The take-up
module 24 may further include a take-uproll proximity sensor 154 that may be configured to detect a distance between the take-uproll proximity sensor 154 and the take-up roll 124 of theresin support 26. As theresin support 26 is translated from thefeed module 22 to the take-upmodule 24, the distance between the take-uproll proximity sensor 154 and the take-up roll 124 of theresin support 26 decreases as a radius of the take-up roll 124 is increased. This change in distance may be provided to thecomputing system 78, which in turn, may be used to calculate a radius of the take-up roll 124. - Referring now to
FIGS. 6 and 7 , a front schematic view of theadditive manufacturing apparatus 10 and a block diagram of acontrol system 156 for theadditive manufacturing apparatus 10 are respectively depicted according to example embodiments of the present disclosure. In various embodiments, theapparatus 10 may include one ormore print modules 158. Eachprint module 158 may include asupport plate 14, awindow 16, astage 18, anactuator assembly 52, and/or aradiant energy device 20. As such, eachprint module 158 may be configured to build a common ordifferent component 12 from any of theother print modules 158. For example, afirst component 12 may have a first geometry and asecond component 12 may have a second geometry with the first geometry being different from the second geometry. - As generally illustrated in
FIG. 6 , theresin support 26 may be maintained in a position in which theresin support 26 generally extends through eachprint module 158 in an upstream/downstream orientation relative to the movement of theresin support 26 in the X-axis direction. In addition, theresin support 26 may be positioned between awindow 16 and a stage of eachrespective print module 158. In the illustrated embodiment, eachprint module 158 includes unique parts (i.e., any device of any print module), however, it will be appreciated that in various embodiments, one or more parts of afirst print module 158 a may be shared with one or moreother print modules 158 b-158 n+1. For example, acommon window 16 may be shared by more than oneprint module 158. - With reference to
FIGS. 6 and 7 , thecontrol system 156 is configured to control the synchronization of multiple printing modules and the various other assemblies of theapparatus 10. The synchronization of themultiple print modules 158 may lead to increased repeatability of component builds and increased output of theapparatus 10 due to the utilization of shared ancillary processes across themultiple print modules 158. - In some embodiments, the
control system 156 is configured to monitor eachprint module 158 independently and to translate theresin support 26 based on a detected condition of one ormore print modules 158. The conditions may include the initiation of a build process within aprint module 158, restarting of a build process within aprint module 158, failure of a build process within aprint module 158, completion of a build process within aprint module 158, and/or any other condition that the one ormore print modules 158 may independently experience during a build process. - Further, the
control system 156 is also configured to independently disable any of theprint modules 158 when a stop operation condition is detected (e.g., when there is a failure within thatrespective print module 158, acomponent 12 with therespective print module 158 has been completed) while allowing for theother print modules 158 to continue a build process. In some instances, thecontrol system 156 may also allow for print recovery if a failure is detected within one of theprint modules 158. For example, thecontrol system 156 may store the defined layer being printed and can reprint the layer to correct the failure and/or resume at any point in the build process by restarting the build process at the defined layer within therespective print module 158 while continuing the progression of eachother component 12 within the remainingprint modules 158. - In various embodiments, the
control system 156 can provide a resin-coated resin support 26 (FIG. 1A ) to each of theprint modules 158 that are to be used during a current indexing of theresin support 26. As used herein, an “index” is a predefined length of movement of theresin support 26. For example, a first indexing of theresin support 26 may move theresin support 26 from thefeed module 22 towards the take-up module 24 a first linear distance and a second indexing of theresin support 26 may subsequently move theresin support 26 from thefeed module 22 towards the take-up module 24 a second linear distance. The first linear distance may be generally equal to, less than, or greater than the second linear distance based on the conditions detected within eachprint module 158. As provided herein, thecontrol system 156 may build one ormore components 12 within eachprint module 158. - As illustrated, the
control system 156 may include acomputing system 78. Thecomputing system 78 can include one or more computing device(s) 78A. The computing device(s) 78A can include one or more processor(s) 78B and one or more memory device(s) 78C. The one or more processor(s) 78B can include any suitable processing device, such as a microprocessor, microcontroller, integrated circuit, an application-specific integrated circuit (ASIC), a digital signal processor (DSP), a field-programmble gate array (FPGA), logic device, one or more central processing units (CPUs), graphics processing units (GPUs) (e.g., dedicated to efficiently rendering images), processing units performing other specialized calculations, etc. The memory device(s) 78C can include one or more non-transitory computer-readable storage medium(s), such as RAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, etc., and/or combinations thereof. - The memory device(s) 78C can include one or more computer-readable media and can store information accessible by the one or more processor(s) 78B, including
routines 78D that can be executed by the one or more processor(s) 78B. The memory device(s) 78C can store theroutines 78D for running one or more software applications, operating thedrive system 28, displaying a user interface, receiving user input, processing user input, etc. In some implementations, theroutines 78D can be executed by the one or more processor(s) 78B to cause the one or more processor(s) 78B to perform operations, e.g., such as one or more portions of methods described herein. Theroutines 78D can be software written in any suitable programming language or can be implemented in hardware. Additionally, and/or alternatively, theroutines 78D can be executed in logically and/or virtually separate threads on processor(s) 78B. - The one or more memory device(s) 78C can also store
data 78E that can be retrieved, manipulated, created, or stored by the one or more processor(s) 78B. Thedata 78E can include, for instance, data to facilitate performance of one or more routines, methods, procedures 200 (FIG. 9 ) and/or methods 300 (FIG. 10 ) described herein. In various embodiments, the one or more memory device(s) 78C may act as a central repository for each of theprint modules 158 running contemporaneously during a build process thereby cutting down on storage costs and complexities of part versioning across multiple systems. - The
data 78E can be stored in one or more database(s). The one or more database(s) can be connected tocomputing system 78 by a high bandwidth LAN or WAN or can also be connected to thecomputing system 78 through network(s). The one or more database(s) can be split up so that they are located in multiple locales. In some implementations, thedata 78E can be received from another device. - The computing device(s) 78A can also include a communication module or
interface 78F used to communicate with one or more other module(s) ofcomputing system 78 or theadditive manufacturing apparatus 10 over the network(s). Thecommunication interface 78F can include any suitable modules for interfacing with one or more network(s), including, for example, transmitters, receivers, ports, controllers, antennas, or other suitable modules. - In the embodiment illustrated in
FIGS. 6 and 7 , auser interface 160 may be operably coupled with thecomputing system 78 through aninterface communication bus 198. Theuser interface 160 may further be operably coupled with abuild controller 162 through a build controller communication bus 197 and/or anetwork switch 164 through a switch communication bus 199. In some instances, thebuild controller 162 may be configured as a programmable logic controller that is responsible for controlling various aspects of the build. Thebuild controller 162 can provide theuser interface 160 and some storage. In various embodiments, thebuild controller 162 can communicate with each of the components described herein. In addition, thebuild controller 162 can utilize the build controller communication bus 197 and/or anetwork switch 164 to communicate with theradiant energy devices 20 a-20 n+1 (e.g., via embedded controllers). - In some instances, the
