Additive Manufacturing Apparatus, System, and Method

Abstract

An apparatus for producing a three-dimensional object includes a support assembly having a build platform, a track extending through a build area, and a deposition mechanism mounted on the track and configured for producing the three-dimensional object in a layer-by-layer technique. The deposition mechanism includes a carriage moveable along the track, a supply of a flowable material mounted on the carriage, a roller in communication with the flowable material, where the roller is rotatably mounted on the carriage and configured for rotating to carry the flowable resin to an application for application to produce the object, and an exposure device mounted on the carriage. The exposure device emits electromagnetic waves to an exposure site to solidify the applied flowable material to produce the object. The roller is permeable to the electromagnetic waves, such that the waves pass through the roller in traveling from the exposure device to the exposure site.

What is claimed is: 
     
         1 . A method comprising:
 providing an apparatus comprising:
 a support assembly comprising a build platform defining a build area; 
 a track extending through the build area; and 
 a deposition mechanism mounted on the track, the deposition mechanism comprising a carriage configured for movement along the track through the build area, a supply of a flowable resin mounted on the carriage, an applicator in communication with the supply of flowable resin and configured for application of the flowable resin, and an exposure device mounted on the carriage and configured for emitting electromagnetic waves, 
 wherein the build platform is moveable between a build position and a tending position, wherein the build platform faces toward the track in the build position, and wherein the build platform faces away from the track in the tending position; 
   moving the deposition mechanism through the build area along the track while the build platform is in the build position, and applying the flowable resin to an application site within the build area, using the applicator, to produce first and second three-dimensional objects simultaneously on the build platform in a layer-by-layer technique as the carriage passes through the build area;   selectively activating the exposure device to emit the electromagnetic waves toward an exposure site within the build area to solidify applied resin applied by the applicator to produce the first and second three-dimensional objects simultaneously;   moving the build platform from the build position to the tending position;   removing the first three-dimensional object from the build platform while the build platform is in the tending position;   returning the build platform to the build position with the second three-dimensional object still supported by the build platform; and   continuing production of the second three-dimensional object by moving the deposition mechanism through the build area along the track while the build platform is in the build position, and applying the flowable resin to an application site within the build area, using the applicator, to produce the second three-dimensional object on the build platform in a layer-by-layer technique as the carriage passes through the build area.   
     
     
         2 . The method of  claim 1 , wherein the support assembly further comprises a rotating base configured for rotation on an axis and a support platform extending from the rotating base in a direction parallel to the axis, wherein the build platform is supported by the support platform, and wherein moving the build platform between the build position and the tending position is performed by rotating the rotating base, which causes the support platform to orbit the axis. 
     
     
         3 . The method of  claim 2 , wherein the rotating base is positioned at a first end of the support platform, and the support assembly further comprises a second rotating base at a second end of the support platform opposite the first end, and wherein the second rotating base is also configured for rotation on the axis, such that the rotating base and the second rotating base rotate in unison to move the build platform between the build position and the tending position. 
     
     
         4 . The method of  claim 2 , wherein the rotating base rotates 180° in moving the build platform between the build position and the tending position. 
     
     
         5 . The method of  claim 1 , wherein the build platform moves between the build position and the tending position by rotating. 
     
     
         6 . The method of  claim 1 , wherein the track extends below the build platform and the build area is defined below the build platform, such that the build platform faces downward in the build position and faces upward in the tending position. 
     
     
         7 . The method of  claim 1 , further comprising connecting the first three-dimensional object to the second three-dimensional object while the build platform is in the tending position. 
     
     
         8 . The method of  claim 1 , wherein an orientation of the build platform in the tending position is selected by a user. 
     
     
         9 . A method comprising:
 providing an apparatus comprising:
 a support assembly comprising a build platform defining a build area for producing a three-dimensional object on the build platform; 
 a track extending through the build area; and 
 a deposition mechanism mounted on the track, the deposition mechanism comprising a carriage configured for movement along the track through the build area, a supply of a flowable resin mounted on the carriage, an applicator in communication with the supply of flowable resin and configured for application of the flowable resin, and an exposure device mounted on the carriage and configured for emitting electromagnetic waves, 
 wherein the build platform is moveable between a build position and a tending position, wherein the build platform faces toward the track in the build position, and wherein the build platform faces away from the track in the tending position; 
   moving the deposition mechanism through the build area along the track while the build platform is in the build position, and applying the flowable resin to an application site within the build area, using the applicator, to produce the three-dimensional object on the build platform in a layer-by-layer technique as the carriage passes through the build area;   selectively activating the exposure device to emit the electromagnetic waves toward an exposure site within the build area to solidify applied resin applied by the applicator to produce the three-dimensional object;   moving the build platform from the build position to the tending position;   performing a tending operation on the three dimensional object;   returning the build platform to the build position with the three-dimensional object still supported by the build platform; and   continuing production of the three-dimensional object using the apparatus.   
     
