RU2773690C2 - Unit, system and method for additive manufacturing - Google Patents

Abstract

FIELD: additive manufacturing technology.

SUBSTANCE: group of inventions relates to an apparatus (variants) and a method (variants) for creating a three-dimensional object on a platform for buildup using resin by a layered technique, a unit for creating a three-dimensional object on a platform for buildup using resin by a layered technique (variants), and a source of resin in a fluid form. The apparatus comprises a carriage with a source of resin in a fluid form installed thereon, a roll for transferring a layer of the fluid material to the application site, and an irradiating apparatus installed on the carriage and configured to emit electromagnetic waves. The irradiating apparatus is configured to emit electromagnetic waves in the direction of the first irradiation site located adjacent to the roll within the source of resin to ensure at least partial hardening of the resin layer and to emit electromagnetic waves in the direction of the second irradiation site within the buildup area in order to apply a layer to create a three-dimensional object.

EFFECT: invention provides a possibility of manufacturing objects from multiple materials, including objects with a removable support structure made of a material different from the material of the main object; also provided is the possibility of creating objects from multiple materials requiring different irradiation sources, as well as the possibility of creating clean, dry, and fully hardened objects, increasing the efficiency of creation.

71 cl, 93 dwg

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is non-provisional and claims priority of U.S. Provisional Application No. 62/654076, filed April 6, 2018, the prior application being incorporated herein by reference in its entirety.

FIELD OF TECHNOLOGY TO WHICH THE INVENTION RELATES

[0002] The present invention generally relates to an apparatus and system for creating a three-dimensional object by additive manufacturing and to a method for operating the apparatus and system, and more specifically to an apparatus, system and method that uses a roller in contact with a flowable resin or another precursor material when building up each layer of the object.

BACKGROUND OF THE INVENTION

[0003] Current 3D additive manufacturing techniques (eg, stereolithography, 3D printing, etc.) produce superior quality products with high fidelity, but such techniques have significant limitations. Typically, such techniques work in one of three ways: (a) continuous polymerization of layers on or near the surface of the liquid resin contained in the stationary bath, (b) continuous polymerization of resin layers at or near the bottom of the stationary resin bath, or (c ) continuous polymerization of layers of resin that have been jet-down by one or more single-nozzle or multi-nozzle printheads. Such techniques are generally limited to small sizes, with maximum sizes for various machines being only a few feet wide or long, or even less. This limits the size of objects that can be created. Inkjet processes have significant size limitations and result in the loss of a large amount of polymeric material during creation.

[0004] Bath-based techniques require the object to be partially or completely immersed during fabrication, and therefore it is necessary to maintain a significant resin bath volume. This can be costly as such resins are usually very expensive and maintenance of the resin baths in machines can be extremely expensive. The size of the bath also limits the size of the object that can be created, as noted above. Additionally, submerging an object during creation often results in cavities within the object being filled with uncured liquid resin that must be drained, often requiring a drain hole to be drilled and then removed. In addition, the bath usually contains only one resin, so making parts from multiple materials is not possible. Bath based techniques also have limitations in build speed due to the wait time for new resin to flow over or under the areas to be cured.

[0005] The purpose of the present invention is to overcome some of these limitations and other shortcomings of existing installations, systems and methods, as well as to provide new features that did not previously exist.

DISCLOSURE OF THE INVENTION

[0006] General aspects of the present invention relate to layering mechanisms configured to create a three-dimensional object on a platform for building using resin or other fluid material in a layering technique, which use a roller or other application device to transfer a layer of fluid material to the application site, an irradiating device for emitting electromagnetic waves to deposit a layer on an object to build up an object, and they optionally further include an initial irradiation with radiated electromagnetic waves to cause at least partial solidification of the layer of fluid material before transferring the layer with a roll to the application site. General aspects of the present invention also relate to systems, installations and methods using such layering mechanisms.

[0007] Aspects of the present invention relate to a layering mechanism configured to create a three-dimensional object on a build platform using resin in a layer-by-layer technique, wherein the build-up area is defined adjacent to the build-up platform, comprising a carriage movable over the build-up area, a source of resin in fluid form, mounted on the carriage, a roll in communication with the resin source and mounted for rotation on the carriage, and an irradiating device mounted on the carriage and configured to emit electromagnetic waves. The irradiating device is configured to radiate electromagnetic waves towards the first irradiation site adjacent to the roller within the resin source to at least partially solidify the resin layer, and the roller is rotatable to transfer the resin layer to the application site within the region. build-up to apply to create a three-dimensional object as the carriage passes over the build-up area. The irradiating device is additionally configured to radiate electromagnetic waves towards the second irradiation site within the build-up area in order to apply a layer to create a three-dimensional object. In one configuration, the first irradiation site and the second irradiation site may be located at an angular distance of approximately 180° from each other relative to the roller. In various configurations, the build-up area may be located below the build-up platform, whereby the roll is configured to pass under the build-up platform to build up an object under the build-up platform, or the build-up area may be above the build-up platform, whereby the roll is configured to pass over an extension platform for the purpose of building an object over an extension platform.

[0008] According to one aspect, the mechanism further comprises a controller configured to control the movement of the carriage and roller and to control the activation of the irradiation device to create a three-dimensional object.

[0009] According to another aspect, the mechanism further comprises a first set of optical fibers containing the first output ends arranged in the form of a first set and the first input ends configured to receive electromagnetic waves from the irradiating device, and a second set of optical fibers containing the second output ends arranged in the form of a second set, and second input ends configured to receive electromagnetic waves from the irradiating device. The first plurality of optical fibers is configured such that the electromagnetic waves emitted by the irradiating device travel through the first plurality of optical fibers and exit from the output ends of the first set directed to the first irradiation site, and the second plurality of optical fibers are configured such that the electromagnetic waves emitted by the irradiating device, move through the second set of optical fibers and exit from the output ends of the second set directed to the second irradiation site. In one configuration, the illuminating device includes a plurality of LEDs, and each of the first plurality of optical fibers and each of the second plurality of optical fibers are associated with one of the plurality of LEDs. In another configuration, the irradiating device comprises a DLP (Digital Light Processing) projector, and each of the first plurality of optical fibers and each of the second plurality of optical fibers are configured to receive electromagnetic waves from the DLP projector.

[0010] According to another aspect, the roller is electromagnetically permeable, and the irradiation device is configured such that the electromagnetic waves pass through the roller while moving towards the first irradiation site and the second irradiation site.

[0011] According to another aspect, the layering mechanism further comprises a resin removal mechanism positioned between the first irradiation site and the second irradiation site and configured to remove excess uncured resin from the layer between the first and second irradiation sites.

[0012] According to yet another aspect, the layering mechanism comprises a first set of lenses located between the irradiating device and the first irradiation site, and a second set of lenses located between the irradiating device and the second irradiation site, wherein the first and second lens sets are configured to focus electromagnetic waves directed to the first irradiation site and the second irradiation site.

[0013] According to a further aspect, the layering mechanism further comprises a thickness stop located at the first irradiation site, whereby the first irradiation site is between the roll and the thickness stop, and the space between the roll and the thickness stop defines the layer thickness. In one configuration, the thickness limiter comprises an auxiliary roll rotatably mounted at least partially within the resin source.

[0014] According to another aspect, the carriage is configured to be mounted on a rail to move around the buildup area. The carriage can be additionally made with the possibility of independent movement separately from the guide.

[0015] Additional aspects of the present invention relate to a layering mechanism configured to create a three-dimensional object on a build platform using resin in a layer-by-layer technique, the build-up area being defined adjacent to the build-up platform, comprising a carriage movable over the build-up area, source resin in fluid form mounted on a carriage, a main roll in communication with the resin source and rotatably mounted on the carriage, an auxiliary roll rotatably mounted at least partially within the resin source, whereby between the main roll and the auxiliary roll a space is formed, and an irradiating device mounted on the carriage and configured to emit electromagnetic waves. The irradiating device is configured to radiate electromagnetic waves towards the first irradiation site, located within the resin source and within the space between the main and auxiliary rolls, to ensure at least partial solidification of the resin layer, whereby the space between the main and auxiliary rolls determines the layer thickness. , and the main roll is rotatable to carry the resin layer to an application site within the build-up area to apply to create a three-dimensional object as the carriage passes through the build-up area. The irradiating device is additionally configured to radiate electromagnetic waves towards the second irradiation site within the build-up area in order to apply a layer to create a three-dimensional object. In one configuration, the first irradiation site and the second irradiation site may be located at an angular distance of approximately 180° from each other relative to the roller. In various configurations, the build-up area may be located below the build-up platform, whereby the main roll is configured to pass under the build-up platform to build up an object under the build-up platform, or the build-up area may be located above the build-up platform, whereby the main roll is configured to passing over the build-up platform to build up the object over the build-up platform.

[0016] According to one aspect, the mechanism further comprises a controller configured to control the movement of the carriage and the main and auxiliary rolls and to control the activation of the irradiation device to create a three-dimensional object.

[0017] According to another aspect, the mechanism further comprises a first set of optical fibers, containing the first output ends arranged in the form of a first set, and the first input ends configured to receive electromagnetic waves from the irradiating device, and the second set of optical fibers, containing the second output ends arranged in the form of a second set, and second input ends configured to receive electromagnetic waves from the irradiating device. The first plurality of optical fibers is configured such that the electromagnetic waves emitted by the irradiating device travel through the first plurality of optical fibers and exit from the output ends of the first set directed to the first irradiation site, and the second plurality of optical fibers are configured such that the electromagnetic waves emitted by the irradiating device, move through the second set of optical fibers and exit from the output ends of the second set directed to the second irradiation site. In one configuration, the illuminator comprises a plurality of LEDs, with each of the first plurality of optical fibers and each of the second plurality of optical fibers associated with one of the plurality of LEDs. In another configuration, the irradiating device comprises a DLP projector, wherein each of the first plurality of optical fibers and each of the second plurality of optical fibers are configured to receive electromagnetic waves from the DLP projector. In some configurations, the exit ends of the first set and the exit ends of the second set are located within the main roll.

[0018] According to another aspect, the main roll is permeable to electromagnetic waves, and the irradiation device is configured such that electromagnetic waves pass through the main roll while moving towards the first irradiation site and the second irradiation site.

[0019] According to yet another aspect, the mechanism further comprises a resin removal mechanism positioned between the first irradiation site and the second irradiation site and configured to remove excess uncured resin from the layer between the first and second irradiation sites. In one configuration, the resin removal mechanism includes a cleaning roll positioned between the first irradiation site and the second irradiation site and rotatable in contact with the layer surface to remove excess uncured resin from the layer between the first and second irradiation sites. The resin removal mechanism may comprise first and second cleaning rolls located between the first irradiation site and the second irradiation site on opposite sides of the second irradiation site, wherein the first and second cleaning rolls are configured such that the first cleaning roll is rotatable while being in contact with the surface of the layer, to remove excess uncured resin from the layer between the first and second irradiation sites, when the layering mechanism moves in the first direction and the second cleaning roller is rotatable in contact with the surface of the layer, to remove excess uncured resin from the layer between the first and second irradiation sites, when the layering mechanism moves in a second direction opposite to the first direction. In this configuration, the first and second cleaning rollers are configured such that the first cleaning roller is configured to contact the main roller to function as the first transfer check sensor when the layering mechanism is moved in the second direction, and the second cleaning roller is configured to contact the main roller to function as a second transfer check sensor when the layering mechanism is moved in the first direction.

[0020] According to another aspect, the layering mechanism further comprises a first set of lenses located between the irradiating device and the first irradiation site, and a second set of lenses located between the irradiating device and the second irradiation site, wherein the first and second lens sets are configured to focus electromagnetic waves directed to the first irradiation site and the second irradiation site.

[0021] According to a further aspect, the carriage is configured to be mounted on a rail to move across the buildup area. In one configuration, the carriage is further configured to move independently from the rail.

[0022] Still further aspects of the present invention relate to a fluid supply assembly that comprises a supply tub configured to contain fluid material, the supply tub having first and second internal support walls located at opposite ends of the supply tub, a roll located at least at least partially within the supply bath and designed so as to be in contact with the fluid material, and the first outer support wall located outside the first internal support wall and located outside the supply bath, as a result of which between the first internal support wall and the first external support wall the first space is formed by the wall. The first inner support wall comprises a first opening extending through it between the supply pool and the first space, and the roller extends through the first opening and is located at least partially within the first space. The first seal contacts the roll around the entire periphery of the roll and is positioned adjacent to the first opening to prevent most leakage of fluid material through the first opening while allowing some slow and/or controlled leakage of portions of the fluid material through the first opening. The assembly also includes a drain system configured to remove portions of fluid material that pass through the first opening from the first space. Aspects of the present invention also relate to a layering mechanism that includes an assembly for supplying a fluid material, as well as a carriage configured to move through the build-up area to build up a three-dimensional object, and an irradiation device configured to emit electromagnetic waves in the direction of the irradiation site within the area. build-up to apply a layer of roll-borne material to create an object.

[0023] According to one aspect, the drain system is further configured to return parts of the fluid material to the supply bath.

[0024] According to another aspect, the assembly also includes a second outer support wall located outside the second inner support wall and located outside the supply pool, as a result of which a second space is formed between the second inner support wall and the second outer support wall. The second inner support wall has a second opening extending through it between the supply pool and the second space, and the roller extends through the second opening and is located at least partially within the second space. The second seal is in contact with the roll along the entire periphery of the roll and is located adjacent to the second opening to prevent most leakage of fluid material through the second opening. The drain system is further configured to remove additional portions of fluid material that pass through the second opening from the second space.

[0025] According to another aspect, the supply tub includes a bottom wall that extends between the first and second inner support walls and further extends between the first inner support wall and the first outer support wall through the first space, and the drain system includes a drain hole in the bottom wall within the first space.

[0026] According to another aspect, the drain system further comprises a drain hole within the first space and a reservoir in communication with the drain hole, and the drain system is configured so that the removal of parts of the fluid material occurs by flowing through the drain hole and into the tank. In one configuration, the drain system further comprises a pumping mechanism configured to pump fluid material from the reservoir to the supply bath. In this configuration, the bottom wall of the supply trough may include an opening in communication with the pumping mechanism, whereby the pumping mechanism is configured to pump fluid material into the supply trough through the opening, and the bottom wall of the supply trough may be inclined downward towards the opening.

[0027] According to yet another aspect, the first bearing is connected to the first outer support wall and engages the roll to rotatably support the roll.

[0028] Other aspects of the present invention relate to a self-contained unit that contains a layering mechanism and/or a node for supplying fluid material, as described herein, and the self-contained unit can be moved to build up one or more objects using the layering mechanism.

[0029] Other aspects of the present invention relate to an apparatus that includes a layering mechanism, as described herein, and a support assembly containing an extension platform, and the extension area is defined adjacent to the extension platform for the purpose of building one or more objects on the extension platform .

[0030] Still other aspects of the present invention relate to a method for growing a three-dimensional object using a layering, mounting, and/or stand-alone block mechanism, as described above. In one configuration, the method includes selectively activating an irradiating device to emit electromagnetic waves towards a first irradiation site adjacent to the roller within the resin source to cause the resin layer to at least partially solidify, rotating the roller to transfer the resin layer to the application site within the build-up area to create a three-dimensional object as the carriage passes through the build-up area; and selectively activating the irradiating device to emit electromagnetic waves towards the second irradiation site within the build-up area to apply a layer to create a three-dimensional object. In another configuration, the method includes selectively activating an irradiating device to emit electromagnetic waves towards a first irradiation site located within a resin source and within a space between the main and sub rolls to cause the resin layer to at least partially solidify, whereby the space between determines the thickness of the layer with the main and auxiliary rollers, rotates the main roller to transfer the resin layer to the application site within the build-up area to apply to create a three-dimensional object as the carriage passes through the build-up area, and selectively activate the irradiating device to emit electromagnetic waves towards the second irradiation site within the build-up area in order to apply a layer to create a three-dimensional object.

[0031] According to one aspect, the method may further include controlling the movement of the carriage and the roller or rollers and controlling the activation of the irradiator to create a three-dimensional object using the controller. In one configuration, the carriage is mounted on a guide and moves along the guide over the buildup area, and the carriage is movable separately from the guide, and the method further includes controlling movement of the layering mechanism away from the guide using a controller. In another configuration, the method includes controlling, using a controller, at least one additional layering engine, which can move independently of the layering engine, to create a three-dimensional object.

[0032] Other features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to understand the present invention, it will be further described by way of example with reference to the accompanying drawings, in which:

[0034] in FIG. 1 is a schematic side view of one embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[0035] in FIG. 2A and 2B are schematic side views of the support assembly of the system and apparatus of FIG. 1, wherein the 3D object is created at the reference node;

[0036] in FIG. 3 is a schematic side view of another embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[0037] in FIG. 4 is a schematic side view of another embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[0038] in FIG. 5A and 5B are schematic plan views of the system and plant of FIG. 1 in operation according to aspects of the present invention;

[0039] in FIG. 6A and 6B are schematic side views of the system and plant of FIG. 1 in operation according to aspects of the present invention;

[0040] in FIG. 7 is a schematic side view of the plant of FIG. 1 further comprising an auxiliary irradiation device;

[0041] in FIG. 8 is a top perspective view of another embodiment of a 3D object generating apparatus in accordance with aspects of the present invention;

[0042] in FIG. 9 is a side view of the apparatus of FIG. eight;

[0043] in FIG. 10 is a top perspective view of the layering mechanism of the apparatus of FIG. eight;

[0044] in FIG. 11 is a plan view of the layering mechanism of the plant of FIG. ten;

[0045] in FIG. 12 is a perspective view of one embodiment of a manifold for use with the layering mechanism of FIG. 8 according to aspects of the present invention;

[0046] in FIG. 13 is a schematic view of the manifold of FIG. 12 shown in operation with one embodiment of an irradiation device according to aspects of the present invention;

[0047] in FIG. 14 is a schematic side view of another embodiment of an irradiation device in accordance with aspects of the present invention;

[0048] in FIG. 15 is a perspective view of another embodiment of an apparatus for creating a three-dimensional object in operation according to aspects of the present invention;

[0049] in FIG. 16 is a side view of the layering mechanism of the plant of FIG. fifteen;

[0050] in FIG. 17 is an exploded view of the layering mechanism of FIG. 16;

[0051] in FIG. 18 is a perspective view of the layering mechanism of FIG. 16;

[0052] in FIG. 19 is a schematic side view of another embodiment of a layering mechanism capable of modular connection of a modular connection of components, in accordance with aspects of the present invention;

[0053] in FIG. 20A and 20B are schematic side views of another embodiment of a 3D object generation facility in operation, in accordance with aspects of the present invention;

[0054] in FIG. 21 is a schematic side view of another embodiment of an apparatus for creating a three-dimensional object in operation according to aspects of the present invention;

[0055] in FIG. 22 is a schematic side view of another embodiment of an apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[0056] in FIG. 23 is a schematic side view of another embodiment of a 3D object generation facility in operation, in accordance with aspects of the present invention;

[0057] in FIG. 24A is a schematic side view of another embodiment of a 3D object generation facility in operation, in accordance with aspects of the present invention;

[0058] in FIG. 24B is a schematic side view of another embodiment of a 3D object generation facility in operation, in accordance with aspects of the present invention;

[0059] in FIG. 25 is a schematic side view of another embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[0060] in FIG. 26 is a schematic view of a controller in accordance with aspects of the present invention;

[0061] in FIG. 27 is a schematic plan view of another embodiment of an applicator and source of fluid material in accordance with aspects of the present invention;

[0062] in FIG. 28 is a schematic side view of another embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention; and

[0063] in FIG. 29 is a schematic side view of another embodiment of a 3D object generation facility in operation, in accordance with aspects of the present invention;

[0064] in FIG. 30 is a schematic side view of another embodiment of an apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[0065] in FIG. 31 is a side view of another embodiment of an apparatus for creating a three-dimensional object in operation according to aspects of the present invention;

[0066] in FIG. 32 is a perspective view of the plant of FIG. 31;

[0067] in FIG. 33 is a perspective view of the plant of FIG. 31 showing the vertical adjustment of the machine's layering mechanism to a new vertical application location;

[0068] in FIG. 34 is a perspective view of the support assembly of the apparatus of FIG. 31 showing the movement of the extension platform from the extension position to the service position;

[0069] in FIG. 35 is a perspective view of the support assembly of the apparatus of FIG. 31 showing the extension platform in service position;

[0070] in FIG. 36 is a perspective view of the plant of FIG. 31 illustrating the execution of a service operation when the extension platform is in the service position;

[0071] in FIG. 37 is a perspective view of the plant of FIG. 31 illustrating further creation of objects when the build platform is in the build position after the maintenance operation of FIG. 36;

[0072] in FIG. 38 is a side view of the layering mechanism of the plant of FIG. 31;