user interface 160 may receive inputs related to a build process and/or provide information related to the build process to the operator. Additionally or alternatively, theuser interface 160 may allow the operator to interact with thecomputing system 78, thebuild controller 162, and/or theradiant energy devices 20 a-20 n+1 to alter one or more settings or operations of eachrespective print module 158. - In some examples, the
user interface 160 may include a display having a touchscreen. The display may be capable of displaying information related to theapparatus 10, the build process, the field, and/or any other information. In some embodiments, theuser interface 160 may also include an input device in the form of circuitry within the touchscreen to receive an input corresponding with a location over the display. Other forms of input devices include one or more joysticks, digital input pads, or the like that can be used in place or in addition to the touchscreen. - With further reference to
FIGS. 6 and 7 , in various embodiments, thebuild controller 162 may be operably coupled with one ormore control devices 166 a-166 n+1. As illustrated, each of thecontrol devices 166 a-166 n+1 may be coupled in series to one another with afirst control device 166 a coupled with thebuild controller 162. However, it will be appreciated that any of thecontrol devices 166 a-166 n+1 may additionally or alternatively be coupled with thebuild controller 162 in parallel. - In several embodiments, the
build controller 162 may be configured as a master device in the form of any one of a variety of computing devices that may include a processor and memory. In addition, thebuild controller 162 may also include wireless communications and/or any wired communications protocols. For example, thecontrol devices 166 a-166 n+1 are connected directly or indirectly via one ormore communication lines control devices 166 a-166 n+1. Thecontrol devices 166 a-166 n+1 may each include a power supply unit, a counter unit, a communication unit, an I/O unit, etc. The communication lines 176, 178, 180, 182 may take on various topologies such as a line, a daisy chain, a tree, and a start, and/or any other topology. In various embodiments, each of thecontrol devices 166 a-166 n+1 may be operably coupled with various assemblies of theapparatus 10 through one or more I/O ports. In some instances, eachcontrol device 166 a-166 n+1 includes a defined number of I/O ports, which may define the maximum inputs within eachcontrol device 166 a-166 n+1. - In some instances, the
build controller 162 and thecontrol devices 166 a-166 n+1 may be configured as an EtherCAT (Ethernet for Control Automation Technology) network that may be used for swiftly updating data and performing a synchronization control among the apparatus. In such instances, thebuild controller 162 can use an Ethernet integrated element as a communication module, and the plurality ofcontrol devices 166 a-166 n+1 can use an EtherCAT ASIC (Application Specific Integrated Circuit) as a communication module. Further, thebuild controller 162 and thecontrol devices 166 a-166 n+1 can use a distributed clock function for synchronizing operations of thecontrol devices 166 a-166 n+1. The distributed clock function is realized by a synchronization signal of the EtherCAT ASIC, which is a communication module mounted at eachcontrol device 166 a-166 n+1. - In the illustrated embodiment, a
first control device 166 a may be operably coupled to thebuild controller 162 through afirst communication line 176. Thefirst control device 166 a includes afirst operation bus 188, which may be in the form of an I/O bus within thefirst control device 166 a, that couples thefirst control device 166 a to thefeed actuation assembly 104, which is configured to drive thefeed mandrel 22A. In various embodiments, thefeed actuation assembly 104 may include an actuator assembly, which may be in the form of one or more of a stepper motor, a servo motor, and/or any other type of rotational actuator. Thefeed actuation assembly 104 may also include a feed controller that can provide the actuator with generated control signals, such as pulse-width modulated (PWM) signals or current control signals, to provide a predefined amount of torque on thefeed mandrel 22A. In turn, thefeed roll 86 of theresin support 26 coupled with thefeed mandrel 22A may also have the amount of torque applied thereto. The feed controller may include control circuitry such as analog and/or digital control circuitry with logic for processing the various inputs and controlling the actuator as described herein. The feed controller may further include any combination of software and/or processing circuitry suitable for controlling the actuator. It will be appreciated that the feed controller may be integrated into the actuation assembly, thecomputing system 78, or otherwise coupled with the actuator. - As illustrated, in some examples, the feed
roll proximity sensor 120 may be operably coupled with thefirst control device 166 a through thefirst operation bus 188. The feedroll proximity sensor 120 may be capable of detecting a distance between the feedroll proximity sensor 120 and an outer circumference of thefeed roll 86. In various examples, the feedroll proximity sensor 120 may be an ultrasonic sensor, a radio detection and ranging (RADAR) sensor, a sound navigation and ranging (SONAR) sensor, a light detection and ranging (LIDAR) sensor, a vision-based sensor, and/or any other type of practicable sensor. - In several embodiments, the
first position sensor 118 of thefeed module 22 may also be operably coupled with thefirst control device 166 a through thefirst operation bus 188. In general, thefirst position sensor 118 can measure and determine a length of linear movement of theresin support 26. Thefirst position sensor 118 can send information in the form of a series of pulse trains (or pulse waves) corresponding to the measured movement to thebuild controller 162, which interprets the pulse trains received to determine the length of linear movement of theresin support 26. Additionally or alternatively, thefirst position sensor 118 has a processing circuitry that is capable of determining a rotational speed of a contact portion of thefirst position sensor 118. - The
tension sensor 110 may also be positioned within thefeed module 22 and operably coupled with thefirst control device 166 a through thefirst operation bus 188. Thetension sensor 110 may be capable of determining a tension of theresin support 26 between thefeed roll 86 and the take-up roll 124. Thetension sensor 110 may be a force transducer that converts a tension or torque provided by theresin support 26 onto thetension sensor 110 into an electrical signal that can be measured by thecomputing system 78 to determine a tension of theresin support 26. - Further, a
first print module 158 a may be operably coupled with thefirst control device 166 a through thefirst operation bus 188. Thefirst print module 158 a may include a firstbuild actuator assembly 52 a that allows for movement of the stage relative to thewindow 16. Thefirst print module 158 a may also include afirst build sensor 168 a, which may be capable of detecting movement of the stage such that the stage of thefirst print module 158 a may be placed in defined positions by thefirst actuator assembly 52 a. - With further reference to
FIGS. 6 and 7 , asecond control device 166 b may be operably coupled to thefirst control device 166 a through a second communication line 178. Thesecond control device 166 b includes asecond operation bus 190, which may be in the form of an I/O bus within thesecond control device 166 b, that couples thesecond control device 166 b with asecond print module 158 b. Like thefirst print module 158 a, thesecond print module 158 b may include a secondbuild actuator assembly 52 b that allows for movement of the stage relative to thewindow 16. Thesecond print module 158 b may also include asecond build sensor 168 b, which may be capable of detecting movement of the stage such that the stage of thesecond print module 158 b may be placed in defined positions by thesecond actuator assembly 52 b. - Likewise, a