     
         10 . The method of  claim 9 , wherein the support assembly further comprises a rotating base configured for rotation on an axis and a support platform extending from the rotating base in a direction parallel to the axis, wherein the build platform is supported by the support platform, and wherein moving the build platform between the build position and the tending position is performed by rotating the rotating base, which causes the support platform to orbit the axis. 
     
     
         11 . The method of  claim 10 , wherein the rotating base is positioned at a first end of the support platform, and the support assembly further comprises a second rotating base at a second end of the support platform opposite the first end, and wherein the second rotating base is also configured for rotation on the axis, such that the rotating base and the second rotating base rotate in unison to move the build platform between the build position and the tending position. 
     
     
         12 . The method of  claim 10 , wherein the rotating base rotates 180° in moving the build platform between the build position and the tending position. 
     
     
         13 . The method of  claim 9 , wherein the build platform moves between the build position and the tending position by rotating. 
     
     
         14 . The method of  claim 9 , wherein the track extends below the build platform and the build area is defined below the build platform, such that the build platform faces downward in the build position and faces upward in the tending position. 
     
     
         15 . The method of  claim 9 , wherein the tending operation comprises connecting a secondary component to the three-dimensional object. 
     
     
         16 . The method of  claim 15 , wherein the secondary component is connected in a configuration such that the secondary component is not exposed to the electromagnetic waves during the continuing production of the three-dimensional object. 
     
     
         17 . A method comprising:
 providing an apparatus comprising:
 a support assembly comprising a build platform defining a build area for producing a three-dimensional object on the build platform; 
 a track extending through the build area; and 
 a deposition mechanism mounted on the track, the deposition mechanism comprising a carriage configured for movement along the track through the build area, a supply of a flowable resin mounted on the carriage, an applicator in communication with the supply of flowable resin and configured for application of the flowable resin, and an exposure device mounted on the carriage and configured for emitting electromagnetic waves; 
   moving the deposition mechanisms through the build area sequentially in a first pass along the track while the build platform is in the build position to produce the three-dimensional object on the build platform in a layer-by-layer technique as each carriage passes through the build area, comprising:
 applying the flowable resin to an application site within the build area, using the applicator of each deposition mechanism; and 
 selectively activating the exposure devices of each deposition mechanism to emit the electromagnetic waves toward an exposure site within the build area to solidify applied resin applied by the applicator to produce the three-dimensional object. 
   
     
     
         18 . The method of  claim 17 , wherein each deposition mechanism applies a separate layer of the three-dimensional object in the first pass. 
     
     
         19 . The method of  claim 17 , wherein at least two of the deposition mechanisms apply different portions of a same layer of the three-dimensional object in the first pass. 
     
     
         20 . The method of  claim 17 , further comprising moving the deposition mechanisms through the build area sequentially in plurality of additional passes along the track while the build platform is in the build position to produce the three-dimensional object on the build platform. 
     
     
         21 . The method of  claim 17 , wherein moving the deposition mechanisms through the build area sequentially along the track while the build platform is in the build position produces a second three-dimensional object on the build platform in the layer-by-layer technique as each carriage passes through the build area simultaneously with the three-dimensional object. 
     
     
         22 . A method comprising:
 providing an apparatus comprising:
 a carriage configured for movement through a build area defined by a build platform; 
 a supply of a flowable resin mounted on the carriage; 
 an applicator in communication with the supply of flowable resin, wherein the applicator is mounted on the carriage and configured for applying the flowable resin; 
 an exposure device mounted on the carriage and configured for emitting electromagnetic waves through an array of outlets; 
   moving the carriage through the build area, and applying the flowable resin to an application site within the build area, using the applicator, to produce a three-dimensional object on the build platform in a layer-by-layer technique as the carriage passes through the build area; and   selectively activating the exposure device to emit the electromagnetic waves toward an exposure site within the build area to solidify applied resin applied by the applicator to produce the three-dimensional object simultaneously, wherein selectively activating the exposure device comprises varying the power output of the electromagnetic waves in order to adjust an exposure size of at least one of the outlets.