[0073] in FIG. 39 is a side view of the layering mechanism of FIG. 38 showing the vertical adjustment of the layering mechanism to a new vertical application location;

[0074] in FIG. 40 is a partial perspective view of the layering mechanism of FIG. 31 showing movement of the layering mechanism apart from the support assembly;

[0075] in FIG. 41A is a partial perspective view of the layering mechanism of FIG. 40 preparing to engage with the support assembly guide;

[0076] in FIG. 41B is a partial perspective view of the layering mechanism of FIG. 41 after engagement with the support assembly guide;

[0077] in FIG. 42 is a side view of the apparatus of FIG. 31, with several application mechanisms operating simultaneously;

[0078] in FIG. 43 is a perspective view of a portion of the removable resin application module of the layering mechanism of FIG. 38;

[0079] in FIG. 44 is a perspective view illustrating the removal of the resin application module from the resin layering mechanism of FIG. 38;

[0080] in FIG. 45 is a perspective view illustrating the removal of the resin application module of FIG. 44 from the resin layering mechanism of FIG. 38;

[0081] in FIG. 46 is a perspective view illustrating the interchange of the second resin application module for the resin layering mechanism of FIG. 38;

[0082] in FIG. 47 is a perspective view of the layering mechanism of FIG. 10 illustrating the removal of the resin application module from the layering mechanism;

[0083] in FIG. 48A and 48B are schematic side views of another embodiment of a 3D object generation facility in operation, in accordance with aspects of the present invention;

[0084] in FIG. 49A and 49B are schematic rear views of another embodiment of a 3D object generation facility in operation, in accordance with aspects of the present invention;

[0085] in FIG. 49C and 49D are schematic side views of another embodiment of a 3D object generation facility in operation, in accordance with aspects of the present invention;

[0086] in FIG. 50 is a schematic side view of one embodiment of an accumulation sensor capable of being used in conjunction with a layering mechanism to create a three-dimensional object in operation, in accordance with aspects of the present invention;

[0087] in FIG. 51 is a schematic side view of another embodiment of a 3D object generation facility in operation, in accordance with aspects of the present invention;

[0088] in FIG. 52 is a schematic side view illustrating the operation of the apparatus of FIG. 51 away from the extension platform;

[0089] in FIG. 53 is a schematic side view of another embodiment of a 3D object generation facility in operation, in accordance with aspects of the present invention;

[0090] in FIG. 54 is a schematic plan view of one embodiment of an irradiating device for use in conjunction with a three-dimensional object creation facility in operation, in accordance with aspects of the present invention;

[0091] in FIG. 55 is a schematic plan view of another embodiment of an irradiation device for use in conjunction with an in-process 3D object generation facility in accordance with aspects of the present invention;

[0092] in FIG. 56 is a schematic plan view of another embodiment of an irradiation device for use in conjunction with an in-process 3D object creation facility in accordance with aspects of the present invention;

[0093] in FIG. 57 is a schematic plan view of another embodiment of an irradiation device for use in conjunction with a three-dimensional object creation facility in operation, in accordance with aspects of the present invention;

[0094] in FIG. 58 is a schematic side view of another embodiment of an irradiation device and an application device for use in conjunction with a three-dimensional object creation facility in operation, in accordance with aspects of the present invention;

[0095] in FIG. 59 is a schematic side view illustrating one embodiment of the operation of the irradiation device and application device of FIG. 58 in conjunction with an on-line 3D object creation facility in accordance with aspects of the present invention;

[0096] in FIG. 60 is a schematic side view illustrating another embodiment of the operation of the irradiation device and application device of FIG. 58 in conjunction with an on-line 3D object creation facility in accordance with aspects of the present invention;

[0097] in FIG. 61A and 61B are schematic side views of another embodiment of an irradiation device and an application device for use in conjunction with a three-dimensional object creation facility in operation, in accordance with aspects of the present invention;

[0098] in FIG. 62 is a perspective view illustrating another embodiment of an in-process 3D object creation apparatus according to aspects of the present invention, with the build-up platform shown in the build-up position;

[0099] in FIG. 63 is a perspective view illustrating the apparatus of FIG. 62, which shows the movement of the extension platform from the extension position to the service position;

[00100] in FIG. 64 is a perspective view illustrating the apparatus of FIG. 62 showing the extension platform in service position;

[00101] in FIG. 65 is a schematic view illustrating a process for relocating and allowing additional material to solidify in accordance with aspects of the present invention;

[00102] in FIG. 66 is a partially enlarged schematic view of another embodiment of an irradiation device and layering mechanism according to aspects of the present invention, with the irradiation device shown on an enlarged scale and a break line illustrating the separation of the enlarged and non-enlarged portions;

[00103] in FIG. 67 is a partial sectional perspective view of one embodiment of a roll and fluid supply pan according to aspects of the present invention;

[00104] in FIG. 68 is a partial sectional side view of the roll and vat of FIG. 67;

[00105] in FIG. 69 is an enlarged sectional view of a portion of the roll and vat of FIG. 67;

[00106] in FIG. 70 is an enlarged partial perspective view in section of a portion of the roll and vat of FIG. 67;

[00107] in FIG. 71 is a schematic side view of another embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[00108] in FIG. 71A is a schematic side view of a portion of the system and apparatus of FIG. 71 including temperature control elements in accordance with aspects of the present invention;

[00109] in FIG. 71B is a schematic side view of another embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[00110] in FIG. 71C is a schematic side view of another embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[00111] in FIG. 71D is a schematic side view of another embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[00112] in FIG. 72 is a schematic side view of another embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[00113] in FIG. 73 is a schematic side view of another embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[00114] in FIG. 74 is a schematic side view of another embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[00115] in FIG. 75 is a schematic side view of another embodiment of a system and apparatus for creating a three-dimensional object in operation, in accordance with aspects of the present invention;

[00116] in FIG. 75A is a schematic side view of a portion of the system and apparatus of FIG. 75 including temperature control elements in accordance with aspects of the present invention;

[00117] in FIG. 76 is a perspective view of another embodiment of a 3D object maker in operation, in accordance with aspects of the present invention, including a layering mechanism moving toward the support assembly;

[00118] in FIG. 77 is a side view of the apparatus of FIG. 76;

[00119] in FIG. 78 is a perspective view of the plant of FIG. 76, which shows the vertical adjustment of the machine's support assembly to a new vertical deposition location and the operation of the layering mechanism to create a three-dimensional object;

[00120] in FIG. 79 is a side view of the apparatus of FIG. 78;

[00121] in FIG. 80 is a bottom perspective view of the layering mechanism of FIG. 76;

[00122] in FIG. 81 is a front view of the layering mechanism of FIG. 80;

[00123] in FIG. 82 is a bottom perspective view of a portion of a layering mechanism creating a layer of another embodiment of a three-dimensional object, in accordance with aspects of the present invention;

[00124] in FIG. 83 is a top perspective view of a portion of the layering mechanism creating a 3D object layer as shown in FIG. 82;

[00125] in FIG. 84 is a bottom perspective view of a portion of the layering mechanism creating the second layer of the 3D object as shown in FIG. 82;

[00126] in FIG. 85 is a top perspective view of the portion of the layering mechanism creating the second layer of the 3D object as shown in FIG. 84;

[00127] in FIG. 86 is a bottom perspective view of a portion of a layering mechanism creating a layer of another embodiment of a three-dimensional object, in accordance with aspects of the present invention;

[00128] in FIG. 87 is a top perspective view of a portion of the layering mechanism creating a 3D object layer as shown in FIG. 86;

[00129] in FIG. 88 is an enlarged perspective view of one example of a 3D object created using the technique of FIG. 86 and 87;

[00130] in FIG. 89 is another enlarged perspective view of a portion of the 3D object of FIG. 88;

[00131] in FIG. 90 is a bottom perspective view of a portion of a layering mechanism creating a layer of another embodiment of a three-dimensional object, in accordance with aspects of the present invention;

[00132] in FIG. 91 is a top perspective view of a portion of the layering mechanism creating a 3D object layer as shown in FIG. 90;

[00133] in FIG. 92 is a bottom perspective view of a portion of a layering mechanism creating a layer of another embodiment of a three-dimensional object, in accordance with aspects of the present invention; and

[00134] in FIG. 93 is a top perspective view of a portion of the layering mechanism creating a 3D object layer as shown in FIG. 92.

DESCRIPTION OF EMBODIMENTS

[00135] While the present invention may be embodied in many different forms, the drawings show and will herein describe in detail certain embodiments of the present invention, with the understanding that the present disclosure is to be considered as exemplifying the principles of the present invention, and that it is not intended to limit the broad aspects of the present invention to the illustrated and described embodiments.

[00136] In general, the present invention relates to systems, installations and methods for creating three-dimensional objects in a layered manner, such as additive manufacturing, three-dimensional printing, stereolithography, or other rapid prototyping techniques. Referring first to FIG. 1, which schematically shows an exemplary embodiment of a system 10 that includes a fabrication machine 12 and a computer controller 100 in communication with one or more components of the machine 12 and configured to control the operation of the machine 12 and/or its components to manufacture the object 11. The apparatus 12 comprises a support assembly 20 for supporting the object 11 within the build-up area 13 during manufacture, a guide 14 extending through the build-up area 13, and a layering mechanism 30 mounted on the guide 14 and configured to create the object 11 within the build-up area 13 by layering the material. The material deposited by the layering mechanism 30 may be any flowable material (e.g., liquids, powders, or other solids and combinations thereof) that can be solidified to form the object 11, such as through polymerization, phase transformation, sintering, and other techniques or combinations. such techniques. In one example, the material may be or contain a resin that can be polymerized by exposure to electromagnetic waves, such as light (visible, infrared, or ultraviolet). When using a resin-based material for manufacturing, the layering mechanism 30 may be referred to as a "resin layering mechanism". In FIG. 3-4 and 25 illustrate further schematic embodiments of system 10 and plant 12, and FIG. 8-13 and 15-19 illustrate structural embodiments of plant 12. FIG. 2A-B, 5A-7, 14, and 20-29 illustrate schematic embodiments of components and/or methods and configurations for operating system 10 and plant 12. Throughout this description, graphics are used to refer to structurally or functionally similar or identical components in all figures. consistent reference positions, and it is understood that features and aspects of some embodiments that have already been described in sufficient detail may not be specifically re-described with respect to each embodiment for the sake of brevity.

[00137] The creation of objects 11 through additive manufacturing often includes the creation of a support structure that is formed during manufacture and supports the object 11 during manufacture, and must be removed later. Such a support structure may be formed from the same material as the desired final parts of the object 11 or from a different material. Removal of such support structures may be accomplished using mechanical means (eg, separation, breaking, machining), solvent-based means (eg, use of a water-soluble polymer that can be washed off), or other means. Any support structure fabricated with object 11 as described herein will be considered part of the "object" as defined herein.

[00138] The support assembly 20 typically includes at least an extension platform 22 that is configured to support the object 11 within the extension region 13 during manufacture. The build-up area 13 is defined within the area adjacent to the build-up platform 22, which is immediately below the build-up platform 22 in the embodiment of FIG. 1. Support assembly 20 in FIG. 1 includes a support platform 24 that is movable in the vertical (z-direction) and supports a removable insert 26 that forms an extension platform 22. Insert 26 may be releasably coupled to support assembly 20 by mechanical connectors such as clips 28 as shown in FIG. 2A and 2B, or other mechanical structures, or various other releasable attachment mechanisms such as vacuum suction, magnetic attraction, release adhesive, and combinations of such mechanisms in certain embodiments. In one embodiment, as shown in FIG. 2A and 2B, the insert 26 is releasably connected to the support assembly 20 primarily through the use of vacuum suction via the vacuum unit 21, with the clips 28 being used as a back-up or redundant connection structure in the event of a malfunction, power outage, etc. As shown in FIG. 2A, when the object 11 is to be supported by the support assembly 20, such as during manufacture, the vacuum unit 21 applies suction to the insert 26 and the clamps 28 are closed to hold the insert 26 connected to the support platform 24. As shown in FIG. 2B, when the object 11 is about to be removed, the vacuum suction is stopped and the jaws 28 are released to remove the insert 26 and the object 11 from the support assembly 20. The insert 26 may be flexible to facilitate separation of the object 11 from the insert 26 after removal. Furthermore, it will be understood that other removable configurations for the buildup platform 22 may exist and may or may not use the support platform 24 that is formed. For example, in the embodiments of FIG. 8-11 and 15-19, the entire support platform 24 is removable to allow the extension platform 22 to be removed from the support assembly 20. It is also understood that the object 11 can be removed from the extension platform 22 without removing the extension platform 22, and that extension platform 22 may be non-removable in other embodiments.

[00139] In one embodiment, support assembly 20 and rail 14 may be partially or completely modular. The support assembly 20 and guide 14 in the embodiment of FIG. 8-11 are made in this way. This makes it easy to customize and modify the entire plant 12 if desired. It also allows the unit 12 to be assembled or disassembled for movement into or out of a room, even if the unit 12 is significantly larger than the door to the room, which can be a problem with today's stereolithography machines.

[00140] Support nodes 20 in the embodiments of FIG. 8-11 and 15-19 comprise vertical positioning mechanisms 23 that are configured to change the height of the extension platform 22 during manufacture, as described elsewhere herein. In the embodiment shown in FIG. 8, the vertical positioning mechanism 23 includes a plurality of jackscrews 25 located on opposite sides of the support assembly 20 and a support frame 27 that engages the jackscrews 25 and connects to and supports the support platform 24. The vertical movement of the support platform 24 (and thus the extension platform 22) is accomplished by the rotation of the jackscrews 25, and it should be understood that the threads of the jackscrews 25 can be angled to allow slight translational changes in the vertical position of the extension platform 22. The jackscrews 25 may be driven by a power assembly (not shown), and this may be controlled by the controller 100. In the embodiment of FIG. 15, the vertical positioning mechanism 23 includes four vertical actuators 29 located at the four corners of the support assembly 20, with a support frame 27 that engages the vertical actuators 29 and connects to and supports the support platform 24. The vertical drive mechanisms 29 in FIG. 15 may be screw jacks, as described herein, or may be of other mechanical design, such as chains, cables, belts, gears, sprockets, wheels, etc. Vertical drive mechanisms 29 may be driven by a power unit ( not shown) and can be controlled by the controller 100.

[00141] FIG. 1 schematically illustrates an embodiment of a layering mechanism 30 that typically includes a carriage 32 engaged with a guide 14 and movable along the guide 14 and in the buildup area 13, a source 34 of fluid material 36 mounted on or otherwise operatively connected to the carriage 32. , an applicator 40 in communication with a source 34 of fluid material 36 and configured to apply fluid material 36 to application site 41 within buildup area 13, and an irradiating device 50 configured to emit electromagnetic waves to cause deposited material 36 to harden with object 11. The application site 41 is generally defined as the area where the material 36 contacts the layering surface, i.e., the build-up platform 22 or the surface of the object 11. Various embodiments of the layering mechanism 30 are described herein as a diagram mathematically, and in relation to specific design options. In FIG. 3 and 4 schematically illustrate embodiments of a layering mechanism 30 that share many features with the embodiment of FIG. 1 and some aspects of the embodiments of FIG. 3 and 4 can only be described with respect to their differences from the embodiment of FIG. 1 for brevity. In FIG. 8-13 and 15-18 illustrate further embodiments of the fabricator 12 and lamination mechanism 30, which include structures that may be more detailed than the schematics and may have the same or different functionality.

[00142] The carriage 32 is movable along the guide 14 to move the layering mechanism 30 over the buildup area 13 during manufacture. The guide 14 is generally configured to guide the carriage 32 of the layering mechanism 30 over the buildup area 13 to form the object 11. The apparatus 12 may include a support frame 19 to support the guide 14 and other components of the apparatus 12, as shown in FIG. 8-11 and 15-19. The guide 14 and carriage 32 may have a complementary engagement structure to allow movement of the carriage 32 along the guide 14. For example, in the embodiments of FIG. 8-11 and 15-19, guide 14 includes two parallel beams 15, and carriage 32 and guide 14 have complementary toothed surfaces 33 that allow carriage 32 to roll on beams 15 by rotating the toothed surfaces 33 on carriage 32. Carriage 32 is driven into motion by rotating the toothed surfaces 33 in the embodiments of FIG. 8-11 and 15-19 and may otherwise be driven to move in various embodiments, such as by means of wheels or other gear arrangements, etc. In other embodiments, the energy to move may be supplied by external mechanisms, which may be either not be built into the guide 14, such as chains, cables, belts, sprockets, pistons, etc. An example of a drive motor 39 is shown in FIG. 15. The speed of the carriage 32 can be adjusted depending on the properties of the material 36, since materials 36 with different viscosities and/or solidification rates may benefit from higher or lower travel speeds. The carriage 32 may be configured to support other components of the layering mechanism 30 such that the other components may move with the carriage 32. For example, in the embodiments of FIG. 1, 3, and 4, carriage 32 supports at least an applicator 40, an irradiator 50, and a material source 34. It will be appreciated that these embodiments are shown schematically, and carriage 32 may also support additional components, including controller 100 and/or other components not shown. The carriage 32 may also be configured to modularly connect components as described elsewhere herein. Controller 100 may be configured to control operation, speed, lift, and other aspects of carriage 32 and the manufacturing process. In one embodiment, multiple parameters may be determined prior to the manufacturing process and/or prior to a single pass and executed by controller 100. Such parameters may be manually determined, automatically determined, or a combination. For example, before a pass is made, the layer thickness, build direction, build rate, roll direction and speed, material-to-roll communication level (determined based on the viscosity of material 36), and power output of irradiator 50 may be determined, and layering mechanism 30 may be at a predetermined initial (registration) position.

[00143] In the embodiments of FIG. 1, 3-4, 8-13, and 15-19, applicator 40 comprises or is in the form of a roller 42 that is in communication with or in contact with a material source 34. In these embodiments, roller 42 is cylindrical and has a cylindrical outer surface 43 in contact with source 34. In the embodiments of FIG. 1 and 3, roll 42 is hollow or otherwise has an inner chamber, but may alternatively be a solid cylinder, such as in the embodiments of FIGS. 3-4. The roller 42 is rotated so that the material 36 is picked up on the outer surface 43 of the roller 42 and carried to the application station 41 to produce the object 11. The roller 42 can be driven in a rotary motion by any of various mechanisms such as gears, sprockets, wheels, belts. etc. In one embodiment, roll 42 is rotatable with movement of carriage 32, i.e., such that the top of roll 42 moves in the opposite direction to that of carriage 32, and at approximately the same speed as and she. This is shown schematically in FIG. 1 and 3-4 and avoids dragging and/or shearing on the surface of the object 11 of the applied material 36. In another embodiment, the roller 42 can be configured to rotate at a different speed, i.e. at a speed that is higher or lower than the speed of translational movement along the layering surface. It is contemplated that rotating roller 42 at a faster speed than the translational speed can improve the curing of material 36 at the layering surface by increasing the exposure time of material 36 at layering surface compared to material 36 at surface 43 of roller 42. Roller 42 can be further configured of a material that is permeable to the electromagnetic waves emitted by the irradiating device 50, whereby the waves can pass through the roller 42 relatively unchanged. The place of application 41 is usually defined between the outer surface 43 of the roll 42 and the layering surface, i.e., the build-up platform 22 or the surface of the object 11. The interval between the outer surface 43 of the roller 42 and the layering surface can determine the thickness of the layered material 36 and the final thickness of the layer 38 of the cured material. It is understood that the material of roll 42 may be tailored to a particular wavelength of electromagnetic waves to provide sufficient permeability. Applicator 40 may have a different configuration in another embodiment and may transfer material 36 to application site 41 using a different mechanism. The applicator 40 may further have a different orientation with respect to the extension platform 22, for example as shown in FIG. 25.

[00144] The use of roll 42 in certain embodiments described herein forms a moving holding region at the top of roll 42, and the fixed distance between the top of roll 42 and the build-up surface (i.e., build-up platform or last layer 38) determines the thickness of the created layer. In addition, because roller 42 is in communication with source 34 of material 36, any uncured material 36 is returned to source 34, reducing or eliminating waste.

[00145] When the applicator 40 is in the form of a roller 42, the surface of the build platform 22 and/or the surface of the roller 42 can be selected or modified to achieve the desired adhesive properties. Preferably, the surface of the build platform 22 and/or the surface of any deposited layer 38 of the object 11 has greater adhesion to the cured material 36 than the surface of the roll 42. If this does not occur, the material may adhere to the roll 42 and harden there, resulting in defects. in the fabricated object 11. In one embodiment, roll 42 may be made of a low adhesion material or treated with a coating to reduce adhesion. Similarly, the surface of the build platform 22 may be made of a highly adhesive material or treated with a coating to increase adhesion. In one embodiment, the roll 42 has a lower adhesive capacity to the set material 36 than the adhesive capacity of the bonding surface for the material 36 (ie, the build-up platform 22 or the last layer 38). The adhesive properties of fluid material 36 may vary from material to material.