third print module 158 c may also be operably coupled with thesecond control device 166 b through thesecond operation bus 190. Thethird print module 158 c may include a thirdbuild actuator assembly 52 c that allows for movement of the stage relative to thewindow 16. Thethird print module 158 c may also include athird build sensor 168 c, which may be capable of detecting movement of the stage such that the stage of thethird print module 158 c may be placed in defined positions by thethird actuator assembly 52 c. - In addition, the
viscosity modification assembly 74 may also be operably coupled with thesecond control device 166 b through thesecond operation bus 190. As provided herein, theviscosity modification assembly 74 can be configured to apply a shearing stress to the resin R to alter (e.g., reduce) a viscosity of the resin R. Additionally or alternatively, theviscosity modification assembly 74 may be configured to heat the resin R to alter the viscosity of the resin R. It will be appreciated that eachprint module 158 a-158 n+1 may include a common or independentviscosity modification assembly 74. Additionally or alternatively, theviscosity modification assembly 74 may include various sections that may be independently operated such that eachprint module 158 a-158 n+1 is associated with a respective independently operable section of theviscosity modification assembly 74. - With further reference to
FIGS. 6 and 7 , a third control device 166 c may be operably coupled to thesecond control device 166 b through athird communication line 180. The third control device 166 c includes athird operation bus 192, which may be in the form of an I/O bus within the third control device 166 c, that couples the third control device 166 c with afourth print module 158 d. Thefourth print module 158 d may include a fourthbuild actuator assembly 52 d that allows for movement of the stage relative to thewindow 16. Thefourth print module 158 d may also include afourth build sensor 168 d, which may be capable of detecting movement of the stage such that the stage of thefourth print module 158 d may be placed in defined positions by thefourth actuator assembly 52 d. - Likewise, a
fifth print module 158 e may also be operably coupled with the third control device 166 c through thethird operation bus 192. Thefifth print module 158 e may include a fifthbuild actuator assembly 52 e that allows for movement of the stage relative to thewindow 16. Thefifth print module 158 e may also include afifth build sensor 168 e, which may be capable of detecting movement of the stage such that the stage of thefifth print module 158 e may be placed in defined positions by thefifth actuator assembly 52 e. - In addition, the
material retention assembly 72 may also be operably coupled with the third control device 166 c through thethird operation bus 192. As provided herein, thematerial retention assembly 72 may be configured to retain theresin support 26 in a predefined position along thesupport plate 14 of the one ormore print modules 158. It will be appreciated that eachprint module 158 a-158 n+1 may include a common or independentmaterial retention assembly 72. Additionally or alternatively, thematerial retention assembly 72 may include various sections that may be independently operated such that eachprint module 158 a-158 n+1 is associated with a respective independently operable section of thematerial retention assembly 72. - Referring still to
FIGS. 6 and 7 , a nth control device 166 n may be operably coupled to the third control device 166 n through a nthcommunication line 182. The nth control device 166 n includes a nthoperation bus 194, which may be in the form of an I/O bus within the nth control device 166 n, that couples the nth control device 166 n with an nth print module 158 n. The nth print module 158 n may include an nthbuild actuator assembly 52 n that allows for movement of the stage relative to thewindow 16. The nth print module 158 n may also include an nth build sensor 168 n, which may be capable of detecting movement of the stage such that the stage of the nth print module 158 n may be placed in defined positions by the nth actuator assembly 52 n. - A pneumatic control system 170 may also be operably coupled with the nth control device 166 n through the nth operation bus 194. The pneumatic control system 170 may be fluidly coupled with the
material retention assembly 72 and/or any other module or assembly of theapparatus 10 through various hoses and one or more ports. The pneumatic control system 170 may include any device capable of providing a vacuum/suction and/or pushing a fluid, such as air or a process gas (e.g., nitrogen or argon), to the modules or assemblies of theapparatus 10. For instance, the pneumatic control system 170 may include a pressurized fluid source that includes a compressor and/or a blower. The pneumatic control system 170 may additionally or alternatively include any assembly capable of altering a pressure, such as a venturi vacuum pump. In some embodiments, one or more valves and/or switches may be coupled with the pneumatic control system 170. In such instances, the valves and/or switches may be operably coupled with the nth control device 166 n and thebuild controller 162 and/or thecomputing system 78. - With further reference to
FIGS. 6 and 7 , in addition to or instead of thefirst position sensor 118 upstream of one ormore print modules 158, theapparatus 10 may include asecond position sensor 152 downstream of one ormore print modules 158. Thesecond position sensor 152 may be operably coupled with the nth control device 166 n through the nth operation bus 194. Thesecond position sensor 152, and/or any other sensor, may be capable of monitoring a movement a linear distance) of theresin support 26 and may be positioned at any point within the take-upmodule 24 or any other location downstream of one ormore print modules 158. Thesecond position sensor 152 can send information in the form of a series of pulse trains (or pulse waves) corresponding to the measured movement to acomputing system 78, which interprets the pulse trains received to determine the length of linear movement of theresin support 26. Alternatively, thesecond position sensor 152 has a processing circuitry that is capable of determining the rotational speed of a contact portion of thesecond position sensor 152. - The take-up
module 24 may also include a take-uproll proximity sensor 154 operably coupled with the nth control device 166 n through the nth operation bus 194. The take-uproll proximity sensor 154 may be configured as any proximity sensor that is capable of detecting a distance between the take-uproll proximity sensor 154 and an outer circumference of the take-up roll 124. For example, like the feedroll proximity sensor 120, the take-uproll proximity sensor 154 may be configured as an ultrasonic sensor, a radio detection and ranging (RADAR) sensor, a sound navigation and ranging (SONAR) sensor, a light detection and ranging (LIDAR) sensor, a vision-based sensor, and/or any other type of practicable sensor. - In the illustrated embodiment, the nth control device 166 n may also be operably coupled with the take-up
actuation assembly 142 that is configured to drive the take-upmandrel 24A through the nth operation bus 194. In various embodiments, the take-upactuation assembly 142 may include an actuator, which may be in the form of one or more of a stepper motor, a servo motor, and/or any other type of rotational actuator. The take-upactuation assembly 142 may also include a take-up controller that can provide the actuator with generated control signals, such as pulse-width modulated (PWM) signals or current control signals, to provide a predefined amount of torque on the take-upmandrel 24A. In turn, the take-up roll 86 of theresin support 26 coupled with the take-upmandrel 24A may also have the amount of torque applied thereto. The take-up controller may include control circuitry such as analog and/or digital control circuitry with logic for processing the various inputs and controlling the actuator as described herein. The take-up controller may further include any combination of software and/or processing circuitry suitable for controlling the actuator. It will be appreciated that the take-up controller may be integrated into the actuation assembly, thebuild controller 162, thecomputing system 78, or otherwise coupled with the actuator. - Referring still to