[00146] In the embodiments of FIG. 1, 3-4, 8-13, and 15-19, source 34 is in the form of a bath of fluid material 36 which is in contact with roller 42, whereby rotation of roller 42 carries material 36 to application site 41. In this configuration, the fluid material 36 must have sufficient viscosity so that the roll 42 can carry a continuous layer of uncured fluid material 36 to the application site 41 . The desired viscosity of the flowable material 36 may depend on the desired build-up or turn rate of roll 42, or the level of roll 42 relative to the level of material 36 in source 34. A lower turn rate and/or lower level of material 36 in the bath may require material 36 with more high viscosity. It is understood that, depending on the power of the irradiator 50, a lower or higher speed may be required, since the more powerful waves 53 may cause materials (eg, polymerizable resins) to solidify more quickly. In another embodiment, source 34 may be more complex, such as by including injectors or nozzles to force material 36 onto roller 42. In the embodiment of FIG. 15-19, source 34 includes fluid connectors 35 that can provide releasable attachment to a container of additional material 36 to replenish or maintain the level of material 36 in the bath. In addition, the source 34 of the fluid material 36 may be configured differently if the configuration of the applicator 40 is changed and the source 34 may be configured to be compatible with the design of the applicator 40, or vice versa.

[00147] In one embodiment, shown in FIG. 27, the source 34 may be configured to hold multiple fluid materials 36A-E to allow the layering mechanism 30 to simultaneously build up multiple objects 11 of different materials 36A-E or a single object 11 of different materials 36A-E. As shown in FIG. 27, source 34 may be in the form of a bath that has baffles 37 to separate different materials 36A-E. The baffles 37 can be adjusted to change the ratios and boundaries of the different materials 36A-E as desired. It is understood that descriptions of the use of "different materials" in the context of this document may also allow the use of the same material in different colors.

[00148] The irradiating device 50 is generally configured to emit electromagnetic waves 53 to cause the applied material 36 to solidify to form an object 11. The wavelength and intensity of the electromagnetic waves can be selected depending on the material 36 to be solidified and the speed or mechanism of solidification. For example, when a light-curing resin is used as the material 36, the irradiation device 50 may be configured to emit light (visible, infrared, ultraviolet, etc.) that has a suitable wavelength to cure/polymerize the resin to form a layer 38 of solid material. . As another example, if a sintering process is used to solidify fluid material 36, waves 53 emitted from irradiator 50 may be of sufficient power to sinter material 36 to form a layer 38 of solid material. The irradiating device 50 may also include various components and structures to direct the emitted waves towards the irradiation site 51 within the buildup area 13, the material 36 being exposed to the waves at the irradiation site 51. The waves can be directed so that the irradiation site 51 is approximately at the application site 41 in one embodiment, or so that the irradiation site 51 is offset from the application site 41 (before or behind the application site 41 in the direction of travel) in another embodiment. In FIG. 1 and 3 illustrate (solid lines) waves 53 directed to the irradiation site 51 approximately at the application site 41, and further illustrated (dashed lines) the waves 53 alternately directed to the irradiation site 51 displaced back or forward relative to the application 41. In FIG. 4 illustrates waves 53 directed at an irradiation site 51 displaced rearward from the application site 41 .

[00149] In general, the irradiation device 50 is configured such that the waves generated by the irradiation device exit through the outlets 54 and are directed to certain areas of the irradiation site 51 in order to selectively solidify the material 36 in the selected areas of the irradiation site 51 as it passes through the mechanism 30 layering. In one embodiment, the irradiating device 50 is part of the irradiating node 60, which contains components for directing and/or focusing waves 53 to the site 51 of exposure. The outlets 54 may be arranged in sets 55 and certain outlets 54 along the set 55 may be selectively activated to selectively solidify portions of material 36 as shown in FIG. 5A and 5B. In FIG. 5A and 5B, active outlets 56 are illustrated as shaded and inactive outlets 57 as light. As seen in FIG. 5A and 5B, active outlets 56 and inactive outlets 57 change when roll 42 reaches a point where the shape or contour of object 11 changes. The selective activation and deactivation of outlets 54 can be controlled by controller 100 as described herein. Set 55 in FIG. 5A and 5B is illustrated as a single horizontal row of outlets 54. In other embodiments, the set 55 may have a different arrangement, such as several offset horizontal rows. By using multiple rows in a set 55, closer lateral spacing between outlets 54 can be achieved than by using a single row. Set 55 in FIG. 14 may be similarly configured and arranged according to any of these embodiments.

[00150] As described above, waves 53 may pass through roll 42 on their way to irradiation site 51. In the embodiment of FIG. 1, the outlets 54 are inside the roller 42 and the radiated waves 53 pass through the surface of the roller 42 once on their way to the irradiation site 51. In the embodiment of FIG. 1, the irradiation device 50 itself may be within the roll 42, or the irradiation device 50 may be outside the roll 42, with outlets 54 located within the roll, as in the embodiment of FIG. 8-13. In the embodiment of FIG. 3, the outlets 54 are located under the roller 42, and the radiated waves 53 pass completely through the roller 42 on their way to the irradiation site 51. The embodiment of FIG. 15-18 is made in a similar way. In this configuration, the layering mechanism 30 may include a window 44 configured to allow the waves 53 to pass through the wall of the supply trough 34, as shown in FIG. 16-17. Additional structures such as doctor blades, O-rings, or other sealing structures may be used to prevent resin from entering between roll 42 and window 44. In the embodiment of FIG. 4, the outlets 54 are located at the irradiation site 51 immediately after and directed towards the application site 41, and the waves 53 need not pass through the roller 42 in this embodiment. It will be understood that the waves 53 in the embodiment of FIG. 4 can be directed so as to pass through part of the roller 42, if necessary.

[00151] In one embodiment, the irradiation device 50 is a projector, such as a digital light processing (DLP) projector, as the wave source 53, and the irradiation node 60 may also use optical fibers 61 to direct the waves 53 to the irradiation site 51 , as shown in FIG. 8-13. In this embodiment, the projector 50 is configured such that the light emitted from the projector 50 enters the input ends 62 of the optical fibers 61, travels down the optical fibers 61, and exits through the output ends 63 of the optical fibers 61 directed to the irradiation site 51. The outlets 54 in this embodiment are formed by the exit ends 63 of the optical fibers 61, and may be inside the roll 42, and may be arranged as a set 55 within the roll, as shown in FIG. 1, 5A-B and 8-12. In such an embodiment, the optical fibers 61 may extend into the roll 42 at one or both ends of the cylinder, in which case appropriate sealing and fixing components may be used around the optical fibers 61. For example, in the embodiment of FIG. 8-12, the output ends 63 of the optical fibers 61 may be assembled and held in place by a housing or similar structure 67 (see FIGS. 5A-5B). The illuminating node 60 may additionally use a focusing mechanism 66 to focus the light waves 53 after they exit the output ends 63 of the optical fibers 61, as illustrated in FIG. 13. In one embodiment, the focusing mechanism 66 comprises a set of microlenses 64 between the output ends 63 of the optical fibers 61 and the object 11, such as a Selfoc Lens Array (SLA) lens, which focuses the waves 53 and prevents diffraction on the way to the site. 51 exposures. In FIG. 8-12 illustrate an array of microlenses 64 held in place within roller 42 by staples 65. In other embodiments, various other lenses, mirrors, and other focusing equipment may be used. It will be understood that such a focusing mechanism 66 may be used in other embodiments described herein, such as the embodiments of FIG. 3, 4, 15-18 and 25. It is also understood that the use of optical fibers 61 allows the source of the waves of the irradiating device 50 to be located remotely from the deposition device 40, for example, elsewhere on the layering mechanism 30 or even away from the layering mechanism 30 in some embodiments. implementation. In this configuration, the heat generated by the irradiator is not transferred to the applicator or material 36, thus avoiding unwanted hardening, material 36 changes, or thermal deformation of applicator 40. This configuration also allows the irradiator 50 to use a much larger and/or more powerful wave source (e.g., high power LEDs or a high power DLP projector) without regard to physical limitations, such as conforming to the dimensions of the interior of roll 42.

[00152] Irradiation node 60 in the embodiment of FIG. 8-13 uses a collector 70 engaged with the input ends 62 of optical fibers 61 to fix the input ends 62 in position relative to the irradiating device 50, whereby waves 53 enter the input ends 62 of optical fibers 61 on the collector 70. One embodiment of the collector 70 is illustrated. in fig. 12 and schematically in FIG. 13. Manifold 70 includes a frame 71 that engages input ends 62 of optical fibers 61 and holds input ends 62 within chamber or passageway 72, with window 73 (which may be configured as a lens in one embodiment) located at end of passageway 72. 53 exiting the irradiator 50 pass through a window 73 to enter the input ends 62 of the optical fibers 61. A lens 66A may be positioned between the irradiator 50 and the window 73 to focus the waves 53 at this stage. The frame 71 is held firmly in place with respect to the illumination device 50 so that the input ends 62 of the optical fibers 61 do not move relative to the illumination device 50. This fixed relative position allows the illumination device 50 to selectively activate and deactivate the outlets 54 by applying pixel mapping. In other words, the input end 62 of each optical fiber 61 is mapped to one or more specific pixels of the illuminating device 50, whereby activation of the specific pixel(s) causes the waves 53 emitted by the specific pixel(s) to travel down the optical fiber 61, activating thereby the outlet 54 associated with that optical fiber 61. The pixel display also includes displaying the specific area of the irradiation site 51 to which the outlet 54 of each optical fiber 61 is directed. In one embodiment in which a DLP projector is used as an irradiation device 50, each optical fiber 61 is mapped to a plurality of pixels (potentially hundreds or more) of a DLP projector. In such a configuration, the loss or deactivation of a few pixels can occur without affecting the ability of the optical fiber 61 to maintain sufficient functionality and power to operate. The use of a collector 70 and optical fibers 61 as described herein makes it possible to convert a two-dimensional projection into an approximately one-dimensional (linear) exposure. This mapping may be stored in the computer's memory and executed by the computer's processor, such as controller 100.

[00153] In another embodiment, the irradiating device 50 is in the form of a set 55 of LEDs 59 that function as wave sources 53, as shown in FIG. 14. LEDs 59 may be designed to emit waves 53 of the appropriate wavelength and intensity to solidify material 36. An array 55 of LEDs 59 may be positioned within roller 42 as shown in FIG. 14, or outside of roll 42 as described herein, and may use a focusing mechanism 66 as also described herein. In either case, the array 64 of microlenses on the outlets 54 as described above can help focus the waves 53. Each of the LEDs 59 in this embodiment is a separate outlet 54 that is directed to a specific area of the irradiation site 51, and the LEDs 59 can selectively be activated and deactivated to expose that particular area of the irradiation site 51 to the irradiation of the waves 53. The activated LEDs 59 constitute the active outlets 56 and are shown shaded in FIG. 14 and the inactive LEDs 59 constitute the inactive outlets 57, which are shown as light. As seen in FIG. 14, the material 36 aligned with the active outlets 56 solidifies to form a layer 38. The LEDs 59 may be mapped to the specific areas of the irradiation site 51 to which they are directed, and this mapping may be stored in a computer memory and executed by a computer processor such as a controller. 100. If the LEDs 59 are located outside of the roller 42, a plurality of optical fibers 61 can be used along with the LEDs 59 to form outlets 54. In FIG. 66 schematically illustrates one embodiment of this configuration, with a set 55 of LEDs 59 located separately from the applicator 40, with the optical fibers 61 having their input ends 62 fixed in position relative to the LEDs 59 such that the waves 53 from the LEDs 59 enter the optical fibers. 61 and radiate at the exit ends 63 to form outlet holes 56 as described above. The outlets 56 may be formed in the same manner as shown and described herein with respect to the embodiment of FIG. 1-13 and other embodiments, including the use of a focusing mechanism 66 and mechanisms for adjusting the direction of the waves 53 forward or backward in the direction of travel of the layering mechanism 30, which are not shown in FIG. 66. The input ends 62 of the optical fibers 61 can be fixed in position with respect to the LEDs 59 using various locking and bonding structures depending on the size and layout of the LED array 55, and it is understood that the LED array 55 cannot be linearly arranged in some configurations. In one embodiment, no lens or other focusing structure may be required between the LEDs 59 and the input ends 62 of the optical fibers 61. Each LED 59 may be mapped to a separate optical fiber 61 in the embodiment shown in FIG. 66, although in other embodiments, multiple optical fibers 61 may be mapped to each LED 59. This configuration allows for a larger array of LEDs than can be built into applicator 40. In additional embodiments, another type of irradiation device 50 may be used and the layering mechanism 60 may include components configured to direct waves 53 from the irradiation device to appropriate areas of the irradiation site 51. For example, in the embodiment of FIG. 15-19, the irradiating device 50 is in the form of a laser, and a focusing mechanism 66 comprising lenses and/or mirrors is used to focus the beam. The focusing mechanism 66 of FIG. 16-17 contains one or more lenses 66A and one or more mirrors 66B. In still other embodiments, the irradiating device 50 may be in the form of an LCD source or a high speed positional mechanical shutter system.

[00154] During operation of the apparatus 12, the interval between the applicator 40 and the layering surface must change for each new layer 38 of the layered object 11. The applicator 40 in the embodiments of FIG. 1, 3-4, 8-11, and 15-19 are oriented such that roller 42 is positioned vertically below the layering surface and forms layer 38 vertically above roller 42. In this embodiment, the relative vertical translation (i.e., parallel to the direction of the layered build-up) occurs between the applicator 40 and the layering surface during the production of successive layers 38. This vertical translational movement is illustrated, for example, in FIG. 6A and 6B illustrating the layering mechanism 30 performing a first pass (FIG. 6A) from left to right to layer the first layer 38 and a second pass (FIG. 6B) from right to left to layer the second layer 38, with a vertical translational movement between the first and second passages are shown by dash-dotted lines. This relative repositioning may be accomplished using one or more different methods and mechanisms, or combinations thereof. In the embodiments of FIG. 8-11 and 15-19, this vertical translational movement can be accomplished by changing the elevation of the extension platform 22 using the vertical positioning mechanism 23 as described herein. In another embodiment, this vertical translation may instead be performed by changing the lift of the rail 14, which may be accomplished using similar vertical positioning mechanisms 23 as described herein. In yet another embodiment, the layering mechanism 30 may include a mechanism for changing the vertical position of the applicator 40 relative to the build-up platform 22, such as by raising or lowering the applicator 40 and/or the entire carriage 32. For example, in the embodiment of FIG. 20A-B, each of the layering mechanisms 30 is configured to vertically translate relative to the guide 14 within a limited range of motion by raising or lowering the carriage 32 relative to the guide 14. The vertical translation may be accomplished by switching the carriage 32 between predetermined vertical positions, such as by vertical movement. drive structure that engages the guide 14 relative to the roll 42. The main vertical translation of the build platform 22 relative to the applicator 40 in this embodiment is achieved by moving the build platform 22 as described herein, and the vertical positioning range of the layering mechanism 30 allows several the layering mechanisms 30 to pass through the extension area 13 without adjusting the position of the extension platform 22, which is more time consuming. The operation of these embodiments is described in more detail herein.

[00155] The layering mechanism 30 may also contain additional components to provide additional functionality in creating a high-quality object 11. It is understood that any of the exemplary embodiments herein may contain any combination of these additional components, even if not specifically illustrated herein. For example, the layering mechanism 30 may include one or more auxiliary irradiation devices 80 configured to follow the applicator 40 in the direction of travel, as shown in FIG. 7. Auxiliary irradiator 80 emits additional electromagnetic waves 53 to further solidify the material, waves 53 may have the same or different wavelength and intensity as waves 53 from irradiator 50. In one embodiment, auxiliary irradiator 80 does not require precise focusing, since the entire surface of the object 11 can be exposed to radiant energy. In this configuration, the waves 53 from the irradiator 50 can be adjusted to ensure that the material 36 solidifies only enough to form a stable layer 38 (known as the "non-dried state") , and the auxiliary irradiator 80 then further solidifies the layer 38 to the desired final degree of solidification. This provides a significant efficiency advantage over existing processes in which the objects 11 are typically created in a non-dried state and require a subsequent separate step of exposure to radiant energy to fully cure. In one embodiment, the power levels of irradiator 50 and auxiliary irradiator 80 can be set such that each irradiator 50, 80 provides partial solidification of material 36 and the combined exposure is sufficient to completely solidify material 36. This setting avoids overexposure of the material. 36, which can cause aesthetic and/or mechanical damage. The embodiment of FIG. 15-19 includes two auxiliary irradiation devices 80 for allowing auxiliary irradiation of the layer 38 while moving the carriage 32 in two opposite directions without turning through 180°. The front auxiliary irradiator 80 may be deactivated for each pass of the carriage 32, and the rear auxiliary irradiator 80 may be active, or both auxiliary irradiators 80 may be active. Components 80A of auxiliary irradiation device 80 are illustrated in FIG. 16. The controller 100 may control the activation of the auxiliary irradiation device(s) 80.

[00156] As another example, the layering mechanism 30 may comprise one or more material removal and/or repositioning mechanisms configured to remove or relocate excess and/or uncured material, such as one or more doctor blades 81 or one or more non-contact doctor blades 82 with the possibility of creating a vacuum. For example, the embodiment in FIG. 15-19 includes two doctor blades 81 located on opposite sides of the roller 42, which wipe the surface of the layer 38 to remove excess and/or uncured material 36 after the solidification process. In one embodiment, the blades 81 can be configured to raise and lower so that only the rear blade 81 engages the surface of the object 11, which operation can be controlled by the controller 100. As another example, the embodiment of FIG. 15-19 also includes two vacuum-capable doctor blades 82 located on opposite sides of roller 42 that remove or reposition excess and/or uncured material 36 after the curing process by applying airflow in a vacuum state by blowing or suction. Components 82A-B of the vacuum-capable doctor blades 82 are shown in FIG. 16. In one embodiment, the vacuum-capable blades 82 can be configured to be activated and deactivated such that only the rear vacuum-capable blades 82 act on the surface of the object 11, which operation can be controlled by the controller 100. In one embodiment, the blades 82 with the possibility of creating a vacuum, the location of the remaining fluid material 36 located on the vertical surfaces of the object 11 can be changed in the direction of the adjacent horizontal surfaces of the applied layer 38, and the material 36 can be removed and returned to the source 34 by mechanical doctor blades 81, or its hardening can be ensured, so that it becomes part of the deposited layer 38, for example, by means of an auxiliary irradiation device 80. Transferring any remaining material 36 to the surface of the object 11 to be solidified has the additional advantages of creating additional edge volume and not flat surface at the edges of the layer, which can assist in holding and bonding the next deposited layer 38. In one embodiment, the vacuum-capable doctor blades 82 may not be activated until one or more layers of the base object 11 have been completed. Alternatively, the doctor blade 82 with the possibility of creating a vacuum can be configured to completely remove excess and/or uncured material in another embodiment. The embodiment in FIG. 8-11 comprises doctor blades 81 and vacuum-capable doctor blades 82 similar to the doctor blades in the embodiment of FIG. 15-19.

[00157] FIG. 65 illustrates repositioning and then causing unsolidified fluid material 36 to solidify using a vacuum-capable doctor blade 82 as described herein, which may occur in one embodiment. In FIG. 65 in step A shows the uncured material 36 remaining at the edges of the last cured layer 38A cured by the irradiator 50, which is overlaid on the previous cured layers 38B. Shading layers 38A-B in FIG. 65 illustrates different degrees of hardening/hardening of material 36. In step B of FIG. 65 shows repositioning of uncured material 36 by means of a squeegee 82 with the ability to create a vacuum as described herein. The location of the uncured material 36 has been changed from the vertical surfaces 93 of layer 38A to the horizontal surface 94 of layer 38A and remains near the edges of the horizontal surface 94. At step C in FIG. 65 depicts causing material 36 to be solidified by means of an auxiliary irradiator 80, as described herein, to form solidified material 38C. The cured material 38C in this configuration forms uneven portions near the edges of the previous layer 38A. At step D in FIG. 65 shows the object 11 after application and curing of the next layer 38D, for which bonding to the previous layer 38A is enhanced by the edge portions of the cured material 38C. Additional uncured material 36 is illustrated in step D, and it is understood that the process may then cycle back to step B until the buildup is complete.

[00158] In other embodiments, further additional components may be included. In one embodiment, one or more additional components 83 may be modularly connected to the carriage 32 and to each other to provide the desired functionality, as shown in FIG. 19. Detachable connections such as fasteners, clips, blocking structures (eg, tabs/slots), or other structures may be used to make these modular connections. As illustrated in FIG. 19, each of the additional components 83 can be connected to the carriage 32 and can be connected to the outside of each other additional component 83 to provide a fully modular and adaptable design. Such additional components 83 may include one or more auxiliary irradiators 80, blades 81, or vacuum-capable blades 82, as described herein. Such additional components 83 may also include other functional components such as a solvent or liquid washer, mechanical wipers/cleaners, a color applicator, or a layerer for additional material. The color applicator used in this configuration can enable layered coloration, giving the final object 11 a color that penetrates the thickness of the object 11 rather than just covering the surface. The apparatus for laminating the additional material may comprise an apparatus for laminating conductive materials or conductors within the body of the object 11, providing conduction and/or functionality of the electrical circuit to the object 11.

[00159] The apparatus 12 may be configured to use multiple layering mechanisms 30 and/or multiple applicators 40 to sequentially pass through the buildup area 13, as illustrated in FIG. 20-23. Several layering mechanisms 30 in FIG. 20-23 are illustrated as being connected to the same guide 14, but in another embodiment, multiple guides 14 may be used. In one embodiment, as illustrated in FIG. 20A-B, multiple layering mechanisms 30 may be configured to pass through the buildup area 13 in succession, with each layering mechanism 30 having an applicator 40 in different vertical positions. The different positions of the applicator 40 are indicated by dashed lines in FIG. 20A-B, and each successive layering engine 30 is spaced lower than the previous layering engine 30. This configuration can be achieved using the vertical positioning structures described elsewhere in this document. It will be understood that the difference in vertical positioning among multiple layering mechanisms 30 may be substantially the same as the desired thickness of each applied layer 38. As shown in FIG. 20A, each of the multiple layering mechanisms 30 passing through the buildup area 13 layers the layer 38, one above the other, in a single pass, which does not require repositioning of the support assembly 20. This configuration results in multiplicative efficiency and time savings since each pass is fig. 20A layers 3 times as many layers as one pass through a single layering mechanism 30. In addition, the multiple layering mechanisms 30 may be configured to adjust their height in reverse order to allow passage in the opposite direction for layering three additional layers 38 after changing the position of the build platform 22 as shown in FIG. 20b. In another embodiment, the support assembly 20 may be configured to rapidly adjust the position of the buildup platform 22 between each pass of the layering mechanism 30 to allow for multiple passes as shown in FIG. 22. In yet another embodiment, the guide 14 may be configured as a closed loop or carousel to allow one or more layering mechanisms 30 to pass at the same relative height of the build platform 22 without reversing the direction of the layering mechanism(s) 30. This may eliminate the need to re-adjust the heights of the layering mechanisms 30 relative to each other, and only the build platform 22 needs to be adjusted relative to the guide 14. It may also eliminate the need for redundant components such as auxiliary irradiators 80, doctor blades 81, doctor blades 82 with the possibility of creating a vacuum, etc., to provide passages in opposite directions. The closed loop guide 14 may be horizontal, vertical, or more complex. When multiple layering mechanisms 30 are used, all of the layering mechanisms 30 may use the same material 36, or different layering mechanisms 30 may be configured to apply different materials 36. Due to differences in the properties of different materials 36, it may be desirable that the mechanism 30 layering carried out the passage at different speeds. The self-propelled carriage 32 described herein allows this operation. In addition, the guide 14 may include a complex structure (not shown) with stop areas for unused layering mechanisms and guide switching mechanisms so that you can switch between the layering mechanisms 30 as desired.

[00160] In another embodiment, multiple layering mechanisms 30 may be implemented as illustrated in FIG. 20A-B to sequentially pass over the buildup area 13, with the layering mechanisms 30 having the applicators 40 in the same vertical positions. This can be used to build up different parts of the same layer of the object 11, and in particular the layering mechanisms 30 can be configured to layer different materials 36 in the layer. For example, different layering mechanisms 30 may create portions of different colors, or one of the layering mechanisms 30 may create the main body of the object 11 while another creates a support structure that is later removed.

[00161] In another embodiment, shown in FIG. 21, a single layering mechanism 30 may comprise multiple applicators 40 positioned at different heights to define distinct applicators 41, with enough outlets 54 for the waves 53 emitted by one or more irradiators 50 to define a distinct irradiation location 51 for each. application devices 40. Multiple applicators 40 may be configured with a single source 34 of fluid material 36 or multiple sources 34 of one or more fluid materials 36, and it is understood that other components may be duplicated if desired. Rolls 42 in FIG. 21 can be adjusted vertically relative to each other in one embodiment.

[00162] In other embodiments shown in FIG. 24A-B, one or more layering mechanisms 30 may be configured to grow multiple objects 11 in a single pass, for example using multiple build platforms 22 or multiple objects 11 that build up on the same build platform 22, wherein each individual object 11 has a separate buildup area 13 over which a guide 14 extends. As shown in FIG. 24A, multiple layering mechanisms 30 may apply multiple successive layers 38 to multiple objects 11 in a single pass. As shown in FIG. 24B, multiple layering engines 30 may apply different portions of the same layer 38 to each of the multiple objects 11 in a single pass. This configuration can be particularly useful for a part where multiple materials are to be layered on the same layer, such as a multi-material object 11 or an object 11 that contains a support structure manufactured with the object 11 that will later be removed. It will be appreciated that the height(s) of the buildup platform(s) 22 relative to the applicator(s) 40 can be adjusted between passes as described herein. In addition, the use of multiple layering mechanisms 30 and/or multiple application devices 40, as shown in FIG. 20-23, with the embodiment as shown in FIG. 24 can provide double multiplier efficiency and time saving. In addition, the use of multiple layering mechanisms 30 and/or multiple application devices 40, as shown in FIG. 20-23 in combination with the embodiment as shown in FIG. 24A or 24B may allow different parts of several identical objects 11 to be produced simultaneously in a single pass of each layering mechanism 30 . For example, the first layering mechanism 30 may be loaded with the first material 36 to form the first part of the object 11, and the second layering mechanism 30 may be loaded with the second material 36 to form the second part of the object 11, and each of these layering mechanisms 30 may be configured to be layered in one pass of a layer 38 (or partial layer) of the desired material 36 at the same location successively over a plurality of identical objects 11, as shown in FIG. 24A-B. It is understood that different layering mechanisms 30 may also comprise different irradiating devices 50 if different materials 36 are used.

[00163] FIG. 28 illustrates a further embodiment of a system 10 for manufacturing one or more objects 11 using a machine 12 and lamination mechanisms 30 according to the embodiments described herein. In particular, the embodiment of FIG. 28 can be configured to sequentially create a series of objects 11 similar to the embodiment of FIG. 24. Each layering mechanism 30 in the embodiment of FIG. 28 may be implemented as a stand-alone unit 90 with a separate sub-controller, with all sub-controllers for all units 90 being integrated with the controller 100, whereby the controller 100 controls the sub-controllers and thereby controls all units 90. Each unit 90 may further comprise one or more positioning systems. , including a local positioning system and/or a global positioning system (GPS). Each block 90 may further comprise a layering mechanism 30 and a drive mechanism 91 operable to move from place to place of block 90 during manufacture. As shown in FIG. 28, all blocks 90 are connected to a carousel 92 which moves blocks 90 around a plurality of stations. Each station can be made for a special purpose. For example, some stations may be manufacturing stations, with block 90 passing through one or more build-up areas 13 to produce one or more objects 11 on one or more build-up platforms 22. Such stations may also contain robotic components, such as robotic arms, that hold the build platform 22 in the proper location to grow with the blocks 90. Other stations can be service stations, such as stations made to replenish the source 34 of the block 90. Carousel 92 may have one or more guides 14, as described herein, to guide the movement of nodes 90 during growth. The drive mechanism 91 may be multi-functional, whereby the blocks 90 are self-powered and can engage and disengage the guide 14 and move separately from the guide 14 when not in the process of being built up, for example, to visit replenishment or maintenance stations. . In the configuration illustrated in FIG. 28, each block 90 can be loaded with a different material 36 to make different parts of the same object 11 or different objects, as described above with reference to FIG. 24. Therefore, this configuration enables a series of objects 11 to be rapidly produced, either identical objects 11 or different objects 11.

[00164] FIG. 29 illustrates a further embodiment of a system 10 for manufacturing one or more objects 11 using a machine 12 and a layering mechanism 30 with an applicator 40 that differs from roll 42 described herein. In the embodiment of FIG. 29, the applicator 40 includes a moving film 84 that is in communication with a source 34 of fluid material 36 and carries fluid material 36 towards application site 41 by lateral movement to form a layer 38 of object 11. Layering mechanism 30 in FIG. 29 has a static surface 85 that determines the location of the application site 41 and the thickness of the applied layer 38 as described above, and the film 84 carries the material 36 towards the application site 41 by moving over the static surface 85. The static surface 85 is formed by the cylinder in FIG. 29, but in other embodiments may be formed by a comb or other structure. For example, in FIG. 30 illustrates an embodiment of system 10 as shown in FIG. 29 with a flattened static surface 85 which is formed by a trapezoidal structure. In other embodiments, an oval, round, or other design with an elongated or flattened surface may be used. The layering mechanism in FIG. 29 also has two rolls 86 on opposite sides of the application 41, which serve as receiving or feeding stations depending on the direction of travel. For example, in FIG. 29, the lamination mechanism moves from left to right as indicated and the film 84 moves from right to left, with the left roll 86 serving as the take-up station and the right roll 86 serving as the feed station. When moving from right to left, this will be done in reverse order. Also included are other components such as guide rolls 87 or other film guides 84, doctor blades 81 or other material removal devices for removing fluid material 36 from film 84 before it reaches take-up roll 86, and a cleaning station 88 for cleaning film 84 stored on rolls 86. Although carriage 32 is not shown in FIG. 29, it is understood that all of these components can be mounted on the carriage 32 as described herein. As shown in FIG. 29, the irradiator 50 or at least its outlets 54 may be located below the static surface 85 and within the cylinder that defines the static surface 85, although any configuration and location of the irradiator 50 and its outlets 54 described herein may be used in conjunction with this embodiment. In the illustrated configuration, the waves 53 from the irradiation device 50 pass through both the static surface 85 and the film 84 on their way to the irradiation site 51. In a further embodiment, the static surface 85 may have a gap that allows waves 53 to pass to the irradiation site 51 without passing through the static surface 85. In another embodiment, the static surface 85 may have a set of outlets 55 54 positioned within such a gap, in which may place the outlets 54 in such close proximity to the irradiation site 51 that lenses or other focusing equipment may not be required.

[00165] FIG. 25 illustrates an alternate embodiment of system 10 and apparatus 12 that utilizes a conventional fluid bath source 34 with layering mechanism 30 positioned above build-up platform 22. The layering mechanism 30 in this embodiment typically comprises a carriage 32 which is movable along a guide 14 with a roll 42 and an irradiation device 50 which emits waves 53 that pass through the roll 42 on its way to the irradiation site 51. In this embodiment, roller 42 does not function as an applicator as in the embodiments of FIG. 1 and 3-4, but determines the thickness of the applied layer 38 of the material 36, similar to such previous embodiments. As such, roller 42 in this embodiment functions as a ply mechanism, and in other embodiments, other configurations may be used for this purpose, such as in the form of a block that slides along or over material 36. Extension platform 22 in FIG. 25 and related structures may be configured to be of a split design, as described elsewhere herein. In addition, the layering mechanism 30 and/or the build-up platform 22 may have adjustment mechanisms (not shown) for relative vertical adjustment of the position of the build-up platform 22 and the roll surface 42. The adjustment mechanism may include the structures described herein and/or structures used in existing bath-based rapid prototyping technologies, such as moving the build-up platform 22 progressively deeper into the bath source 34. This embodiment allows the object 11 to be fabricated below the surface of the fluid material 36, if desired, with adjustable layer thickness 38. However, this embodiment does not provide some of the advantages of the other embodiments described herein, such as eliminating the requirement to maintain a large bath source 34 with flowable material 36. It will be understood that the embodiment of FIG. 25 may include additional construction, components, and features described herein. For example, system 10 illustrated in FIG. 25 also includes a controller 100 configured to control and/or monitor components of plant 12 as described herein. As another example, the irradiation device 50, or at least its outlets 54, is illustrated in FIG. 25 as being within roller 42, but in another embodiment, irradiation device 50 may have a configuration similar to that shown in FIG. 3 to protrude completely through roll 42.

[00166] FIG. 31-46 illustrate another embodiment of a system 10 that includes a manufacturing machine 12 that may be coupled to a computer controller 100 in communication with one or more components of the machine 12 and configured to control the operation of the machine 12 and/or its components for manufacturing. object 11. Installation 12 according to FIG. 31-46 comprises a support assembly 20 for supporting the object 11 within the build-up area 13 during manufacture, a guide 14 extending through the build-up area 13, and a layering mechanism 30 mounted on the guide 14 and configured to create the object 11 within the build-up area 13 building by layer-by-layer application of material. Many components of system 10 and plant 12 of FIG. 31-46 are similar in construction and operation to other components described herein with respect to other embodiments, and such components may not be described in detail again with respect to the embodiment of FIG. 31-46. It is understood that similar reference numbers may be used to refer to such like components. The layering mechanisms 30 in FIG. 31-46 are configured to operate as stand-alone units 90 as described herein, and each stand-alone unit 90 may include on board a processor 2604, memory 2612, and/or other computer components necessary to execute computer-executable instructions to automate the stand-alone unit. 90 and/or communicating with computer controller 100.

[00167] Reference assembly 20 in FIG. 31-46 includes a support frame 19 to support some or all of the rail 14, extension platform 22, and other components of the plant 12. In the embodiment of FIG. 31-46, guide 14 is not supported by support frame 19 and is attached separately to the floor, but in another embodiment, guide 14 may be connected to and supported by support frame 19. The guide 14 comprises two parallel beams or two parallel rails 15 and at least one conductive bar 101 configured to supply power to the layering mechanism 30. The busbar(s) 101 may be part of one or both rails 15 in one embodiment. In addition, substantially one or both of the guides 15 may function as the busbar(s) 101 in one embodiment. One or more conductive bars 101 may be provided separately from the rails 15 in another embodiment. The guide 14 may not include any conductor rail 101 in another embodiment, and the layering mechanism 30 (i.e., self-contained unit 90) may be self-powered for movement and operation, such as from an internal battery. It will be understood that the guide 14, build-up platform 22, support assembly 20, and other components may be constructed to any desired size, including lengths and widths that are significantly larger than those illustrated in FIG. 31-42.

[00168] The layering mechanism 30 in the embodiment of FIG. 31-46 includes a carriage 32 engaged with a guide 14 and configured to move along the guide 14 and along the buildup region 13, a source 34 of fluid material 36 mounted on or otherwise operatively connected to the carriage 32, an applicator 40 in communication with a source 34 of a fluid material 36 and configured to apply a fluid material 36 to the application site 41 within the buildup area 13, and an irradiating device 50 configured to emit electromagnetic waves to cause the applied material 36 to solidify to form an object 11. Function and Structure source 34 of fluid material 36, applicator 40, and irradiator assembly 60 in the embodiment of FIG. 31-46 are similar or identical in function and structure to the same components in the embodiment of FIG. 8-13 and need not be detailed again herein. Source 34 of fluid material 36 and applicator 40 in the embodiment of FIG. 31-46 are connected so as to form an integrated application module 110, also referred to as a resin application module 110, which can be removed from the carriage 32 and replaced with a second application module 110. In FIG. 44-46 illustrate an example of such an application module 110 and the process of removing and replacing the application module 110. In FIG. 43 illustrates a portion of the application module 110 containing the roll 42 and the structures forming the source 34. As seen in FIG. 43-46, source 34 is provided in the form of a tub or reservoir with roller 42 at least partially positioned within the reservoir so as to be in communication with flowing resin 36, and source 34 can optionally be removed without draining resin 36. Apparatus The deposition 40 in this embodiment is in the form of an elongated roller 42, and one or both ends of the roller 42 are connected to the side walls 111 of the bath 34. Optical fibers 61 pass through an opening 112 extending through one of the side walls 111 and the end of the roller 42 to pass inside roll 42 to form a set 55 of outlets 54 within roll 42. Retainers 65 and associated support structure 113 holding fibers 61, microlens set 64, and other components of irradiator 50 remain in place when application module 110 is removed. It should be understood that the side panel 114 of the carriage 32 is removed in this embodiment in order to remove the application module 110 as shown in FIG. 44. Removable side panel 114 in the embodiment of FIG. 31-46 is located on the opposite side of the carriage, as is the drive unit 115, which drives the roller 42 in a rotary motion. In one embodiment, one or both side panels 114 of the layering mechanism 30 may include a resin reservoir connected to the source 34 to replace used material 36 and/or maintain a constant level of material 36. The layering mechanism of FIG. 8-13 may also include the removable application module 110 described herein, such as that shown in FIG. 47.

[00169] After removing the application module 110, as shown in FIG. 44-45, the same or a different application module 110 can be installed instead, as shown in FIG. 46. In one embodiment, the first application module 110 can be removed and replaced with a second application module 110 having a different characteristic. For example, the second applicator 110 may have a differently configured applicator 40 or may contain a different fluid material 36, allowing fluid materials 36 to be changed without draining, cleaning, and refilling the source 34. As another example, applicator 110 may be removed for repair or replenishment. and replace with a backup application module 110 to avoid equipment downtime. In other embodiments, either source 34 or applicator 40 can be removed and replaced independently using a similar configuration. In other embodiments, other removable configurations may be used.

[00170] The support assembly 20 further comprises a mechanism 102 for moving the build-up platform 22 between the build-up position and the service position, with the build-up platform 22 facing the guide 14 to create the object 11 in the build-up position, and the build-up platform 22 facing away from the guide 14 in the service position to allow a maintenance operation to be performed on the object 11. Examples of maintenance operations include modifying the object 11, for example by removing material, including removing the support structure (for example, by cutting, machining, etc. .), painting, cleaning, or removing the object 11 from the build-up platform 22, for example, after the completion of the object 11, or the introduction or attachment of functional or non-functional components previously made by the same or a different process (also referred to as auxiliary objects), such as RFID chips, magnets, add weights or structural supports, printed circuit boards, liquid containers, etc. Such an auxiliary object can be attached in a configuration that is not exposed to waves 53 during the continuous creation of the object 11 when the build-up platform 22 returns to the build-up position. For example, an auxiliary object can be inserted into the internal cavity of the partially extended object 11 and/or provided with a protective sheath. In one embodiment, the auxiliary object(s) may be other objects 11 fabricated simultaneously on the same or different build platforms 22 as described herein. In the embodiment of FIG. 31-46, the mechanism 102 moves the extension platform 22 between the extension position and the service position by pivoting. In FIG. 31-33 and 37 illustrate the extension platform 22 in the extension position, FIG. 34 illustrates an extension platform 22 being moved from an extension position to a service position, and FIG. 35 and 36 illustrate an extension platform 22 in a service position in this embodiment.

[00171] The mechanism 102 for moving the extension platform 22 in the embodiment of FIG. 31-46 comprises a support platform 24 that defines and/or supports an extension platform 22, as described herein, by means of one or more pivot bases 103 attached to the support platform 24 and rotatable to move the support platform 24. As shown in FIG. 31-37, the mechanism 102 includes two rotary bases 103 at opposite ends of the support platform 24, which are synchronously rotated about an axis, and the support platform 24 is fixed relative to the rotary bases 103. The rotary bases 103 are mounted on the main frame 19 and are rotatable. relative to the main frame 19. The support platform 24 in this embodiment is axially offset and parallel to the axis, whereby the support platform 24 and the build-up platform 22 move in a circle around the axis as the turn bases 103 rotate. This circle movement causes the platform to 22 for extension both reverses direction and changes height when moving between the extension position and service position. The build-up platform 22 in this embodiment is higher in the build-up position to provide more space for build-up in the vertical direction, and lower in the maintenance position to facilitate manual handling of any object(s) 11 on the build-up platform. In another embodiment, the support platform 24 may be pivotally aligned with the axis of the rotation base(s) 103 so that the support platform 24 rotates rather than circles when moving between the build-up position and the service position. In another embodiment, the support platform 24 may have a different arrangement, such as a cantilevered arrangement where only one pivot base 103 is provided at one end of the support platform 24, or an arrangement where the pivot base(s) 103 are not (are) at the ends. support platform 24. In another embodiment, another type of movement mechanism 102 may be used.