FIGS. 6 and 7 , an nth+1 control device 166 n+1 may be operably coupled to the nth control device 166 n through an nth+1 communication line 184. The nth+1 control device 166 n+1 includes an nth−1 operation bus 196, which may be in the form of an I/O bus within the nth+1 control device 166 n+1, that couples the nth+1 control device 166 n with an nth+1 print module 158 n+1. The nth+1 print module 158 n+1 may include an nth+1build actuator assembly 52 n+1 that allows for movement of the stage relative to thewindow 16. The nth+1 print module 158 n+1 may also include an nth+1 build sensor 168 n+1, which may be capable of detecting movement of the stage such that the stage of the nth+1 print module 158 n+1 may be placed in defined positions by the nth+1 actuator assembly 52n + 1. - A
resin mixing assembly 172 may also be operably coupled with the n′control device 166 n+1 through the nth+1 operation bus 196. For example, theresin mixing assembly 172 may be configured to agitate the resin before the resin being deposited on theresin support 26. In some instances, adeposition assembly 34 may receive the resin from theresin mixing assembly 172. Thedeposition assembly 34 may also be operably coupled with the nth+1 control device 166 n+1. Theresin deposition assembly 34 may be any device or combination of devices that is operable to apply a resin R on theresin support 26. - Further, a
thickness sensor 174 may also be operably coupled with the nth+1 control device 166 n+1 through the nth+1 operation bus 196. Thethickness sensor 174 is configured to determine a thickness of resin deposited on theresin support 26. Thethickness sensor 174 may be embodied as one or more confocals, imaging sensor, or any other vision-based device. Thethickness sensor 174 may additionally and/or alternatively be configured as any other practicable proximity sensor, such as, but not limited to, an ultrasonic sensor, a radar sensor, a LIDAR sensor, or the like. - In some embodiments, a
reclamation system 50 may also be operably coupled with the nth+1 control device 166 n+1 through the nth+1 operation bus 196. Thereclamation system 50 may be configured to remove at least a portion of the resin R that remains on thefoil resin support 26 after thefoil resin support 26 is removed from abuild zone 32. - It will be appreciated that any of the modules, assemblies, etc. discussed herein may be operably coupled with any of the control devices 166 (e.g.,
first control device 166 a,second control device 166 b, third control device 166 c, nth control device 166 n, nth+1 control device 166 n+1) without departing from the teachings of the present disclosure. In addition, each of the modules, assemblies, etc. described herein may be independently coupled with anycontrol device 166, directly to thebuild controller 162, and/or to thecomputing system 78 without departing from the scope of the present disclosure. - Still referring to
FIGS. 6 and 7 , in various embodiments, one or moreradiant energy devices 20 a-20 n+1 may be coupled in parallel to thecomputing system 78 through an energydevice communication bus 186. Each of theradiant energy devices 20 a-20 n+1 may be configured to generate a radiant energy patterned image of suitable energy level and other operating characteristics to cure the resin R. It will be appreciated that the patterned image emitted from each of the one or moreradiant energy devices 20 a-20 n+1 may be different from one another, similar to one another, common with at least one of the remaining one or moreradiant energy devices 20 a-20 n+1, and/or different from at least one of the remaining one or moreradiant energy 20 a-20 n+1. - In some examples, a
network switch 164 may operably couple the energydevice communication bus 186 with theuser interface 160. Thenetwork switch 164 may allow for various inputs for controlling or altering the performance of the one or moreradiant energy devices 20 a-20 n+1 through theuser interface 160. In addition, a network-attached storage (NAS) device 187 may be operably coupled with the energydevice communication bus 186. The NAS device 187 includes a NAS controller and one or more storage devices. The NAS device 187 is configured to be in communication with a network, a local device, such as thecomputing system 78, and a peripheral device, such as theradiant energy devices 20 a-20 n+1. - The NAS controller can include a network interface for enabling connection with and transferring data to and from the network, and a local device interface that enables the transfer of data to and from the
computing system 78. A storage device interface is configured to be in communication with the storage devices for obtaining status information of the storage devices and facilitating data transfer between the storage devices and the network and/or thecomputing system 78. A local peripheral interface enables the transfer of data to and from the network and/or thecomputing system 78 to the one or moreradiant energy devices 20 a-20 n+1. A NAS processor oversees the overall operations of the NAS controller and coordinates functions between various modules of the NAS controller described above. A memory is provided to store the programs for enabling the NAS processor to perform its functions. - Referring now to
FIG. 8 , a block diagram of acontrol system 156 for theadditive manufacturing apparatus 10 is depicted according to example embodiments of the present disclosure. It will be appreciated that each component illustrated inFIG. 8 may operate as described herein (for example, as described with reference toFIGS. 6 and 7 ). - With further reference to
FIG. 8 , in some embodiments, a part of theapparatus 10 may be operably coupled with thebuild controller 162 through acommunication line 176. For example, as illustrated thebuild controller 162 may be operably coupled with thefeed actuation assembly 104. Thefeed actuation assembly 104 may include a feed controller that can provide an actuator therein with generated control signals, such as pulse-width modulated (PWM) signals or current control signals, to provide a predefined amount of torque on thefeed mandrel 22A. The feed controller may include control circuitry such as analog and/or digital control circuitry with logic for processing the various inputs and controlling the actuator as described herein. The feed controller may further include any combination of software and/or processing circuitry suitable for controlling the actuator. In addition, thefeed actuation assembly 104 may include thefirst operation bus 188, which may be in the form of an I/O bus, that couples thefeed actuation assembly 104 to one or more additional parts of theapparatus 10. For example, thefirst operation bus 188 may be operably coupled with the feedroll proximity sensor 120, thefirst position sensor 118, thetension sensor 110, and/or thefirst print module 158 a. - In the example illustrated in
FIG. 8 , theviscosity modification assembly 74 may be operably coupled to thefeed actuation assembly 104 through a communication line 178. The communication line 178 may be operably coupled with thefirst operation bus 188 and/or any other I/O port of thefeed actuation assembly 104. In some instances, theviscosity modification assembly 74 may include a controller having control circuitry such as analog and/or digital control circuitry with logic for processing the various inputs and controlling theviscosity modification assembly 74 as described herein. The controller may further include any combination of software and/or processing circuitry suitable for controlling theviscosity modification assembly 74. In addition, theviscosity modification assembly 74 may include thesecond operation bus 190, which may be in the form of an I/O bus, which couples theviscosity modification assembly 74 to one or more additional parts of theapparatus 10. For example, thesecond operation bus 190 may be operably coupled with thesecond print module 158 b and/or thethird print module 158 c. - In the example illustrated in
FIG. 8 , thematerial retention assembly 72 may be operably coupled to theviscosity modification assembly 74 through acommunication line 180. Thecommunication line 180 may be operably coupled with thesecond operation bus 190 and/or any other I/O port of theviscosity modification assembly 74. In some instances, thematerial retention assembly 72 may include a controller having control circuitry such as analog and/or digital control circuitry with logic for processing the various inputs and controlling thematerial retention assembly 72 as described herein. The controller may further include any combination of software and/or processing circuitry suitable for controlling thematerial retention assembly 72. In addition, thematerial retention assembly 72 may include thethird operation bus 192, which may be in the form of an I/O bus, which couples thematerial retention assembly 72 to one or more additional parts of theapparatus 10. For example, thethird operation bus 192 may be operably coupled with thefourth print module 158 d and/or thefifth print module 158 e. - Further, in the example illustrated in
FIG. 8 , the take-upactuation assembly 142 may be operably coupled to thematerial retention assembly 72 through acommunication line 182. Thecommunication line 182 may be operably coupled with thethird operation bus 192 and/or any other I/O port of thematerial retention assembly 72. In some instances, the take-upactuation assembly 142 may include a controller having control circuitry such as analog and/or digital control circuitry with logic for processing the various inputs and controlling the take-upactuation assembly 142 as described herein. The controller may further include any combination of software and/or processing circuitry suitable for controlling the take-upactuation assembly 142. In addition, the take-upactuation assembly 142 may include thefourth operation bus 194, which may be in the form of an I/O bus, that couples the take-upactuation assembly 142 to one or more additional parts of theapparatus 10. For example, thefourth operation bus 194 may be operably coupled with the nth print module 158 n, the pneumatic control system 170, thesecond position sensor 152, and/or the take-uproll proximity sensor 154. - Still further, in the example illustrated in
FIG. 8 , thedeposition assembly 34 may be operably coupled to the take-upactuation assembly 142 through acommunication line 184. Thecommunication line 184 may be operably coupled with thefourth operation bus 194 and/or any other I/O port of the take-upactuation assembly 142. In some instances, thedeposition assembly 34 may include a controller having control circuitry such as analog and/or digital control circuitry with logic for processing the various inputs and controlling thedeposition assembly 34 as described herein. The controller may further include any combination of software and/or processing circuitry suitable for controlling thedeposition assembly 34. In addition, thedeposition assembly 34 may include the nth+1 operation bus 196, which may be in the form of an I/O bus, that couples thedeposition assembly 34 to one or more additional parts of theapparatus 10. For example, the nth+1 operation bus 196 may be operably coupled with the nth+1 print module 158 n+1, the mixingassembly 172, thethickness sensor 174, and/or thereclamation system 50. - It will be appreciated that any first part described herein may include a controller that is operably coupled with the
build controller 162. In addition, any additional part may be coupled with the first part in parallel and/or in series without departing from the scope of the present disclosure. As such, the illustrated topology is anexample control system 156 for theapparatus 10 and is not limiting in any fashion. In addition, any part may be positioned within any branch of the topology without departing from the scope of the present disclosure. As used herein, a part of the apparatus may include any assembly, module, sensor, actuator, or another element that is within theapparatus 10. - Now that the construction and configuration of the additive manufacturing apparatus have been described according to various examples of the present subject matter, a
procedure 200 for operating an additive manufacturing apparatus is provided inFIG. 9 and amethod 300 of a build process of an additive manufacturing apparatus is provided inFIG. 10 . Theprocedure 200 and/or themethod 300 can be used to operate the additive manufacturing apparatus having any of the features described with reference toFIGS. 1A-8 . It should be appreciated that theexample procedure 200 and/or theexample method 300 are discussed herein only to describe example aspects of the present subject matter, and are not intended to be limiting. Moreover, the steps set forth in theexample procedure 200 and/or theexample method 300 may be performed in any sequence without departing from the scope of the present disclosure. - Referring to
FIG. 9 , in operation, various portions of a build products may be completed remotely and/or within the apparatus while other portions of the build procedure may be completed by the apparatus. For instance, theprocedure 200 may include aremote process 202 having one or more steps that may be completed by a device remote from the additive manufacturing apparatus and/or anonline process 210 having one or more steps that may be completed by the components of the additive manufacturing apparatus. - In the illustrated example, a
process 202 of defining one or more components to be built within the one or more print modules may be completed remotely. For instance, a three-dimensional design model of the component may be defined before manufacturing atstep 204. In this regard, a model or prototype of the component may be scanned to determine the three-dimensional information of the component. As another example, a model of the component may be constructed using a suitable computer-aided design (CAD) program to define the three-dimensional design model of the component. The design model may include 3D numeric coordinates of the configuration of the component including both external and internal surfaces of the component. For example, the design model may define the body, the surface, and/or internal passageways such as openings, support structures, etc. In some exemplary embodiments, the three-dimensional design model is converted into a plurality of slices or segments atstep 206, e.g., along a central (e.g., vertical) axis of the component or any other suitable axis. Each slice may define a thin cross section of the component for a height of the slice. At 208, the plurality of successive cross-sectional slices is stored as images that together form the 3D component. - An
online process 210 may include defining the parameters of the build process. For example, atstep 212, the parameters of the build process may be defined. Atstep 214, the parameters may be inputted through the user interface to the computing system. Atstep 216, the computing system may also receive the images of the component. Based on the parameters and the inputted parameters, atstep 218, a build file for each component to be built may be created and stored within the apparatus and/or any other location that is accessible by the control device of the apparatus. In some instances, atstep 220, a build parameter check may be performed to verify whether the parameter sets of each build module is compatible with the apparatus. - Once the file is saved, at
step 222, the print process may be initiated. In such instances, the parameters related to one or more devices operably coupled with the build controller are directed thereto atstep 224. From the build controller, shared parameters of a print configuration (resin support speed, slurry thickness, etc.) may be directed to the shared components of the apparatus. In addition, different print configurations can be sent to each print module. Atstep 226, the parameters related to the radiant energy sources, such as the images to be radiated by each of the radiant energy devices may be directed to the NAS device. Once each system receives the appropriate information, the build process is executed atstep 228. - In various embodiments, the computing system is configured to provide instructions to each of the components within the apparatus to build one or more predefined components during the build process. For instance, the computing system may provide instructions to at least one of the first actuation assembly or the second actuation assembly of the drive system. For example, in some instances, the first actuation assembly can receive instructions to control the feed mandrel to obtain a target tension on the resin support and the second actuation assembly can receive instructions to control at least one of a velocity, distance, or acceleration of a movement of the resin support from the feed module to the take-up module. In various embodiments, the first actuation assembly and the second actuation assembly can operate independently from each other. The drive system may receive a plurality of inputs from one or more feed module sensors, such as the first position sensor, the tension sensor, the feed roll proximity sensor. Additionally or alternatively, the plurality of inputs may be provided by one or more take-up module sensors, such as the second position sensor, the take-up roll proximity sensor, or any other sensor of the apparatus.