[00172] FIG. 62-64 illustrate another embodiment of the mechanism 102 for moving the extension platform 22 between the extension position and the service position. In FIG. 62 illustrates the extension platform 22 in the extension position, FIG. 63 illustrates an extension platform 22 being moved from an extension position to a service position, and FIG. 64 illustrates an extension platform 22 in a service position in this embodiment. In the embodiment of FIG. 62-64, the mechanism includes one or more rotating bases (or rotating side portions) 116 attached to the support platform 24 and rotatable to move the support platform 24 up and down. As shown in FIG. 62-64, the mechanism 102 includes two rotating bases 116 at opposite ends of the support platform 24, configured to rotate synchronously about a common axis, and the support platform 24 is rotatable relative to the rotating bases 116. The rotating bases 116 are rotatably mounted on the main frame. 19 and are rotatable relative to the main frame 19. As shown in FIG. 63 and 64, when moving from the extension position to the service position, the rotating bases 116 rotate downward towards the lower level of the extension platform 22 to facilitate access, and the support platform 24 rotates relative to the rotating bases 116 so that the extension platform 22 faces upward. and/or away from the guide 14. Similarly, when moving from the service position to the extension position, the rotating bases 116 rotate upward to raise the level of the extension platform 22, and the support platform 24 rotates relative to the rotating bases 116 so that the platform 22 for extension was directed downwards and/or towards the guide 14 for use in creation. In another embodiment, the support platform 24 can rotate about a central axis on the rotating bases 116 rather than rotate relative to the rotating bases 116. The configuration in FIG. 62-64 allows for significant height adjustment of the build-up platform 22 in the service position, and also provides more clearance for the self-contained unit 90 to engage the rail 14 (eg, without lowering the applicator 40 as described herein).

[00173] FIG. 34-37 and 62-64 illustrate the extension platform 22 and support platform 24 pivoting 180° between the extension position and the service position so that the extension platform 22 faces down in the extension position and upward in the service position. In other embodiments, extension platform 22 and support platform 24 may be oriented differently in the service position, such as rotated 90° or 135° from the extension position. For example, the mechanism 102 for moving the build-up platform 22 in one embodiment may be configured to provide multiple service positions with different orientations, such as a first service position facing down (i.e., rotated 180° relative to position 22 for extension, as shown in Figures 37 and 62), a second service position laterally outward (i.e., rotated 90° from extension position 22, as shown in Figures 37 and 62), and/or a third service position in a different angle orientation (eg, rotated 135° from extension position 22, as shown in FIGS. 37 and 62). In a further embodiment, the mechanism 102 for moving the extension platform 22 may be configured to provide a service position in any desired orientation that may be selected by the user, and the mechanism 102 may be operated manually. Any combination of service positions may be provided by the structures described herein and other embodiments of the mechanisms 102 to move the build platform 22 between the build position and the service position.

[00174] In one embodiment, as shown in FIG. 36 and 37, system 10 and machine 12 can be used to create multiple objects 11 at the same time, including multiple objects that are different from each other and have different build times, build requirements, and/or build heights. As described herein, the installation 12 and layering engine 30 according to various embodiments are capable of creating multiple objects 11 at the same time, including multiple objects 11 on the same build platform 22 or multiple objects 11 on different build platforms 22 supported by the same and the same support node 20. In the installation 12 of FIG. 31-46 multiple objects 11 can be extended when the extension platform 22 is in the extension position as shown in FIG. 37. When a maintenance operation is required on one or more objects 11, the extension platform 22 can be moved to a maintenance position as shown in FIG. 36 and the maintenance operation can be performed. In FIG. 36 illustrates a maintenance operation in the form of removing one of the objects 11 whose growth is completed, and it should be understood that additional maintenance operations can be performed on any objects 11, including objects 11, that are not removed at this stage. When the maintenance operation is completed, the extension platform 22 can be returned to the extension position as shown in FIG. 37, which illustrates the plant 12 continuing to grow the two remaining unfinished objects 11. This allows different objects to be produced at the same time.

[00175] The guide 14 in the embodiment of FIG. 31-46 is configured to "open" to allow the layering mechanism 30 (such as the self-contained block 90) to engage and disengage with the guide 14 as needed. The guide 14 may be considered to have one or both open ends where the layering mechanism 30 can engage and disengage with the guide 14. As shown in FIG. 41A-42, a hole 104 is provided in the main frame 19 formed between two vertical columns 105 at one or both ends of the rail 14 to allow the layering mechanism 30 to be engaged with the rail by the main frame 19. The hole 104 is also present between the rails 15 of the rail 14. The rails 15 of the guide 14 shown in FIG. 31-46 extend outwardly beyond the opening 104 and/or beyond an adjacent portion of the main frame 19 and have ends 106 beveled on one or more surfaces to facilitate engagement of the carriage 32 with the guide 14. The carriage 32 includes a guide engagement mechanism 109 configured with the possibility of engaging the guide 14 to allow movement of the layering mechanism 30 along the guide 14. The mechanism 109 to engage with the guide in the embodiment of FIG. 31-46 includes grooves 107 configured to receive ends 106 during engagement and to further accommodate a portion of a respective rail 15 when carriage 32 is engaged with guide 14. Each rail 15 in the embodiment of FIG. 31-46 includes a flange or other outwardly extending portion 108 disposed in a groove 107, and the guide engagement mechanism 109 includes wheels, rolls, sleds, gears, sprockets, or other engagement structures disposed within the grooves 107 and engaged with rails 15 on several surfaces, including the underside and/or insides of outwardly extending portion 108. As shown in FIG. 41A-B, the guide engagement mechanism 109 in the embodiment of FIG. 31-46 includes rolls 119 that engage the top and inner surfaces of the rails 15 and the undersides of the outwardly extending portions 108 to stabilize the carriage 32 relative to the guide 14. Movement of the carriage 32 along the guide 14 is provided by a guide engagement mechanism 109 which includes a mechanism movement engaging with a guide 14 such as wheels, gears, sprockets, etc. In one embodiment, the layering mechanism 30 includes a circular gear that engages with a linear gear on one or each rail 15 to drive carriage 32 move along track 14. In other embodiments, movement of carriage 32 along track 14 may be provided by wheels 117 connected to a propulsion system or linear induction motors, among other mechanisms. The guide engagement mechanism 109 in one embodiment may also include one or more electrical contacts (not shown) for engaging with and receiving power from the busbar(s) 101. The layering mechanism 30 may be powered by other mechanisms, including an internal power source, a temporary releasable connection to a power source, and/or a non-contact inductive power source. Other guide engagement mechanisms 109 may be used in other embodiments, including other travel mechanisms, and it should be understood that guide 14 and guide engagement mechanism 109 may be designed to complement each other.

[00176] The layering mechanism 30 in FIG. 31-46 is designed as a self-contained unit 90 that can move independently of the guide 14 in some cases, as described herein in connection with FIG. 28. In FIG. 40-41B illustrate the movement of the layering mechanism 30 independently of the guide 14 and the engagement of the layering mechanism 30 with the guide 14. As illustrated in FIG. 42, multiple layering mechanisms 30 may be simultaneously used on rail 14. Such multiple layering mechanisms 30 may be configured to take multiple passes in opposite directions, or to make a single pass. For example, the layering mechanism 30 may engage one end of the guide 14, make one pass over the buildup area 13, and then exit the guide 14 at the opposite end, either to move on to the next task (e.g., another setup) or to re-engage with guide 14 again at the first end. It is contemplated that a continuous series of layering mechanisms 30 may sequentially pass over the buildup area 13, with each layering mechanism 30 making one pass and returning to re-engage the guide 14 to make another pass. In another embodiment, installation 12 may use a combination of layering mechanisms, including self-contained units 90 that can disengage from rail 14, and on-line and/or permanent layering mechanisms 30 that cannot be quickly detached from rail 14.

[00177] As described above, the layering mechanism 30 can be moved separately and independently from the rail 14 in the embodiment of FIG. 31-46, where the layering mechanism 30 is provided as a self-contained unit 90. In this embodiment, the layering mechanism 30 uses a ground engaging mechanism for support and movement independent of the rail 14. The ground engaging mechanism in the embodiment of FIG. 31-46 uses wheels 117 to move independently of track 14, such as on a surface on which plant 12 is located. The ground engagement mechanism in FIG. 31-46 also includes stabilizers 118 in front and behind the wheels 117 to stabilize the layering mechanism 30 and to prevent overturning when traveling on the wheels 117 outside the guide 14. In this embodiment, the stabilizers 118 can be folded when not needed, i.e. stabilizers 118 are movable between the extended position shown in FIG. 33 and 39 for use when moving outside of rail 14, and the retracted position shown in FIG. 31, 32, and 38 when the layering mechanism 30 is engaged with the track 14. The stabilizers 118 may include additional wheels, wheels, sleds, or other structures to provide ground engagement during movement. In other embodiments, the layering mechanism 30 may comprise other ground engaging mechanism(s), including rails, movable legs, or other similar structures.

[00178] The layering mechanism 30 in the embodiment of FIG. 31-46 includes a vertical adjustment mechanism 120 configured to adjust the position of the applicator 40 and/or other components of the layering mechanism 30 in a vertical direction, i.e., parallel to the build-up direction in the illustrated embodiment. This configuration is different from the configurations illustrated in FIG. 8-11 and 15-18, where the vertical adjustment was made by adjusting the position of the extension platform 22. The layering mechanism 30 in FIG. 31-46 has a bottom 121 that is engaged with the rail 14 and/or the ground, and an top 122 that rests on the bottom 121 and is movable in a vertical direction relative to the bottom 121. The top 122 includes at least an applicator 40 , source 34 of fluid material 36, and outlets 54 in the embodiment of FIG. 31-46, whereby at least these components move in the vertical direction along with the top 122. The vertical adjustment mechanism 120 moves the top 122 relative to the bottom 121. In the embodiment of FIG. 31-46, the vertical adjustment mechanism 120 includes two lifters 123 on opposite sides of the layering mechanism 30 . These lifters 123 may comprise a telescoping structure and may be powered by a variety of mechanisms including hydraulic or pneumatic cylinders, screw jacks, sprocket/chain drive, gear members, etc. In other embodiments, the build platform 22 of FIG. 31-46 may additionally or alternatively be vertically adjustable as described herein. For example, the extension platform 22 is not vertically adjustable in the embodiment of FIG. 31-46, but may be configured to do so in other embodiments, in addition to or instead of the vertical adjustment of the layering mechanism 30. In one embodiment, both the build platform 22 and the layering mechanism 30 can be vertically adjustable to further increase the potential vertical size of the object 11 to be built up. In this configuration, the build-up platform 22 can only be vertically adjustable when the range of vertical adjustment of the layering mechanism 30 is not sufficient for the build-up requirements, or vice versa.

[00179] The build platform 22 can be movable to allow the creation of larger objects and/or more objects than the size of the guide 14 would allow in some embodiments. For example, in one embodiment shown in FIG. 48A-B, the build platform 22 is located on a support platform 24 that includes multiple build platforms 22 and can move to selectively place different build platforms 22 in the build region 13 to create different objects 11. As shown in FIG. 48A, the support platform 24 can be rotated to accommodate the first build-up platform 22A within the build-up area 13 to create the first object 11A, and then can be rotated to accommodate one of three additional build-up platforms 22B-D within the build-up area 13 to create one of the other three. objects 11B-D. This configuration allows one layering mechanism 30 and/or one guide 14 with several layering mechanisms 30 to sequentially create objects 11 or parts of objects. This has the advantage of allowing one object 11A to be created and then the creation of the second object 11B to begin immediately without having to wait for the completed object 11A to be removed from the build-up platform 22A, which can be done later. It may also provide the advantage of allowing one or more layering engines 30 to sequentially create the first part of multiple objects 11 and then switch the layering engine(s) 30 to create another part of the objects 11 (eg, which may be made from a different material), reducing the number of changes. or switching mechanism(s) 30 layering, which must be performed in the process of creating multiple objects.

[00180] As another example, an extension platform 22 may be located on a support platform 24 movable in one or more directions, as shown in FIG. 49A-D. In the embodiment of FIG. 49A-B, the support platform 22 is movable in the transverse direction (i.e., in the y direction). In this embodiment, the layering mechanism(s) 30 may make one or more passes over the buildup area 13 to create the first object or part of the object 11E, then buildup platform 22 and/or support platform 24 can be moved laterally to allow the creation of a second object or part of an object 11F. It should be understood that FIG. 49A-B are shown in the x direction, that is, in the direction of movement of the layering mechanism 30 . The lateral movement shown in Fig. 49A-B may allow the layering mechanism(s) 30 to operate to build up several different objects 11 on the same or different build platforms 22, or to build up portions of a single object 11 that is wider than the buildup area. In the embodiment of FIG. 49C-D, the build platform 22 is movable in the horizontal direction (i.e., in the x direction). In this embodiment, the layering mechanism(s) 30 may be stationary(s) and the buildup platform 22 and/or support platform can be moved horizontally to apply material 36. In other words, the relative movement of the mechanism(s) 30 layering and build-up platform 22 is done by moving the build-up platform 22 rather than moving the layering mechanism(s). This configuration may be practiced by the movable layering mechanism 30 described herein, which is held stationary to create and which may be connected to the "open" track 14 described herein, or alternatively this configuration may be implemented in practice by means of a permanently stationary layering mechanism 30 . It should be understood that in the embodiments of FIG. 49A-D, vertical adjustment can be performed by adjusting the height of the applicator 40, the height of the build-up platform 22, or a combination of the two. In another embodiment, the movement of the extension platform of FIG. 49A-B can be combined with the movement of FIG. 49C-D, suggesting a further increase in the potential size of the buildup region 13.

[00181] In one embodiment, the apparatus 12 may include a material accumulation sensor 124 configured to detect the accumulation of material (eg, cured resin) on the applicator 40. For example, as shown in FIG. 50, when roller 42 is used, material 129 cured by irradiator 50 may spontaneously adhere to roller 42. This adhesively attached material 129 may lead to further accumulation and adversely affect the quality of object 11. In the embodiment of FIG. 50 contact element 125 may be positioned such that any discontinuity in the surface of roll 42 (eg, material 129) will cause displacement of contact element 125, thereby allowing the discontinuity to be detected by a displacement sensor 126 configured to detect displacement of contact element 125. Contact element 125 in the embodiment of FIG. 50 is shown as a contact roll, but in other embodiments, other contact elements such as sliding contact, fibers, etc. may be used. In other embodiments, other non-contact accumulation sensors 124 may be used, such as optical sensors, conductivity/resistance sensors. or other sensors. The material accumulation sensor 124 described herein may be built into the layering mechanism 30 in one embodiment, or may be provided separately from the layering mechanism 30 in another embodiment.

[00182] In another embodiment, the layering mechanism 30 may be equipped with a leveling device 127 to provide better control of the thickness of the material 36 applied by the applicator 40. In FIG. 51-52 illustrate one embodiment of an installation with a leveling device 127, and FIG. 53 illustrates another such embodiment. In the embodiment of FIG. 51-52, the layering mechanism 30 comprises an applicator 40 in the form of a roller 42 that rotates to transfer fluid material 36 from source 34 to buildup area 13, an irradiation device 50 to cause solidification of fluid material 36, and a leveling device 127 in the form of a leveling roller 128 located between roller 42 and outlet 54 of irradiator 50. In this embodiment, roller 42 carries fluid material 36 to surface 130 on which material 36 is to be applied (i.e., build-up platform 22 or object surface 11) and leveling roller 128 rotates in the opposite direction to that of roll 42 to transfer any excess material 36 back to source 34. Movement of carriage 32 causes irradiator 50 to solidify material 36 after material 36 passes leveling roll 128 and the interval between leveling roll 128 and surface 130 approximately m is the thickness of the applied layer 38. As shown in FIG. 52, when there is no surface 130 to apply material 36, rotation of the leveling roller 128 pushes all of the material 36 back into source 34. It should be understood that the increased adhesive force between material 36 and surface 130 may assist in the formation of object 11 via layering mechanism 30 as shown. in fig. 51-52 because there is an air gap between the applied material 36 and the layering mechanism 30 at the intersection of the waves 53 and the material 36. In this embodiment, the application site 41 may be at a distance from the irradiation site 51, and it should be understood that the outlet 54 can be directed forward, as described herein, to move the irradiation site 51 closer to or to the application site 41. The layering mechanism 30 further comprises a second roller 42 and a leveling roller 128 on the opposite side of the carriage 32 (ie, on the left side in FIGS. 51 and 52). The second roller 42 does not spin as it passes last over the application site 41 to avoid carrying excess material 36 to the surface 130. When the carriage 32 moves in the opposite direction (i.e., from right to left in FIGS. 51-52), the second (front) roller 42 rotates, and the rear roller 42 is stationary. The layering mechanism 30 in FIG. 51-52 can thus apply the material 36 moving in two opposite directions.

[00183] FIG. 53 illustrates another embodiment of the layering mechanism 30 that uses a leveling device 127 in the form of two leveling rolls 128. In this embodiment, the applicator 40 is in the form of a roll 42 that carries the material 36 to the surface 130 and the leveling roll 128 on the front side rotates into opposite direction of rotation of roll 42 to remove excess material 36 from roll 42. The spacing between roll 42 and leveling roll 128 approximately determines the thickness of the applied layer 38. The layering mechanism 30 includes a second leveling roll 128 on the opposite side of carriage 32 (i.e., left side in Fig. 53), which performs a leveling function when the carriage 32 moves in the opposite direction (i.e., from right to left in Fig. 53). Additionally, the rear leveling roller 128 provides the additional function of removing uncured material (eg, uncured resin) from the surface of the deposited layer 38 after irradiation. It should be understood that roller 42 will rotate in the opposite direction when the carriage moves in the opposite direction. The layering mechanism 30 in FIG. 51-52 can thus apply the material 36 moving in two opposite directions. The layering mechanism 30 further comprises a plurality of wipers or squeegees 131 configured to wipe excess material 36 from a variety of surfaces, including the surface of the roll 42, the surfaces of the leveling rolls 128, and the surface of the applied layer 38. The layering mechanism 30 may also include a squeegee with the ability to create a vacuum ( not shown) or other vacuum device for material removal as described herein, located after the last wiping device 131. This vacuum device may additionally contain a trap vessel for storing unused material 36 removed by the vacuum device, and it should be understood that any vacuum devices material removal devices described herein (including squeegees 82 with the ability to create a vacuum) may contain such a trapping container.

[00184] Irradiator 50 and associated structures for transmitting and directing electromagnetic waves 53 may be adjustable to provide improved performance and/or versatility to layering mechanism 30. Such adjustability may include the ability to adjust selection, layout, power output, pointing, and/or other aspects and properties of irradiator 50 and associated structures (including outlets 54). In FIG. 54-61B illustrate various embodiments providing such adjustment capability, and it should be understood that aspects of the embodiments of FIG. 54-61B may be used in combination with each other and with other embodiments described herein, including other adjustable configurations (and applications thereof) already described herein.

[00185] FIG. 54 illustrates one embodiment of a set 55 of outlets 54 of an irradiator assembly 60 that can provide improved detail resolution. The outlets 54 in the embodiment of FIG. 54 are zigzag with respect to each other such that each outlet 54 in set 55 is transversely (ie, y-directed) overlapped by at least one other outlet 54. As shown in FIG. 54, all outlets 54, other than outlets 54 at opposite ends, in set 55 are overlapped at both ends by other outlets 54. This arrangement allows more precise selection of the transverse (y-direction) boundaries of the irradiation site, improving the resolution of the irradiation assembly 60. The zigzag arrangement of the outlets 54 also allows more outlets 54 to be placed in a given transverse width compared to a single row arrangement, thus improving the overall power output of the set 55.

[00186] FIG. 55 illustrates an embodiment of a set 55 of outlets 54 of an irradiation assembly 60 configured to allow position adjustment in the y direction. In one embodiment, this position adjustment may be accomplished by mounting the kit 55 on a sliding/sliding structure in one embodiment, where the sliding movement may be triggered by a piston, jackscrew, or other one-dimensionally movable structure. In another embodiment, this position adjustment may be accomplished by placing the set 55 on a structure capable of tilting/tilting, which may be actuated by a piston, jackscrew, or other structure capable of raising and lowering one or both transverse ends of the set 55. In In a further embodiment, the outlets 54 may be adjusted individually or in separate groups or sets. The outlets 54 may further be configured to rapidly reciprocate in the y direction, allowing the single outlet 54 to direct waves 53 into an area that increases in the y direction. This y-direction adjustment and/or reciprocation allows more precise selection of the transverse (y-direction) boundaries of the irradiation area, improving the resolution of the irradiation assembly 60. It should be understood that in other embodiments, the set 55 may include more rows. and/or other offset arrangements.

[00187] FIG. 56 illustrates an embodiment of a set 55 of outlets 54 of an irradiation assembly 60 configured to provide adjustment of the power output. This output power adjustment may be performed by varying the output power of the irradiation device 50. In one embodiment, the output power adjustment may be configured to adjust the size of the irradiation region 58 of each outlet 54, thereby allowing more precise selection of the lateral (in the y direction) boundaries of the region. irradiation, improving the resolution of the irradiation node 60. As seen in FIG. 56, the size of the irradiation area 58 can be increased or decreased (indicated by broken lines) by increasing or decreasing the output power, respectively. In another embodiment, the power output adjustment may be tailored to the properties of the fluid material 36, since some materials 36 may require more or less power to solidify. It should be understood that other factors, such as the speed of movement of the layering mechanism 30, may affect the desired power output.

[00188] FIG. 57 illustrates an embodiment of a set 55 of outlets 54 of an irradiating assembly 60 configured such that the first subgroup 132 of the set 55 is configured to emit waves 53 having a first property and the second subgroup 133 of the set is configured to emit waves 53 having a second property. In one embodiment, the first and second subgroups 132, 133 can be configured to emit waves having different output power levels, providing substantially better design versatility. For example, the first subgroup 132 may include smaller outlets 54 (eg, smaller diameter optical fibers 61) with relatively lower output power levels that are more densely spaced to provide greater y-direction resolution for critical sizes, and the second subgroup 132 may include large outlets 54 (eg, large diameter optical fibers 61) with relatively high energy output levels to provide faster solidification to fill the bulk of the object. Different power outputs can be achieved by connecting outlets 54 of different subgroups 132, 133 to different irradiation devices 50, connecting outlets 54 of different subgroups 132, 133 to one irradiation device 50 capable of varying power, or by means of the input ends 62 of the second subgroup 133, receiving waves 53 emitted by a large number of pixels (when using a DLP projector) due to their larger size. A combination of outlets 54 from different subgroups 132, 133 (including transversely overlapping outlets 54) can be used to provide additional process variation capability such as additional increased irradiation power and/or a combination of more power for the middle portions of object 11 and greater resolution. at the edges of the object 11. In an alternative embodiment, some of these advantages can be achieved by using subgroups 132, 133 of smaller and larger diameter optical fibers 61, without any difference in power output between the two subgroups 132, 133. In another embodiment The outlets 54 of the first and second subsets 132, 133 can be connected to other irradiators emitting different wavelengths 53 that can cure other types of materials 36, or to cure the same material 36 at different speeds. It should be understood that a larger number of subgroups 132, 133 with additional different properties may be used in other embodiments, and that the waves 53 emitted by each subgroup may have several properties that differ from each other.

[00189] FIG. 61A and 61B illustrate an embodiment of the layering mechanism 30 using multiple outlets 54 or sets 55A-C of outlets 54 that can be selectively switched. In one embodiment, multiple sets 55A-C of outlets 54 may be mounted on a mounting structure 135 that can be rotated around an axis (e.g., mounted on a gimbal), whereby sets 55A-C can be selectively aimed at the site 51 of irradiation. Each set 55A-C can be customized. For example, sets 55A-C may be configured to emit waves 53 having one or more different properties, such as wavelength values, power, or other properties described herein, or sets 55A-C may have outlets 54 with a different size or other layout to create a different resolution. This configuration increases the versatility of the process because a single layering mechanism 30 can handle different materials 36 that require waves 53 with different properties to set, and different projects that require different resolutions, similar to the configuration of FIG. 57. It should be understood that subgroups 132, 133 in FIG. 57 in one embodiment can be movably mounted to selectively target each subgroup 132, 133 at the irradiation site 51, for example by translational movement and/or by rotational movement, as shown in FIG. 61A-B. In other embodiments, the layering mechanism 30 may include a different number of sets 55A-C and the mounting structure 135 may be moved in other ways to select sets 55A-C.

[00190] FIG. 58 illustrates one embodiment of a design for directing waves 53 such that the irradiation site 51 is approximately at the application site 41 in one embodiment, or such that the irradiation site 51 is offset from the application site 41 (before or behind the application site 41 in the direction of travel) in another embodiment, as described herein and illustrated in FIG. 1, 3 and 4. In this embodiment, the targeting of the outlet holes 54 can be adjusted in the x direction forward and backward. As illustrated in FIG. 58, in one embodiment, the outlets 54 of the irradiation assembly 60 can be tilted, for example, by mounting the outlets 54 using a structure (for example, latches 65) capable of pivoting or rotating through a range of motion to move the irradiation site 51 forward. or back. For example, the layering mechanism 30 may include a mounting structure for the outlets 54 mounted on a universal joint to allow rotation about one axis. It should be understood that the degree of inclination shown in FIG. 58 may be exaggerated compared to the actual degree of inclination required to achieve this goal in many embodiments. In another embodiment, the irradiation device 50 may include multiple sets of outlets 54 directed at different angles, with selective actuation of the outlets 54 allowing the irradiation site 51 to move forward or backward. In a further embodiment, the outlets 54 can be targeted differently by translation in the x direction. It should be understood that the degree of displacement of the irradiation site 51 may depend on the properties of the fluid material 36 and the speed of the layering mechanism 30, among other factors. Displacement of the irradiation site 51 may improve the binding of the fluid material 36 to the surface 130 and/or the separation of the fluid material 36 from the roller 42. is not separated from roller 42 in a manner causing dimensional distortion (eg, outward curvature) of the surface of roller 42. Therefore, shifting the irradiation site 51 can be particularly advantageous for such configurations.

[00191] FIG. 59 and 60 illustrate an embodiment of a layering mechanism 30 with an irradiating unit 60 capable of directing waves 53 offset from the application site 41 . In the embodiment of FIG. 59 and 60, the targeting of the outlets 54 is adjusted in the direction of travel of the layering mechanism as the applicator 40 passes through the applicator 41 to focus the waves 53 on a particular point 134 within the buildup region 22 as the applicator 40 passes through a certain point 134, to increase the time of irradiation of a certain point 134. As illustrated in FIG. 59, the irradiation assembly 60 is configured to continuously adjust the targeting of the outlets 54 backwards relative to the direction of travel, whereby the targeting of the outlets 54 tracks a certain point 134 and continues to focus on a certain point 134 after the applicator 40 (i.e., the swath top) 42 in this embodiment) will pass a certain point 134. As illustrated in FIG. 60, the irradiation assembly 60 is configured to continuously adjust and re-adjust the targeting of the outlets 54 forward relative to the direction of travel, whereby the targeting of the outlets 54 tracks a certain point 134 in front of the applicator 40 and continues to focus on a certain point until the applicator 40 (i.e., the top of the roll 42 in this embodiment) will not reach a certain point 134. This constitutes instants of constant irradiation at a certain point 134, and it should be understood that targeting start/end angles can be based on factors such as buildup rate and material properties 36. It should be understood that the embodiments of FIG. 59 and 60 can be combined so that the targeting of the outlets 54 tracks a certain point 134 both before and after the applicator 40 arrives at a certain point 134.

[00192] In a further embodiment, the plant 12 described herein may be enclosed in a sealed chamber, which may be temperature controlled, pressure controlled, humidity controlled, and/or filled with a specific gas (including mixtures of gases). Adjusting the temperature, pressure and humidity may be able to influence the growth rate and thus improve efficiency. Additionally, plant 12 has the ability to grow hollow, hermetically sealed objects 11, and thus the choice of ambient gas can allow the creation of a hollow, hermetically sealed object 11 filled with a particular gas. For example, such an object 11 filled with an inert gas can be used, for example, in the aerospace industry.

[00193] FIG. 67-70 illustrate another embodiment of a supply assembly 79 comprising a tub-shaped source 34 of fluid material 36 that can be used in conjunction with any of the embodiments described herein. The configuration of Fig. 67-70 uses seals 95 and a drain system 140 to minimize material 36 loss and prevent material 36 from leaking to undesirable locations. As shown in FIG. 67-70, the supply unit 79 has inner support walls 97 and outer support walls 98, with the inner support walls 97 parallel to and inside the outer support walls 98. The inner support walls 97 in this configuration define the boundaries of the tub 34 for supplying fluid material 36 for use in product creation. The inner and outer support walls 97, 98 have circular openings 99 and the roller 42 extends through the holes 99 in the inner and outer support walls 97, 98 to support the roller 42. It should be understood that any components contained within the roller 42 may also extend through support walls 97, 98. Inner support walls 97 comprise seals 95 around roll 42 at the inner and outer ends of opening 99, which are in the form of O-rings 95 in FIG. 67-70. Thus, the inner support walls 97 may be considered sealing walls in the embodiment of FIG. 67-70. In one embodiment, seals 95 contact roll 42 and rotate with roll 42, and roll 42 may include grooves to form seats for seals 95 to prevent movement of seals 95. In other embodiments, seals 95 may be in the form of a sleeve located around the roll. 42, or a ridge extending outward from the outer surface of roll 42, among other configurations. In another embodiment, extremely tight tolerances may be used to minimize leakage. The outer support walls 98 include bearings 96 around the roller 42 at the inner and outer ends of the hole 99, whereby the outer support walls 98 and the bearings 96 support the roller 42 to rotate. The seals 95 are configured to generate minimal friction with the inner support walls 97 as the seals 95 rotate adjacent the inner and outer surfaces of the inner support walls 97 to prevent friction-induced solidification of the fluid 36, which can occur under some circumstances. It should be understood that in one embodiment, fluid material 36 can slowly, controlled leak through seals 95 to minimize friction. Drainage system 140 is configured to remove any material 36 penetrating seals 95 and internal support walls 97 to avoid fluid contact. 36 with bearings 96. Leakage of material 36 through seals 95 can be small enough that drain system 140 can remove any leaked material 36 from spaces 143 before material 36 comes into contact with bearings 96. This configuration can also be used with fluid materials containing aerosol material or filler dispersed in them.

[00194] The drain system 140 includes drain holes 141 located in the walls (for example, in the bottom wall 142) of the bath in the spaces 143 formed between the inner and outer support walls 97, 98, and may also contain a reservoir or drain pan into which fluid material 36 may drain from drain holes 141. In one embodiment, shown in FIG. 68, drain holes 141 are in communication with a reservoir or container 144 for fluid material 36 located under the bottom wall 142, for example, by means of contours. Reservoir 144 is shown schematically in FIG. 68 and is configured to supply fluid material 36 to supply tank 34, for example, by using a pumping mechanism 146. In one embodiment, reservoir 144 may be a primary source or reservoir for fluid material 36 that contains much more fluid material 36 than bath 34 supply, to ensure continuous operation without stopping to replenish the bath 34 supply. Any material 36 passing through the inner support wall 97, such as through the seals 95, will flow into the drain holes 141 and into the tank 144, and thus prevent its penetration or even contact with the bearings 96 on the outer support wall 98. Additionally, the bottom wall 142 in fig. 67-70 includes an opening 145 adjacent to the inner support wall 97 at the lowermost end of the bottom wall 142 that may allow material 36 in reservoir 144 to return to source 34 for use. The opening 145 can also be used to drain the supply trough 34, and the bottom wall 142 of the supply trough 34 slopes downward from the left end to the right end in the orientation shown in FIG. 67-70, to facilitate the draining process. The reservoir 144 may also be removable for the purpose of emptying it and/or replacing it with a new reservoir. Seals 95 can also be replaced if damaged or coated with cured material 36.

[00195] It should be understood that supply node 79 and source 34 and associated components shown in FIG. 67-70 may be included in the same or similar configuration in some of the embodiments described herein (e.g., in FIGS. 1, 3-4, 7-11, 15-18, 43-47, etc. ), and that a modified version of supply node 79, source 34, and/or components thereof may be included in some of the other embodiments described herein. For example, seals 95 and overflow system 140 may be included in some form in any embodiment comprising one or more rolls 42 submerged or partially submerged in source 34 of fluid material 36, including the embodiments of FIG. 71-81 described below.

[00196] FIG. 71-75 illustrate additional embodiments of a manufacturing plant 12 that may be used with the system 10 and method described herein, and which may include any components of the system 10 and method according to any of the embodiments described herein. For example, plant 12 according to the embodiments of FIG. 71-75 may be connected to a computer controller 100 in communication with one or more components of plant 12 and configured to control the operation of plant 12 and/or its components to manufacture object 11. The embodiments of FIG. 71-75 contain layering mechanisms 30 that differ from the embodiments of FIGS. 1-66, including source 34 of fluid material 36, applicator 40, irradiator assembly 60, and other components configured differently from other embodiments described herein. Source 34, applicator 40, irradiator 60, and other components of the layering mechanisms 30 illustrated in FIG. 71-75 may be used in conjunction with other components and features of other embodiments described herein. Source 34, applicator 40, irradiator assembly 60, and other associated structures in the embodiments of FIG. 71-75 may be included in the layering mechanism 30 and apparatus 12 shown in FIG. 8-13, 15-18 or 31-46. For example, source 34, applicator 40, and other associated structures in the embodiments of FIG. 71-75 may be mounted on a carriage 32 and/or coupled to other components of the irradiation assembly 60 according to one or more of the embodiments shown and described herein to form a layering mechanism 30, and such layering mechanism 30 may be used in conjunction with a rail 14 and/or anchor assembly 20 according to one or more of the embodiments shown and described herein. It should be understood that the installations 12 in FIG. 71-75 may be provided with any of the components, features, and functionality described herein in relation to other embodiments, including, but not limited to, components, features, and configurations of irradiation assembly 60 and irradiation device 50, carriage 32, various modular components, etc. Components that have already been described with reference to one or more embodiments herein may not be re-described with reference to FIGS. 71-75 for the sake of brevity, and identical reference numbers may be used to refer to previously described components.

[00197] The layering mechanisms 30 shown in FIG. 71-75 may further be implemented as part of a stand-alone unit 90 according to one or more of the embodiments shown and described herein, and may include on board a processor 2604, memory 2612, and/or other computer components necessary to execute computer-executable commands for automating stand-alone unit 90 and/or communicating with computer controller 100. Layering mechanisms 30 in FIG. 71-74 may be built into a self-contained unit 90 as shown in FIG. 31-47 with some modifications, and in FIG. 76-81 illustrate an example of a self-contained unit 90 and associated system 10 configured to use the layering mechanism 30 of FIG. 75 as described below.

[00198] The layering mechanism 30 in FIG. 71 uses a first or initial irradiation site 150 that at least partially forms a layer 38 before the material 36 reaches the application site 41, whereby the irradiation site 51 located at or near the application site 41 becomes the auxiliary irradiation site 51 for linking layer 38 to object 11. In one embodiment, secondary irradiation site 51 may be a post-irradiation site. It should be understood that additional irradiation operations can be performed after the auxiliary irradiation site 51, for example, by the auxiliary irradiation device 80, as shown in FIG. 7 and/or between the original irradiation site 150 and the secondary irradiation site 51 in other embodiments. The original irradiation site 150 and the auxiliary irradiation site 51 may be referred to as "first" and "second" irradiation sites, it being understood that the words "first" and "second" are not intended to be in any order unless explicitly stated otherwise. For example, the words "first" and "second" do not imply that the "first" action precedes the "second" action, and "first" does not imply that no other action precedes the "first" action, unless explicitly stated otherwise. The terms "initial" and "terminal" are used to indicate that the activities (eg, irradiation operations) are the first or last in the sequence. In the embodiments of FIG. 71-75, the initial irradiation site 150 is within (i.e., immersed in) the fluid material 36, and the layering mechanism may use a thickness limiter in conjunction with the initial irradiation site 150, whereby there is some space between the thickness limiter and the surface of roll 42, and the original irradiation site 150 is within this space. The space between roll 42 and thickness limiter defines the thickness of layer 38 in one embodiment. The layering mechanism 30 in FIG. 71 includes a thickness limiter in the form of an auxiliary roll 151 located at a distance from the roll 42, whereby the space between the roll 42 and the auxiliary roll 151 determines the thickness of the layer 38 formed at the original irradiation site 150. Roll 42 may be considered a main roll or a main build-up roll, and an auxiliary roll may be considered an intermediate build-up roll in this configuration. Plant 12 may include a mechanism for adjusting the spacing between rolls 42, 151 to vary the thickness of layer 38, which may be a manual or automated mechanism as described herein. The auxiliary roll 151 is illustrated in FIG. 71 is fully submerged, with the original irradiation site 150 within the fluid material 36, i.e., below the surface of the fluid material 36. In another embodiment, the auxiliary roll 151 may be partially submerged, whereby the original irradiation site 150 is still below surface of the fluid material 36. In a further embodiment, the initial irradiation site 150 may be on or above the surface of the fluid material 36. In this configuration, a thickness limiter may or may not be used (eg, an auxiliary roll 151 located partially or completely above the surface of the fluid material 36).

[00199] In one embodiment, the auxiliary roll 151 may be made of silicone rubber or polytetrafluoroethylene (PTFE), which typically has poor adhesion to most photocurable resins. Other materials with poor adhesion to the cured layer 38 may also be used. In one embodiment, the material of the auxiliary roll 151 may be chosen such that it does not adhere adhesively to the layer 38 as it cures. In the embodiment of FIG. 71, the auxiliary roll 151 may be opaque because the waves 53 do not need to penetrate the surface of the auxiliary roll 151. In fact, it may be desirable that the waves 53 do not penetrate the auxiliary roll 151 to prevent the material 36 from unintentionally solidifying. In one embodiment, the auxiliary roll 151 may have reflective properties (eg, a mirror surface) adapted to reflect waves 53 back to original irradiation site 150, which may allow less power to be used for irradiation device 50 because reflected waves 53 will increase irradiation of fluid material 36. Auxiliary roll 151 may be is rotatable such that the surface of the auxiliary roll 151 moves in the same general direction and at the same speed as the adjacent surface of the roll 42. The auxiliary roll 151 can be energized for such rotation in one embodiment. or can be freely rotated in another embodiment. One or more additional auxiliary rolls 152 may be used in other embodiments (shown in broken lines in FIG. 71), and additional auxiliary roll(s) 152 may be used to hold layer 38 in place and/or to provide additional irradiation sites. Auxiliary roll 151 and initial irradiation site 150 are shown in FIG. 71 located at the bottom of the roller 42, opposite the place of application 41, but this position can be changed in other embodiments. For example, placing the auxiliary roll 151 on the side of the roll 42 may reduce the required depth of the tank 34 supply.

[00200] The layering mechanism 30 in other embodiments may include a different type of thickness limiter or may not contain a thickness limiter at all. For example, in FIG. 71C illustrates an embodiment of a layering mechanism 30 with surface 172 (or a portion thereof) immersed in fluid material 36 and positioned at a distance from roller 42 to form a thickness limiter. In this configuration, initial irradiation site 150 is in the space between surface 172 and roller 42. Surface 172 may be formed from materials with poor adhesion to fluid material 36, low friction, and/or reflective properties, as described herein. In one embodiment, surface 172 may be a fixed surface, and in another embodiment, surface 172 may be a movable surface, such as a conveyor belt that runs in a closed loop around one or more pulleys. Surface 172 is shown flat in FIG. 172, but this surface 172 may be convex, concave, or have a different contour in other embodiments. As another example, in FIG. 71D illustrates an embodiment of a layering mechanism 30 without a thickness limiter. In this embodiment, the power of the irradiating device 50 is carefully controlled depending on the transparency of the roller 42 and the properties of the fluid material 36, so that the waves 53 penetrate only a predetermined distance deep into the fluid material 36, thereby forming a layer 38 with the desired thickness. The cure depth of a photocurable resin, for example, is a function of the power of the electromagnetic waves 53 and the duration of exposure, and the controller 100 may contain algorithms to achieve the desired cure depth based on these factors. More precisely, the curing depth of the photocurable resin depends on the function P*t/A, where P is the power, A is the irradiation area, and t is the time.

[00201] In the embodiments of FIG. 71A and 75A, the layering mechanism 30 may include one or more temperature control elements 170 configured to control the temperature of the fluid material 36 in the supply bath 34 . For example, some resins may function better at temperatures above ambient temperature, and the layering mechanism 30 may include one or more heating elements to raise the temperature of the fluid 36 to a more optimal temperature. As another example, solidification of the fluid material 36, such as by curing, can generate heat that will raise the temperature of the fluid material 36 to an undesirable level, particularly when the initial irradiation site 150 is immersed in the fluid material 36. In this example, the layering mechanism 30 may contain one or more cooling elements to limit the rise in temperature of the fluid material 36 and/or to cool the fluid material 36 to a more optimal temperature. The temperature control element(s) 170 may be placed at various locations, for example, within the supply pool 34, within or adjacent to the walls of the supply pool 34, or within roll 42 and/or auxiliary roll 151. An example of such a temperature control element 170 is a circuit with a circulating heating or cooling fluid, which may be supplied from an external source 171 of heating and/or cooling fluid, but other temperature control elements 170 may be used in other embodiments. For example, in one embodiment, roll 42 and/or auxiliary roll 151 may comprise one or more fluid paths extending substantially the entire length of rolls 42, 151. The same path(s) may (may) ) be used to selectively circulate heating or cooling fluid as needed. In one embodiment, the layering mechanism 30 may further comprise separate temperature control elements 170 configured for heating and cooling. In one embodiment, the temperature control element(s) 170 may initially be used to raise the temperature of the fluid material 36 to a suitable or optimal temperature for creating the product 11, but after heat build-up from prolonged solidification/cure, the temperature control element(s) may be used to reduce the temperature of the fluid material 36 and/or limit the rise in temperature to maintain a suitable or optimal temperature. The controller 100 may include logic to control the temperature of the layering mechanism 30 and/or parts thereof by controlling one or more of such temperature control elements 170 to perform a heating or cooling function.