- A target length is received by the computing system, which may be a user-inputted value and/or generated by the computing system. The target distance may be based on various factors, such as the dimensions of the component to be formed, the dimensions of each stage, the number of print modules within the apparatus, the number of print modules being used for a print process, the number of radiant energy devices within the apparatus, the number of radiant energy devices being used for a print process, the size of each window within each print module of the apparatus, the size of each window within each print module being used for a print process, the size of the layer of the component to be formed within each print module, the thickness of the layer of the component that was just formed, the distance between each print module of the apparatus, the distance between each print module being used for a print process, etc. The target length of linear movement may be the same and/or altered for each successive layer of the component during the build process. As the first and second actuation assemblies are operated such that the resin support moves a target distance (or within a target distance range) at a target tension (or within a target tension range) by the control system, the first controller, and/or the second controller using one or more suitable timing algorithms to intermittently and/or constantly update the torque command through a control loop.
- While the resin support is translated, the deposition assembly can receive resin from the resin mixing assembly that is then deposited on the resin support. The resin is then translated into the one or more print modules.
- Once the resin is positioned within the one or more print modules, the stage of each print module that is used for a defined layer may be moved towards the resin. Once the stage is in a defined location, as determined by the build sensor of each respective print module, a corresponding radiant energy device of the print module may emit a defined image to at least partially cure a portion of the resin thereby forming a new layer of the component. Once each image is radiated from a respective radiant energy device, the corresponding stage is translated to a position further from the resin support, and the resin support is translated to deliver additional portions of resin to each defined print module.
- In various embodiments, the translational distance of the resin support may be varied from one layer to the next. For instance, the control system may determine a failure has occurred within one of the print modules. When the control system determines a failure has occurred within one of the print modules, the print module may pause the build process for that component while the remaining components of the other print modules continue to be built. Similarly, if the control system determines that one of the components has finished being built while others have not, the print module may stop actuation of the stage for that component while the remaining components of the other print modules continue to be built. Likewise, the control system may determine that a print module is not in use for the build process. Based on the variances in operation between the various print modules, the control system may vary the translational length of the resin support for each layer of the
component 12. - Referring now to
FIG. 10 , themethod 300 or build process, atstep 302, includes starting a build. The build process may be started through a user interface operably coupled with a computing system of the apparatus and/or through any other method. As provided herein, atstep 304, various parameters are inputted into the apparatus to define the building of one or more components. In such instances, the parameters relate to one or more devices operably coupled with the build controller are directed thereto. From the build controller, shared parameters of a print configuration (resin support speed, slurry thickness, etc.) may be directed to the shared components of the apparatus. In addition, different print configurations can be sent to each print module. The parameters related to the radiant energy sources, such as the images to be radiated by each of the radiant energy devices may be directed to the NAS device. - Next, at step (306), the build controller runs through a pre-print system check to assure that each sub-system of the apparatus that will be utilized is ready for starting a build. If any of the sub-systems do not pass the check, a notification is generated at
step 308 and themethod 300 may be restarted atstep 302. In some instances, the notification is provided on the user interface. - If each of the sub-systems does pass the check at (306), the
method 300 includes initializing communication between the build controller and each of the radiant energy devices atstep 310. Once communication has been established at (310), themethod 300, atstep 312, can include setting the deposition assembly to an initial height. The initial height may be a pre-calibrated height and/or the defined thickness of the first layer of the one or more components to be built. - Next, at
step 314, themethod 300 can include transferring resin from a mixing assembly, or another source, to a reservoir of the deposition assembly. In some instances, the reservoir of the deposition may continue to receive resin until a predefined volume is detected. - At
step 316, themethod 300 can include initiating a resin support calibration translation in which the resin support is translated from the feed module to the take-up module. During resin support calibration translation, linear motion of the resin support may be calibrated based on the data provided by the first position sensor and/or the second position sensor. Additionally or alternatively, the resin thickness deposition assembly height can be calibrated based on the resin thickness measured by the thickness sensor. - At
step 318, themethod 300 can include determining whether a resin flush should be completed. The determination may be made based on detected variances in the thickness of the resin exceeds a predefined range of the thickness of the resin, as detected by the thickness sensor duringstep 316. The variations in thickness may be caused by particulate and/or a foreign object being present with the reservoir of the deposition assembly. If variations in the resin thickness are determined, themethod 300, atstep 320, may include flushing the resin. To flush the resin, a device or combination of devices that define a height of the resin on the resin support may be moved to an elevated height while the resin support is translated. - If at
step 318 it is determined that a resin flush is not needed and/or after the resin flush atstep 320, themethod 300 can include performing a deposition assembly height adjustment. The height adjustment can be based on data provided by the thickness sensor duringstep 310 so that the requested resin casting thickness in the print parameter can be provided to one or more downstream print modules. - At
step 324, themethod 300 can include refilling the reservoir of the deposition assembly. In some instances, the reservoir of the deposition may continue to receive resin until a predefined volume is detected. In various examples, a volume sensor may be positioned within the deposition assembly that is configured to alert a user that the predefined volume has been obtained and/or the sensor may be operably coupled with a control valve that ceases movement of the resin from a vessel to the reservoir once the predefined volume has been obtained. - At
step 326, themethod 300 includes performing a resin support recoating. The recoating of the resin support can provide resin-coated resin support to each of the print modules that are to be used during a current indexing of the resin support. As provided herein, the system may build one or more components within each print module within the apparatus. Alternatively, less than all of the print modules may be used for a specific indexing of the resin support for various reasons. In instances in which various print modules are not in use for a specific indexing, the recoating area of the resin support may be reduced relative to the recoating area of the resin support when each of the print modules is in use. - Once the resin support is translated to place the resin within one or more print modules, at
step 328, themethod 300 can include activating the material retention assembly to retain the resin support in a predefined position within one or more print modules. In various embodiments, the material retention assembly may include a pneumatic assembly, a clamp, a combination thereof, and/or any other retention device. - At
step 330, themethod 300 can include loading a layer image within each of the radiant energy devices to be used during a specific indexing of the resin support. Atstep 332, themethod 300 can include moving each respective stage of the print modules to be used during the first index to a layer-specific print position. As discussed herein, each print module may be configured to build a common or varied component from any of the other print modules. Based on the potential variance in layer number and/or component design, each of the stages may be moved to a common and/or varied height from any of the other stages within the apparatus. - Once each of the stages are moved to a layer-specific print position, at