[00202] Irradiation node 60 in FIG. 71 comprises two irradiation devices 50, each of which has its own outlet 54, whereby one irradiation device 50 emits waves 53 towards the original irradiation site 150 and the other irradiation device 50 emits waves 53 towards the auxiliary irradiation site 51 at the application site 41 . In one embodiment, the irradiation assembly 60 comprises two sets 55 of outlets 54 described herein, each of which can be provided by the irradiation device 50 in the form of a set 55 of LEDs 59 directed to the irradiation site 51, 150, or a set 55 of optical fibers 61 connected to an irradiation device 50 in the form of a DLP projector or a set of LEDs 59. The irradiation assembly 60 may further comprise focusing mechanisms 66 to focus the waves 53 between the outlets 54 and the irradiation site 51, 150, as also described herein. For example, focusing mechanisms 66 may include a set of microlenses 64 or a set of other lenses as described herein. Irradiation devices 50 may be configured to selectively solidify portions of fluid material 36 as described herein to create each layer 38, for example by selectively actuating certain outlets 54 and through other techniques. In one embodiment, the irradiator 50 for the original irradiation site 150 may be configured to selectively actuate the outlets 54 to solidify the same portions of the layer 38 as the irradiator 50 for the secondary irradiation site 51. In a further embodiment (not shown), some or all of the outlet(s) 54 for the original irradiation site 150 may be within the auxiliary roll 151, whereby the auxiliary roll 151 has a structure similar to the roll 42 shown and described in herein, for example, as shown in FIG. 8-11, 15-18 and 43-47. It should be appreciated that the irradiation assembly 60 may be configured to move the irradiation sites 51, 150 forward or backward as needed, as described herein. Additionally, in one embodiment, the focusing mechanism 66 for the original irradiation site 150 may have a focal length adjusted such that the waves 53 are focused on the surface of the roll 42, and the focusing mechanism 66 for the secondary irradiation site 51 may have a focal length adjusted such that the waves 53 are focused on the outer surface of the layer 38 and/or on the surface of the object 11 to which the layer 38 is applied/bonded.

[00203] In other embodiments, the installation 12 and layering mechanism 30 of FIG. 71 may be provided in a similar or identical configuration, with the irradiating node 60 having a different configuration. In FIG. 72-74 illustrate such similar or identical layering setups 12 and mechanisms 30 with different irradiating assemblies 60, and it should be understood that the embodiments of FIG. 72-74 may contain any of the components and features described herein in connection with FIGS. 71. As in other embodiments described herein, the irradiation device(s) 50 is(are) schematically depicted as being(s) within roller 42 in FIG. 71-74, but in many configurations, the irradiating device(s) is (are) outside of the roller 42, while the outlet(s) 54 is (are) inside the roller 42. In the embodiment of FIG. 72, the irradiation assembly 60 comprises a single irradiation device 50 having two outlets 54 or sets 55 of outlets 54 directed to two irradiation sites 51, 150. For example, irradiation assembly 60 may comprise a single irradiation device 50 in the form of a set of LEDs 59 or a DLP projector, with optical fibers 61 arranged and directed to form two sets 55 of outlets 54 within roller 42. In the embodiment of FIG. 73, the irradiation assembly 60 comprises a single irradiation device 50 with a single outlet 54 or a single set 55 of outlets 54 where the outlets 54 can be moved to direct the waves 53 to the desired irradiation site 51, 150. For example, outlets 54 (eg, exit ends 63 of optical fibers 61 or LEDs 59) may be mounted on a gimbal or other rotatable structure and may use variable gating to achieve this functionality. In the embodiment of FIG. 74, the irradiation assembly 60 comprises a single irradiation device 50 with a single outlet 54 or a single set 55 of outlets 54 and includes a focusing mechanism 66 configured to direct the waves 53 to any of the irradiation locations 51, 150, as needed. For example, the focusing mechanism 66 may include one or more movable mirrors configured to reflect and/or direct the waves 53 to the desired irradiation site 51, 150, which can be moved by being mounted on a gimbal or other pivoting structure, and which can use variable gating. to achieve this functionality. It should be understood that other configurations of irradiating nodes 60 may be used in conjunction with the embodiments of FIG. 71-74, including any configuration described herein in connection with another embodiment.

[00204] The layering mechanism 30 in FIG. 71 causes the layer 38 to at least partially or completely solidify at the original irradiation site 150, below the surface of the fluid material 36, to the desired thickness. The roller 42 then carries the layer 38 upwards to the application site 41, and after that the layer is applied to the object 11/associated with it and (if necessary) further hardened in the auxiliary irradiation site 51. It should be understood that plant 12 may further comprise one or more additional auxiliary irradiation devices 80, as in FIG. 7 to further harden layer 38. In one embodiment, layering mechanism 30 can be configured to promote proper adhesion of layer 38 at the proper time. For example, auxiliary roll 151 may have an outer surface that is less adhesive to the material forming layer 38 than outer surface 43 of roller 42 to facilitate adhesive bonding of layer 38 to transfer roller 42 to application site 41 instead of adhesive bonding with auxiliary roll 151. Similarly, the outer surface 43 of roll 42 may have less adhesive property with respect to the material forming layer 38 than the surface of object 11 to facilitate adhesive bonding of layer 38 to object 11 and/or build-up platform 22 instead of adhesively bonding to the roll. 42. Installation 12 in FIG. 71 also includes a removal device 155 for removing excess uncured fluid material 36, which is in the form of the pneumatic wiping device of FIG. 71, but may additionally or alternatively include a squeegee or other mechanical removal device in other embodiments. The removal device 155 is configured to remove most, but not all, of the fluid material 36 from the layer 38, leaving a small amount of uncured material 36 on the layer 38 to adhesively bond the layer 38 to the object 11. The characteristics of the removal device 155, such as the angle and power of the pneumatic wipe devices can be adjusted to ensure proper removal of fluid material 36 without damaging or separating layer 38 from the surface(s) to which it is adhesively bonded. The removal device 155 may further be configured to direct the removed material 36 back to the source 34 to reduce waste. It should be understood that additional removal devices 155 may be used, including at specific locations, to remove fluid material 36 after layer 38 has been adhesively bonded to object 11.

[00205] Installation 12 in the embodiment of FIG. 71 contains sensors for confirming the correct operation of the layering mechanism 30, such as build-up check sensors 153 and transfer check sensors 154. The build-up check sensor 153 is positioned to scan the surface of the roll 42 between the original irradiation site 150 and the secondary irradiation site 51 to confirm that the layer 38 is formed and is adhesively bonded to the roll 42. The transfer check sensor 154 is positioned to scan the surface of the roll 42 after passing through ancillary irradiation site 51 to confirm that layer 38 is separated from roll 42 and is adhesively bonded to object 11. Both build-up and transfer test sensors 153, 154 may be a set of photosensors or other sensor(s) capable of ( able) to detect the presence of layer 38. If any of the sensors 153, 154 detects that the appropriate actions have not been performed properly, for example, the build-up check sensor 153 does not detect the layer 38, or the transfer check sensor 154 does not detect the presence of the layer 38, the creation can be stopped to solve the problem and prevent Avoid a manufacturing defect that may be discovered much later. The use of check sensors 153, 154 helps to ensure that the object 11 is created reliably and accurately.

[00206] FIG. 71B illustrates another embodiment of a layering mechanism 30 comprising a removal device 155 that includes one or more cleaning rollers 173 configured to contact the surface of layer 38 against roller 42 and scrape excess fluid material 36 from layer 38. FIG. 71B, the removal device 155 includes two cleaning rolls 173 located on opposite sides of the application site 41 and the irradiation site 51, whereby one of the cleaning rolls 173 (right roll 173 in FIG. 71B) contacts the bed 38 to scrape excess fluid material when the layering mechanism 30 moves in one direction (to the right in FIG. 71B), and the other cleaning roller 173 (left roller 173 in FIG. 71B) performs the same action when the layering mechanism 30 moves in the opposite direction (to the left in FIG. 71B). The cleaning rolls 173 may be energized to rotate, whereby the surface of the cleaning roll 173 in contact with the layer 38 moves in the opposite direction relative to the layer 38 and the adjacent surface of the roll 42. The removal device 155 may further comprise wiping devices 174 configured to scrape the fluid material. from the surface of the cleaning rolls 173, as also shown in FIG. 71b. Additional wipers 174 may be included to clean other components of the layering mechanism 30, including the auxiliary roller 151, as shown in FIG. 71B, or roll 42. Wipers 174 may also be shown in FIG. 71C-D, and it should be understood that wipers 174, such as those shown in FIGS. 71B-D and described herein may be used in combination with any of the rolls in any of the embodiments described herein, including roll 42, auxiliary roll 151, cleaning rolls 173, leveling rolls 128, etc. In one embodiment, the cleaning rolls 173 may also function as sensors, such as an extension check sensor 153 or a transfer check sensor 154. For example, in one embodiment, the cleaning roller 173 that does not contact layer 38 (i.e., left roller 173 in FIG. 71B) is positioned and configured to contact roller 42 and rotate freely with roller 42, and acts as a transfer check sensor. Any parts of layer 38 that are not detached from roller 42 and not transferred to object 11 will cause cleaning roller 173 to push off roller 42 slightly, and cleaning roller 173 is equipped with a position sensor to detect this movement, allowing it to function as a transfer check sensor. It should be understood that when the layering mechanism 30 is moved in the opposite direction, the other cleaning roller 173 may function as a transfer check sensor. In another embodiment, the cleaning roll 173 that contacts the layer 38 may use a position sensor to function as a build-up check sensor in a similar manner. Cleaning roll(s) 173 in FIG. 71B-D may be used in conjunction with other embodiments shown and described herein, including the embodiments of FIG. 72-75, and the positions of the cleaning roll(s) 173 in such embodiments may be changed as necessary and appropriate.

[00207] FIG. 75 illustrates another embodiment of the installation 12 and the layering mechanism 30 configured to build up the object 11 on the buildup platform 22 below the applicator 40 . The embodiment of FIG. 75 contains many of the same components as the embodiments of FIG. 71-74 including an auxiliary roll 151, an optional additional auxiliary roll(s) 152, inspection sensors 153, 154, and a removal device 155. These components perform the same functions as in FIG. 71-74, although some components have a different location in FIG. 75, and these components may not be described in detail with respect to FIG. 75. It should be noted that in the embodiment of FIG. 75 illustrates the use of two irradiation devices 50, each containing an outlet 54 or a set 55 of outlets 54, and that any configuration of the irradiation assembly 60 described herein may be used in conjunction with the embodiment of FIG. 75, including any of the configurations in FIG. 72-74. In the embodiment of FIG. 75, a source 34 of fluid material 36 holds fluid material 36 above application site 41 and is in communication with only one side of roll 42. Auxiliary roll 151 is adjacent to roll 42 and is immersed in fluid material 36 to form an initial irradiation site 150 between roll 42 and the auxiliary roll 151. As described above, the spacing between rolls 42, 151 determines the thickness of layer 38. Roll 42 then carries layer 38 over the roll and down to application site 41 and auxiliary irradiation site 51 for bonding to object 11 and/or build-up platform 22. The layering mechanism in FIG. 75 further comprises an airtight seal 163, such as a flexible lip or O-ring, which prevents fluid material 36 from leaking down from the supply pool 34 at the junction between the supply pool 34 and roll 42. In the event of any leakage, a tray 164 is provided under the airtight seal 163 to collect any fluid material 36 that has leaked through seal 163. Sump 164 may be configured to return fluid material 36 to supply pool 34, for example by using a pumping mechanism or by retrieval to pour fluid material 36 back into supply pool 34. It should be noted that the removal mechanism 155 in FIG. 75 is a pneumatic wiping device configured to blow excess material 36 back to source 34.

[00208] The embodiments of FIG. 71-75 using a post-solidification step provide advantages over existing additive manufacturing methods. For example, building up layer 38 prior to bonding to object 11 provides improved control over shrinkage during curing. As another example, the post-cure step prevents the buildup of heat that may be involved in the curing process using fewer steps and creates a layer 38 with a greater degree of cure/hardening. As another example, at least the embodiments of FIG. 75 allow the creation of the article 11 from the bottom up, with the article 11 supported by the build-up platform 22, which can provide advantages for the creation of many articles 11. The embodiments of FIG. 71-75 are also able to construct object 11 using the minimum desired amount of fluid material 36 embedded in object 11, since excess fluid material 36 can be removed from layer 38 before bonding to object 11. This minimizes the use of fluid material and increases the economics of the process. In one embodiment, up to 98% of excess resin is removed, allowing the part to be cleaned with detergent rather than harsh chemicals. It also allows an object to be formed with internal cavities, without unsolidified fluid material 36 trapped in voids within the object. The ability to create such porous objects allows the construction of objects with reduced weight and reduced material consumption, increasing the versatility of the process and reducing the cost of creation. Such porous objects can also provide enhanced buoyancy, heat and sound insulation properties, among other improved properties. In FIG. 82-93 illustrate the various construction techniques available due to the embodiments of FIG. 71-75, including techniques for creating objects 11 with internal porosity. The embodiments of FIG. 71-75 can also be used to build up a part with an internal configuration in the form of honeycombs, i.e. hexagonal cells (not shown). It should be understood that internally porous objects 11 may include an outer "shell" layer of hard (non-porous) material to form a smoother and more rigid outer surface and to resist the ingress of moisture and other contaminants.

[00209] FIG. 82-85 illustrate a first creation technique where the object 11 is created by means of layers 38 consisting of obliquely oriented strips 156, 157. In FIG. 82-83 illustrate the creation of a first layer 38 containing strips 156 of solidified material, continuing in the axial direction on the roll 42, ie in the y direction. In FIG. 84-85 illustrate the creation of a second layer 38 adhesively bonded to a first layer 38 containing strips 157 of cured material extending circumferentially on roller 42, i.e., in the x direction. Each successive layer is created in an alternating manner. The resulting object 11 has internal porosity as shown in FIG. 82-85, with internal air pockets or voids 147 partially or completely surrounded by the cured product material 11.

[00210] FIG. 86-89 illustrate a second creation technique where the object 11 is created by layers 38 consisting of cubes 158 of solidified material arranged in an offset or zigzag pattern. In FIG. 86-87 illustrate the creation of a layer 38 of such cubes 158 that are offset in the x-direction, y-direction and z-direction relative to the previous applied layer forming the surface of the object 11 to which the layer 38 currently being created is associated. Each successive layer 38 is created with the same offset, forming a repeating porous internal structure of the object 11 with internal air pockets or voids 147 partially or completely surrounded by the cured material of the product 11. The size of the cubes 158 is chosen so that they can communicate with each other at their corners 159 as shown in FIG. 88-89, where the structure of object 11 is shown at high magnification. It should be understood that the height position (in the z direction) of roll 42 must be adjusted to achieve such bonding.

[00211] FIG. 90-91 illustrates a third creation technique where the object 11 is created by layers 38 consisting of strips 157 of cured material arranged in an offset or zigzag pattern. Stripes 157 in FIG. 90-91 continue circumferentially on roller 42, i.e., in the x direction, but the process can be modified to use strips that continue axially on roller 42, i.e., in the y direction, instead. In FIG. 90-91, the stripes 157 of the layer 38 currently being applied are parallel to, and offset from, the stripes 157 forming the surface of the object 11 to which the layer 38 currently being created is associated, in the y direction and in the z direction. Each successive layer 38 is created with the same offset, forming a repeating porous internal structure of the object 11 with internal air pockets or voids 147 partially or completely surrounded by the cured material of the article 11. The strips 157 are connected at the corners 159 to adjacent strips to create such a structure. It should be understood that the height position (in the z direction) of roll 42 must be adjusted to achieve such bonding. It should also be understood that if stripes are used in the process that continue in the y direction rather than in the x direction, the stripes will be offset in the x direction in adjacent layers 38.

[00212] FIG. 92-93 illustrate a fourth creation technique where the object 11 is created by layers 38 consisting of strips 157 of cured material arranged in an offset or zigzag pattern. Stripes 157 in FIG. 92-93 continue circumferentially on roll 42, i.e., in the x direction, but the process can be modified to use strips that continue axially on roll 42, i.e., in the y direction, instead. In FIG. 92-93, the stripes 157 of the layer 38 currently being applied are parallel to and offset from the stripes 157 forming the surface of the object 11 to which the layer 38 currently being created is associated, and also offset from them in the y direction. Layers 38 are applied in pairs, with first layer 38 being applied to object 11 and then applying a second layer 38 with stripes 157 at a z position that is offset by about half the thickness of first layer 38 from first layer 38 but offset in the y direction to fill gaps between strips 157 and form a solid object. In FIG. 92-93 illustrate the creation of a second such layer 38, and it will be understood that the first layer 38 will be applied to the flat surface of object 11. It will be understood that the height (z-direction) position of roll 42 must be adjusted to achieve such bonding. It should also be appreciated that if stripes are used in the process that continue in the y direction rather than the x direction, the stripes will be offset in the x direction in adjacent layers 38. This fabrication technique can provide advantages for creating large parts with little internal porosity, from - for the problems that arise when applying large continuous sheets of material. Such problems include the potential increase in speed, accumulation of uncured material at the application site 41 (eg, "grooving"), and deformation of the layer 38 caused by stresses. The extension configuration in FIG. 92-93 can also potentially form an object with greater strength and/or stiffness due to displacement of binding locations.

[00213] FIG. 76-81 illustrate a self-contained block 90 and build-up platform 22 configured to use a layering mechanism 30 as shown in FIG. 75. The components of stand-alone unit 90 are identical to those of unit 90 described herein and shown in FIG. 31-47, and similar or identical components are not described again with respect to this embodiment for the sake of brevity. As seen in FIG. 80-81, the self-contained unit 90 is configured to hold the layering mechanism 30, in which the application site 41 is at the bottom of the layering mechanism 30. Thus, the block 90 includes two legs 160 defining a space 161 between the legs 160, and the applicator 40 is configured to apply a layer 38 to build up the object 11 in the space 161 between the legs 160 and under the applicator 40. In FIG. 76-79 illustrate the use of a self-contained build block 90 for object 11 on build platform 22, and build platform 22 passes through gap 161 during manufacture as shown in FIG. 78-79. The height (position in the z direction) of the layering mechanism 30 can be adjusted by the vertical adjustment mechanism 120 of the block 90, and the height of the extension platform 22 can also be adjusted by the vertical adjustment mechanism 162 of the extension platform 22. The combination of these adjustment mechanisms 120, 162 provides a wide range of relative movement between the layering mechanism 30 and build-up platform 22 to create objects 11 having large heights.

[00214] System 10 also includes a controller 100 configured to control and/or monitor the operation of one or more mechanisms of plant 12, including numerous examples described herein. In one embodiment of the present invention, controller 100 may be implemented by a computer system, such as computer 2602. Computer 2602 includes a CPU 2604 that controls the overall operation of the computer and a system bus 2606 that connects CPU 210 to the components described below. System bus 2606 may be implemented with any of a variety of conventional bus architectures.

[00215] The computer 2602 may include various interface units and drives for reading or writing data or files. For example, computer 2602 may include a memory interface 2608 connecting storage device 2610 to system bus 2606. Storage device 2610 may be implemented by physical storage, magnetic storage, optical storage, or another type of storage device. The data store 2610 may store data, CAD files, and other electronic files used to create three-dimensional objects, as described herein. It may also include system memory 2612 implemented by a conventional computer-readable storage medium having a read-only memory section that stores a basic input/output system (BIOS) and random access memory (RAM) that stores other data and files. Both data storage 2610 and system memory 2612 may contain computer-executable instructions for execution by processor 2604. ) in each installation 12 may be stored in the data drive 2610 and/or system memory 2612.

[00216] Computer 2602 may include additional interfaces for connecting peripheral devices to system bus 2606. For example, computer 2602 may also include a network interface 2614 connecting system bus 2602 to a local area network (LAN) 2616. LAN 2616 may have one or more well-known LAN topologies and can use a variety of protocols such as Ethernet. Computer 2602 may also have access to a wide area network (WAN) 2618, such as the Internet. In FIG. 26 shows a router 2620 that can traditionally connect a LAN 2616 and a WAN 2618. A server 2622 is shown connected to the WAN 204. Of course, numerous additional servers, computers, portable devices, PDAs, phones, and other devices can also be attached to the WAN. 2618. In some embodiments, server 2622 stores data, CAD files, control programs, and/or other electronic files that can be accessed by computer 2602 and used to create three-dimensional objects as described herein.

[00217] Various embodiments are described herein with various combinations of features and components. It should be understood that features and components of each of the various embodiments described herein may be incorporated into other embodiments described herein.