step 334, themethod 300 can include commanding each of the energy sources to draw or flash the layer image of the cross section of the component onto the surface of the resin. Exposure to the radiation cures and solidifies the pattern in the resin and joins it to a previously-cured layer of the component. In some instances, themethod 300 can include radiating a first image from a first radiant energy device at a first portion of resin positioned between the first radiant energy device and the first stage and a second image from a second radiant energy device at a second portion of resin positioned between the second radiant energy device and second first stage. - At
step 336, themethod 300 can include moving each respective stage of the print modules to be used during the first index to a separated position. As discussed herein, each print module may be configured to build a common or varied component from any of the other print modules. Based on the potential variance in layer number and/or component design, each of the stages may be moved to a common and/or varied height from any of the other stages within the apparatus. - At
step 338, themethod 300 can include deactivating the material retention assembly to release the resin support within one or more print modules. - At
step 340, themethod 300 can include determining whether an additional layer is to be formed for any of the one or more components within the apparatus. If any additional layers are to be formed, themethod 300 can progress to step 342. Atstep 342, the control system may determine whether the resin support should be moved for a second index and/or whether a new resin thickness is needed for the second index. If the resin support should be moved for a second index and/or if a new resin thickness is needed for the second index, themethod 300 may return to step 318. If the control system determines that the resin support should not be moved for a second index and/or a new resin thickness is not needed for the second index, themethod 300, atstep 344, may include conducting a resin support index move such that the resin support is translated by a short index distance to position a fresh resin-coated resin support section within each print module for the build of next layer. - Steps 328-344 may be performed to finish the build process layer-by-layer until a resin flush is to be performed. When a subsequent resin flush is to be performed, the
method 300 may return to step 318. As the subsequent resin flush is performed atstep 320, the thickness sensor data, first position sensor data, and/or second position data are recorded for the calibration of deposition assembly height and resin support linear translation distance for the next indexing. - If at
step 340, the control system determines that the system has reached the last layer in the build process, themethod 300 may continue to step 346. Atstep 346, themethod 300 can include draining any remaining resin from the reservoir of the deposition assembly. In such instances, a valve within the deposition may be closed to prevent additional resin from being transferred to the reservoir. In addition, the device or combination of devices that define the height of the resin on the resin support may be moved to an elevated height while the resin support is translated to drain any remaining resin in the reservoir. - At
step 348, once each the build process within a print module is complete, the respective stage may be raised to a preset removal position for component removal. Once each stage is raised, themethod 300 may end atstep 350. In some instances, a notification may be provided by the control system, such as to the user interface, indicating that the process has been completed and that each component is ready to be removed from the apparatus. - It should be appreciated that the additive manufacturing apparatus is described herein only for the purpose of explaining aspects of the present subject matter. In other example embodiments, the additive manufacturing apparatus may have any other suitable configuration and may use any other suitable additive manufacturing technology. Further, the additive manufacturing apparatus and processes or methods described herein may be used for forming components using any suitable material. For example, the material may be plastic, metal, concrete, ceramic, polymer, epoxy, photopolymer resin, or any other suitable material that may be embodied in a layer of slurry, resin, or any other suitable form of sheet material having any suitable consistency, viscosity, or material properties. For example, according to various embodiments of the present subject matter, the additively manufactured components described herein may be formed in part, in whole, or in some combination of materials including but not limited to pure metals, nickel alloys, chrome alloys, titanium, titanium alloys, magnesium, magnesium alloys, aluminum, aluminum alloys, iron, iron alloys, stainless steel, and nickel or cobalt-based superalloys (e.g., those available under the name Inconel® available from Special Metals Corporation). These materials are examples of materials suitable for use in the additive manufacturing processes described herein, and may be generally referred to as “additive materials.”
- Aspects of the present disclosure are provided by the subject matter of the following clauses, which are intended to cover all suitable combinations unless dictated otherwise based on logic or the context of the clauses and/or associated figures and description:
- An additive manufacturing apparatus comprising: a first print module including a first radiant energy device and a first stage configured to hold a first component; a second print module including a second radiant energy device and a second stage configured to hold a second component, wherein the first print module and the second print module are configured to receive at least a portion of a resin support between the first stage and the first radiant energy device and between the second stage and the second radiant energy device; and a control system configured to translate the resin support based on a condition of the first print module and the second print module through the first print module and the second print module.
- The additive manufacturing apparatus of one or more of these clauses, wherein the first print module further includes a first actuator and a first build sensor, and wherein the second print module further includes a second actuator and a second build sensor.
- The additive manufacturing apparatus of one or more of these clauses, wherein the first component has a first geometry and the second component has a second geometry, the first geometry being different from the second geometry.
- The additive manufacturing apparatus of one or more of these clauses, wherein the control system includes a build controller operably coupled with a computing system, and wherein the build controller is further coupled with one or more control devices.
- The additive manufacturing apparatus of one or more of these clauses, wherein the one or more control devices includes a first control device and a second control device, the first control device including a first communication line operably coupled with the build controller and a first operation bus operably coupled with the first print module, the second control device includes a second communication line operably coupled with the first control device and second operation bus operably coupled with the second print module.
- The additive manufacturing apparatus of one or more of these clauses, wherein the build controller is operably coupled with a user interface.
- The additive manufacturing apparatus of one or more of these clauses, wherein the control system further includes an energy device communication bus operably coupling one or more radiant energy devices to the computing system.
- The additive manufacturing apparatus of one or more of these clauses, wherein a network-attached storage is operably coupled with the energy device communication bus and configured to store data related to one or more images to be emitted by the first radiant energy device or the second energy device.
- The additive manufacturing apparatus of one or more of these clauses, wherein the control system is configured to receive defined parameters of a build process and images of each layer of the first component and the second component, and wherein the parameters are directed to the build controller while the images are provided to the network-attached storage.
- A method of operating an additive manufacturing apparatus, the method comprising: providing parameters of a build process to a control system; performing a first indexing of a resin support having a resin applied thereto to translate the resin support a first linear distance into a first print module and a second print module; moving a first stage within the first print module to a first stage position based on the provided parameters to form a first layer of a first component; moving a second stage within the second print module to a second stage position based on the provided parameters to form a first layer of a second component; radiating a first image from a first radiant energy device at a first portion of resin positioned between the first radiant energy device and the first stage; and radiating a second image from a second radiant energy device at a second portion of resin positioned between the second radiant energy device and second first stage.
- The method of one or more of these clauses, further comprising: calibrating a resin deposition assembly and a drive system prior to translating the resin support into the first print module and the second print module.
- The method of one or more of these clauses, further comprising: determining a thickness of the resin on the resin support; and flushing the resin from a deposition assembly when a variance in the thickness exceeds a predefined range.
- The method of one or more of these clauses, wherein the first stage position is offset from the second stage position in a Z-axis direction.
- The method of one or more of these clauses, further comprising: performing a second indexing of the resin support to translate the resin support a second linear distance that is different than the first linear distance when a failure within the first print module or the second print module is detected.
- The method of one or more of these clauses, further comprising: performing a second indexing of the resin support to translate the resin support a second linear distance that is different than the first linear distance when at least one of the first component or the second component is completed and the other of the first component or the second component is still being built.
- The method of one or more of these clauses, wherein each of the first stage and the second stage are moved to a separated position prior to performing a second indexing of the resin support to translate the resin support a second linear distance.
- An additive manufacturing apparatus comprising: a first print module including a first stage configured to hold a first component and a first radiant energy device; a second print module including a second stage configured to hold a second component and a second radiant energy device, wherein a resin support is configured to be positioned between the first stage and the first radiant energy device and between the second stage and the second radiant energy device; and a control system configured to translate the resin support based on a condition of the first print module and the second print module, the control system comprising: a build controller operably coupled with a computing system and one or more control devices; a user interface operably coupled with the build controller and the computing system, the user interface configured to receive one or more parameters; and an energy device communication bus operably coupled with the computing system in parallel with the build controller.
- The additive manufacturing apparatus of one or more of these clauses, wherein the one or more control devices includes a first control device coupled with the build controller and a second control device coupled with the first control device.
- The additive manufacturing apparatus of one or more of these clauses, wherein the one or more control devices includes a first control device and a second control device, the first control device including a first communication line operably coupled with the build controller and a first operation bus operably coupled with the first print module, the second control device includes a second communication line operably coupled with the first control device and second operation bus operably coupled with the second print module.
- The additive manufacturing apparatus of one or more of these clauses, wherein the first print module and the second print module are coupled with the build controller in series, and wherein the first radiant energy device and the second energy device are coupled with the computing system in series.
- This written description uses examples to disclose the concepts presented herein, including the best mode, and also to enable any person skilled in the art to practice the present disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the present disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
Claims (21)
1-20. (canceled)
21. An additive manufacturing apparatus comprising:
a first print module including a first radiant energy device and a first stage configured to hold a first additively-manufactured component;
a second print module including a second radiant energy device and a second stage configured to hold a second additively-manufactured component, wherein the first print module and the second print module are configured to receive at least a portion of a resin support between the first stage and the first radiant energy device and between the second stage and the second radiant energy device;
a shared component of the additive manufacturing apparatus operably coupled with the first print module and the second print module; and
a control system configured to control the first print module, the second print module, and the shared component based on one or more parameters that define a building of the first additively-manufactured component or the second additively-manufactured component.
22. The additive manufacturing apparatus of claim 21 , wherein the one or more parameters includes a shared parameter related to at least one of a resin support speed or a slurry thickness that is directed to the shared component of the additive manufacturing apparatus.
23. The additive manufacturing apparatus of claim 21 , wherein the one or more parameters includes a first parameter related to a first print configuration of the first print module.
24. The additive manufacturing apparatus of claim 23 , wherein the one or more parameters includes a second parameter related to a second print configuration of the second print module, the second parameter varied from the first parameter.
25. The additive manufacturing apparatus of claim 21 , wherein the control system is further configured to initiate a pre-print system check to assure that each sub-system of the additive manufacturing apparatus that will be utilized is ready for starting a build.
26. The additive manufacturing apparatus of claim 25 , wherein the control system includes a build controller operably coupled with a computing system, and wherein the build controller is further coupled with one or more control devices.
27. The additive manufacturing apparatus of claim 21 , wherein the control system is further configured to flush resin from a deposition assembly.
28. The additive manufacturing apparatus of claim 27 , wherein the control system is further configured to set an initial deposition height, wherein the initial deposition height is at least partially based on a defined thickness of a first layer of the first additively-manufactured component or the second additively-manufactured component.
29. The additive manufacturing apparatus of claim 27 , wherein the control system is further configured to activate a material retention assembly to retain the resin support in a predefined position within at least one of the first print module or the second print module.
30. The additive manufacturing apparatus of claim 21 , wherein the first additively-manufactured component has a first geometry and the second additively-manufactured component has a second geometry, the first geometry being different from the second geometry.
31. A method of operating an additive manufacturing apparatus, the method comprising:
providing parameters of a build process to a control system;
setting a deposition assembly to an initial height;
performing a resin support recoating; and
performing a first indexing of a resin support having a resin applied thereto to translate the resin support a first linear distance into a first print module and a second print module.
32. The method of claim 31 , further comprising:
moving a first stage within the first print module to a first stage position based on a parameter to form a first layer of a first additively-manufactured component; and
moving a second stage within the second print module to a second stage position based on the parameter to form a first layer of a second additively-manufactured component;
33. The method of claim 31 , further comprising:
radiating a first image from a first radiant energy device at a first portion of the resin positioned between the first radiant energy device and a first stage; and
radiating a second image from a second radiant energy device at a second portion of the resin positioned between the second radiant energy device and a second stage.
34. The method of claim 31 , further comprising:
calibrating a resin deposition assembly and a drive system prior to translating the resin support into the first print module and the second print module.
35. The method of claim 31 , further comprising:
performing a second indexing of the resin support to translate the resin support a second linear distance that is different than the first linear distance when a failure within the first print module or the second print module is detected.
36. The method of claim 31 , wherein a first stage and a second stage are moved to a separated position prior to performing a second indexing of the resin support to translate the resin support a second linear distance.
37. An additive manufacturing apparatus comprising:
a first print module including a first radiant energy device and a first stage configured to hold a first additively-manufactured component;
a second print module including a second radiant energy device and a second stage configured to hold a second additively-manufactured component, wherein the first print module and the second print module are configured to receive at least a portion of a resin support between the first stage and the first radiant energy device and between the second stage and the second radiant energy device;
a deposition system including a reservoir; and
a control system configured to control the first print module, the second print module, and the deposition system, the control system configured to an amount of resin within the reservoir based one or more parameters that define a building of the first additively-manufactured component or the second additively-manufactured component.
38. The additive manufacturing apparatus of claim 37 , wherein the control system is further configured to flush the resin within the reservoir.
39. The additive manufacturing apparatus of claim 37 , wherein the control system is further configured to refill the reservoir after one or more layers of the first additively-manufactured component or the second additively-manufactured component is formed.
40. The additive manufacturing apparatus of claim 37 , wherein the control system is further configured to drain the resin from the reservoir after a final layer of the first additively-manufactured component or the second additively-manufactured component is formed.
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