[00218] The use of the system and setup described herein provides benefits and advantages over existing technology. For example, consumables costs are greatly reduced because the plant generates little waste and does not require the constant availability of a large bath of material to be solidified for manufacture, as required by many current technologies. Additionally, the installation design does not prescribe specific size restrictions, and the installation can be configured to form an object that is significantly larger than in existing technologies. The length of the rail and the width of the applicator can be increased as needed without adversely affecting performance, and the size of the room in which the unit is located becomes the size limit of the unit. In addition, the plant can be configured to produce an object or multiple objects many times faster than any existing technology. The apparatus also provides the ability to manufacture objects from multiple materials, including objects that have a removable support structure made from a material different from that of the main object. It also provides the ability to create objects from several materials that require different sources of radiation. The setup also allows the production of functional objects such as a window or other transparent object, or a conductive object. In addition, objects made using the apparatus described herein may not require liquid material to be drained from any internal cavities in the finished object, which may require drilling a drain hole. The unit can also create clean, dry and fully cured objects, which increases the efficiency of creation. Modular plant configuration also has good versatility, customization and other advantages.

[00219] Additional benefits are provided by configuring the layering mechanism 30 as a self-contained block 90 with a vertical adjustment mechanism 120 in combination with an open-ended guide 14 with which the block 90 and build-up platform 22 can engage and disengage with the guide. 14 and configured to manufacture the object 11 in a top-down layer-by-layer technique. This configuration allows multiple layering mechanisms 30 to operate on the same rail 14 to apply multiple layers to one or more objects 11 at the same time. Multiple layering mechanisms 30 operating on the same rail 14 can be combined to build one or more objects 11, or they can build multiple objects 11 separately and simultaneously on the same build platform 22. This configuration also allows for the rapid growth of multiple objects of the same or different materials at separate locations on the same build platform 22 . This configuration also facilitates maintenance of the layering mechanism 30 because the self-contained block 90 can be quickly and easily removed from the building process for maintenance, and can also be quickly and easily replaced with another block 90 to achieve substantially continuous building. A system containing several of these units 90 can operate with several different build platforms 22, for example as part of a large manufacturing facility where units 90 can be assigned and reassigned to specific build areas 13 as required by optimized production. Other benefits and advantages over existing technology are provided by the systems, facilities, and methods described herein, and such benefits and advantages will be apparent to those skilled in the art.

[00220] Several alternative embodiments and examples have been described and illustrated herein. The person skilled in the art will recognize the features of the individual embodiments and possible combinations and variations of the components. It will also be apparent to a person skilled in the art that any of the embodiments may be provided in any combination with the other embodiments disclosed herein. It should be understood that the present invention may be embodied in other specific forms without departing from its spirit and essential characteristics. Therefore, the present examples and embodiments are to be regarded in all respects as illustrative, but not limiting, and the present invention should not be limited to the details provided herein. The terms "first", "second", "upper", "lower", etc. used in this document are for illustrative purposes only and do not limit the embodiments in any way. In particular, these terms do not imply any indication of the order or position of the components associated with these terms. Additionally, the term "multiple" as used herein refers to any number that is greater than one, in a divisive or unifying sense as appropriate, up to infinity. In addition, "providing" a product or installation in the context of this document refers generally to making the product available or accessible for further actions performed on the object, and does not imply that the party providing the product has manufactured, created or supplied the product, or that the party providing the product owns or operates the product. Accordingly, while specific embodiments have been illustrated and described, numerous modifications can be devised without substantially deviating from the spirit of the present invention.

Claims (119)

1. A device for creating a three-dimensional object on a build-up platform using resin using a layer-by-layer technique, the build-up area being defined adjacent to the build-up platform, comprising: a carriage configured to move along the build-up area; a resin source in fluid form mounted on the carriage; a roll in communication with the resin source and rotatably mounted on a carriage; and an irradiating device mounted on the carriage and configured to emit electromagnetic waves, wherein the irradiating device is configured to radiate electromagnetic waves in the direction of the first irradiation site located adjacent to the roll within the resin source, to ensure at least partial solidification of the resin layer, wherein the roll is rotatable to transfer the resin layer to the application site within the build-up area to apply to create a three-dimensional object as the carriage passes through the build-up area, and wherein the irradiating device is further configured to radiate electromagnetic waves towards the second irradiation site within the build-up area to deposit a layer to create a three-dimensional object. 2. The apparatus of claim. 1, which further comprises a controller configured to control the movement of the carriage and roller and to control the activation of the irradiating device to create a three-dimensional object. 3. The device according to claim. 1, which further comprises a first set of optical fibers containing the first output ends arranged in the form of a first set, and the first input ends configured to receive electromagnetic waves from the irradiating device, and the second set of optical fibers containing the second output ends configured as a second set, and second input ends configured to receive electromagnetic waves from the irradiating device, wherein the first plurality of optical fibers are configured such that electromagnetic waves emitted by the irradiating device move through the first plurality of optical fibers and exit from the output ends of the first set directed to the first irradiation site, and the second set of optical fibers are made in such a way that electromagnetic waves emitted by the irradiating device move through the second set of optical fibers and exit from the output ends of the second set directed to the second is the site of exposure. 4. The apparatus of claim 3, wherein the illuminating device comprises a plurality of LEDs, each of the first plurality of optical fibers and each of the second plurality of optical fibers associated with one of the plurality of LEDs. 5. The apparatus of claim 3, wherein the irradiating device comprises a DLP projector, wherein each of the first plurality of optical fibers and each of the second plurality of optical fibers are configured to receive electromagnetic waves from the DLP projector. 6. The device according to claim 1, wherein the roll is made permeable to electromagnetic waves, while the irradiating device is configured to allow electromagnetic waves to pass through the roll while moving towards the first irradiation site and the second irradiation site. 7. The apparatus of claim. 1, which further comprises a resin removal mechanism located between the first irradiation site and the second irradiation site and configured to remove excess uncured resin from the layer between the first and second irradiation sites. 8. The device according to claim 1, which further comprises a first set of lenses located between the irradiating device and the first irradiation site, and a second set of lenses located between the irradiating device and the second irradiation site, wherein the first and second lens sets are configured to focus electromagnetic waves directed to the first irradiation site and the second irradiation site. 9. The device according to claim 1, which further comprises a thickness limiter located at the first irradiation site, whereby the first irradiation site is located between the roller and the thickness limiter, while the space between the roller and the thickness limiter determines the layer thickness. 10. The apparatus of claim 9, wherein the thickness gauge comprises an auxiliary roll pivotally mounted at least partially within the resin source. 11. The device according to claim. 1, in which the carriage is configured to be mounted on a guide to move around the area of building. 12. The device according to claim. 11, in which the carriage is additionally made with the possibility of autonomous movement separately from the guide. 13. The apparatus of claim. 1, wherein the first irradiation site and the second irradiation site are at an angular distance of approximately 180° from each other relative to the roll. 14. The apparatus of claim 1, wherein the build-up area is located under the build-up platform, wherein the roll is configured to pass under the build-up platform to grow the object under the build-up platform. 15. The device of claim. 1, in which the area of growth is above the platform for building, while the roll is configured to pass over the platform for building to build the object above the platform for building. 16. Installation for creating a three-dimensional object on the platform for building using resin by layering technique, containing the device according to p. 17. A device for creating a three-dimensional object on a platform for building using resin according to a layer-by-layer technique, and the region of building is defined adjacent to the platform for building, containing: a carriage configured to move along the build-up area; a resin source in fluid form mounted on the carriage; a main roll in communication with the resin source and rotatably mounted on the carriage; an auxiliary roll rotatably mounted at least partially within the resin source, whereby a space is formed between the main roll and the auxiliary roll; and an irradiating device mounted on the carriage and configured to emit electromagnetic waves, wherein the irradiating device is configured to radiate electromagnetic waves towards the first irradiation site located within the resin source and within the space between the main and auxiliary rolls, to ensure at least partial solidification of the resin layer, as a result of which the space between the main and auxiliary rolls determines layer thickness, wherein the main roller is rotatable to transfer the resin layer to the application site within the build-up area to apply to create a three-dimensional object as the carriage passes through the build-up area, and wherein the irradiating device is further configured to radiate electromagnetic waves towards the second irradiation site within the build-up area in order to deposit a layer to create a three-dimensional object. 18. The apparatus of claim. 17, which further comprises a controller configured to control the movement of the carriage and the main and auxiliary rolls and to control the activation of the irradiating device to create a three-dimensional object. 19. The device according to claim 17, which further comprises a first set of optical fibers containing the first output ends arranged in the form of a first set, and the first input ends configured to receive electromagnetic waves from the irradiating device, and a second set of optical fibers containing the second output ends configured as a second set, and second input ends configured to receive electromagnetic waves from the irradiating device, wherein the first plurality of optical fibers are configured such that electromagnetic waves emitted by the irradiating device move through the first plurality of optical fibers and exit from the output ends of the first set directed to the first irradiation site, and the second set of optical fibers are made in such a way that electromagnetic waves emitted by the irradiating device move through the second set of optical fibers and exit from the output ends of the second set directed to the second local irradiation site. 20. The apparatus of claim 19, wherein the illuminating device comprises a plurality of LEDs, each of the first plurality of optical fibers and each of the second plurality of optical fibers associated with one of the plurality of LEDs. 21. The apparatus of claim 19, wherein the irradiating device comprises a DLP projector, wherein each of the first plurality of optical fibers and each of the second plurality of optical fibers are configured to receive electromagnetic waves from the DLP projector. 22. The apparatus of claim. 19, wherein the exit ends of the first set and the exit ends of the second set are located within the main roll. 23. The apparatus of claim 17, wherein the main roll is electromagnetically permeable and the irradiation device is configured such that the electromagnetic waves pass through the main roll while moving towards the first irradiation site and the second irradiation site. 24. The apparatus of claim 17 further comprising a resin removal mechanism positioned between the first irradiation site and the second irradiation site and configured to remove excess uncured resin from the layer between the first and second irradiation sites. 25. The apparatus of claim 24, wherein the resin removal mechanism comprises a cleaning roll positioned between the first irradiation site and the second irradiation site and rotatable while in contact with the surface of the layer to remove excess uncured resin from the layer between the first and second irradiation sites. 26. The apparatus of claim 24, wherein the resin removal mechanism comprises first and second cleaning rolls located between the first irradiation site and the second irradiation site on opposite sides of the second irradiation site, wherein the first and second cleaning rolls are configured such that the first the cleaning roller is rotatable while in contact with the layer surface to remove excess uncured resin from the layer between the first and second irradiation sites when the device is moved in the first direction, and the second cleaning roller is rotatable while in contact with the layer surface , to remove excess uncured resin from the layer between the first and second irradiation sites when the device is moved in a second direction opposite to the first direction. 27. The apparatus of claim 26, wherein the first and second cleaning rollers are configured such that the first cleaning roller is configured to contact the main roller to function as a first transfer check sensor when the device is moved in the second direction, and the second cleaning roller is configured capable of contacting the main roll to function as a second transfer check sensor when the device is moved in the first direction. 28. The device according to claim 17, which further comprises a first set of lenses located between the irradiating device and the first irradiation site, and a second set of lenses located between the irradiating device and the second irradiation site, wherein the first and second lens sets are configured to focus electromagnetic waves directed to the first irradiation site and the second irradiation site. 29. The device according to claim 17, in which the carriage is configured to be mounted on a guide to move along the build-up area. 30. The device according to claim 29, in which the carriage is additionally made with the possibility of autonomous movement separately from the guide. 31. The apparatus of claim 17, wherein the build-up area is located under the build-up platform and the main roll is operable to pass under the build-up platform to grow the object under the build-up platform. 32. The apparatus of claim 17, wherein the build-up area is above the build-up platform and the main roll is configured to pass over the build-up platform to build the object over the build-up platform. 33. Installation for layer-by-layer building of a three-dimensional object using resin, containing the device according to p. 17 and the support node containing the platform for building, and the region of growth is defined adjacent to the platform for building. 34. A method for layer-by-layer building up of a three-dimensional object using resin, which includes: providing a plant containing: a support assembly with an extension platform, wherein the extension area is defined adjacent to the extension platform; and layering mechanism configured to create a three-dimensional object on a platform for building using resin in a layer-by-layer technique, and the layering mechanism includes a carriage configured to move along the building area, a resin source in fluid form mounted on the carriage, a roller in communication with a resin source and rotatably mounted on the carriage, and an irradiating device mounted on the carriage and configured to emit electromagnetic waves; moving the carriage along the extension area; selectively activating the irradiation device to radiate electromagnetic waves towards a first irradiation site adjacent to the roller within the resin source to at least partially solidify the resin layer; turning the roller to transfer the resin layer to the application site within the build-up area to apply to create a three-dimensional object as the carriage passes through the build-up area; and selectively activating the irradiation device to radiate electromagnetic waves towards the second irradiation site within the buildup area to deposit a layer to create a three-dimensional object. 35. The method of claim. 34, which further includes controlling the movement of the carriage and roller and controlling the activation of the irradiation device to create a three-dimensional object using the controller. 36. The method of claim 35, wherein the carriage is mounted on the guide and moved along the guide over the build-up area, the carriage is movable separately from the guide, and the method further includes controlling movement of the layering mechanism separately from the guide using controller. 37. The method of claim 35, which further includes controlling, using a controller, at least one additional layering mechanism that is movable independently of the layering mechanism to create a three-dimensional object. 38. The method of claim 34, wherein the layering mechanism further comprises a first plurality of optical fibers comprising first output ends arranged as a first set and first input ends configured to receive electromagnetic waves from an irradiating device, and a second plurality of optical fibers , containing the second output ends, arranged in the form of a second set, and the second input ends, configured to receive electromagnetic waves from the irradiating device, while the first set of optical fibers is made in such a way that electromagnetic waves emitted by the irradiating device move through the first set of optical fibers and exit from the output ends of the first set directed to the first irradiation site, and the second set of optical fibers is made in such a way that electromagnetic waves emitted by the irradiating device move through the second set of optical fibers and exit from the output ends of the second set, directed to the second place of irradiation. 39. The method of claim 34, wherein the layering mechanism further comprises a resin removal mechanism positioned between the first irradiation site and the second irradiation site and configured to remove excess uncured resin from the layer between the first and second irradiation sites. 40. The method of claim 34, wherein the layering mechanism further comprises a first set of lenses located between the irradiating device and the first irradiation site, and a second set of lenses located between the irradiating device and the second irradiation site, wherein the first and second lens sets are made with the possibility of focusing electromagnetic waves directed to the first place of exposure and the second place of exposure. 41. The method of claim 34, wherein the layering mechanism further comprises a thickness stop located at the first irradiation site, whereby the first irradiation site is between the roll and the thickness stop, and wherein the space between the roll and the thickness stop defines the layer thickness. 42. The method of claim. 41, characterized in that the thickness limiter includes an auxiliary roll mounted for rotation at least partially within the resin source. 43. A method for layer-by-layer building up of a three-dimensional object using resin, which includes: providing a plant containing: a reference node containing the platform for extension, and the region of extension is defined adjacent to the platform for extension; and a layering mechanism configured to create a three-dimensional object on a platform for building up using resin in a layer-by-layer technique, the layering mechanism comprising a carriage configured to move along the building area, a resin source in fluid form mounted on the carriage, a main roll in communication with a resin source and rotatably mounted on the carriage, an auxiliary roll rotatably mounted at least partially within the resin source, as a result of which a space is formed between the main roll and the auxiliary roll, and an irradiating device mounted on the carriage and configured to irradiate electromagnetic waves; moving the carriage along the extension area; selectively activating the irradiation device to radiate electromagnetic waves in the direction of the first irradiation site located within the resin source and within the space between the main and auxiliary rolls, to ensure at least partial solidification of the resin layer, whereby the space between the main and auxiliary rolls determines the thickness of the layer ; turning the main roller to transfer the resin layer to the application site within the build-up area to apply to create a three-dimensional object as the carriage passes through the build-up area; and selectively activating the irradiation device to radiate electromagnetic waves towards the second irradiation site within the buildup area to deposit a layer to create a three-dimensional object. 44. The method of claim. 43, which further includes controlling the movement of the carriage, the main roller and the auxiliary roller and controlling the activation of the irradiation device to create a three-dimensional object using the controller. 45. The method of claim 44, wherein the carriage is mounted on the guide and moves along the guide over the buildup area and the carriage is movable separately from the guide, and the method further includes controlling movement of the layering mechanism away from the guide using a controller. 46. The method of claim 44, which further includes controlling, using a controller, at least one additional layering mechanism, which can move independently of the layering mechanism, to create a three-dimensional object. 47. The method of claim 43, wherein the layering mechanism further comprises a first plurality of optical fibers comprising first output ends arranged as a first set and first input ends configured to receive electromagnetic waves from an irradiating device, and a second plurality of optical fibers , containing the second output ends, arranged in the form of a second set, and the second input ends, configured to receive electromagnetic waves from the irradiating device, while the first set of optical fibers is made in such a way that electromagnetic waves emitted by the irradiating device move through the first set of optical fibers and exit from the output ends of the first set directed to the first irradiation site, and the second set of optical fibers is made in such a way that electromagnetic waves emitted by the irradiating device move through the second set of optical fibers and exit from the output ends of the second set, directed to the second place of irradiation. 48. The method of claim 43, wherein the layering mechanism further comprises a resin removal mechanism positioned between the first irradiation site and the second irradiation site and configured to remove excess uncured resin from the layer between the first and second irradiation sites. 49. The method according to claim 43, wherein the layering mechanism further comprises a first set of lenses located between the irradiating device and the first irradiation site, and a second set of lenses located between the irradiating device and the second irradiation site, wherein the first and second lens sets are made with the possibility of focusing electromagnetic waves directed to the first place of exposure and the second place of exposure. 50. The method according to claim 43, which further provides the first and second cleaning rolls located between the first irradiation site and the second irradiation site on opposite sides of the second irradiation site, while the first and second cleaning rolls are made in such a way that the first cleaning roll is made rotatable while in contact with the layer surface to remove excess uncured resin from the layer between the first and second irradiation sites when the layering mechanism is moved in the first direction and the second cleaning roller is rotatable while in contact with the layer surface, to removing excess uncured resin from the layer between the first and second irradiation sites when the layering mechanism is moved in a second direction opposite to the first direction. 51. The method of claim 50, wherein the first and second cleaning rollers are configured such that the first cleaning roller is configured to contact the main roller to function as a first transfer check sensor when the layering mechanism is moved in the second direction, and the second cleaning roller configured to contact the main roll to function as a second transfer test sensor when the layering mechanism moves in the first direction. 52. A method for layer-by-layer building up a three-dimensional object using resin, which includes: providing a reference node containing the platform for extension, and the extension area is defined adjacent to the platform for extension; and creation of a three-dimensional object on the build platform by applying a plurality of successive layers of resin using one or more layering mechanisms, each of which contains a carriage configured to move around the build area, a resin source in fluid form mounted on the carriage, a roll in communication with a resin source and mounted for rotation on the carriage, and an irradiating device mounted on the carriage and configured to emit electromagnetic waves, wherein applying a plurality of successive layers of resin includes moving one or more layering mechanisms in successive passes along the build-up area, turning the roll for transferring layers to a deposition site within the buildup area for the purpose of deposition to create a three-dimensional object as one or more layering mechanisms pass through the buildup area and selectively activate an irradiating device to emit elec- tric magnetic waves in the direction of the irradiation site within the build-up area in order to apply each successive layer to create a three-dimensional object, wherein the first layer of the plurality of successive layers is made containing a plurality of first parts having spaces formed between at least some of the first parts, and wherein the second layer of a plurality of successive layers is applied to the first layer, and the second layer is made containing a plurality of second parts that are offset relative to the first parts or oriented across the first parts. 53. The method according to claim 52, in which the first parts of the first layer are made containing a plurality of first elongated strips oriented along the first direction, and the second parts of the second layer are made containing a plurality of second elongated strips oriented in the first direction and offset relative to the first elongated strips in the second direction perpendicular to the first direction. 54. The method of claim 53, wherein the first direction is parallel or perpendicular to the direction of movement of the carriage over the buildup area. 55. The method according to claim 52, in which the first parts of the first layer are made containing a plurality of first elongated strips oriented along the first direction, and the second parts of the second layer are made containing a plurality of second elongated strips oriented in a second direction perpendicular to the first direction. 56. The method of claim 55, wherein the first direction is parallel or perpendicular to the direction of movement of the carriage over the buildup area. 57. The method of claim 52, wherein the first portions of the first layer are configured to comprise a plurality of first blocks and the second portions of the second layer are configured to comprise a plurality of second blocks that are offset from the first blocks in at least one direction. 58. The method of claim 57, wherein the second blocks are offset from the first blocks in two perpendicular directions, whereby the first blocks and the second blocks are adhesively bonded to each other at the corners of the first and second blocks after the first and second layers have been applied. 59. The method of claim 52, wherein additional layers from a plurality of successive layers are arranged and oriented identically to the first and second layers in an alternating manner. 60. The method of claim 52, wherein the first layer and the second layer are applied through different layering mechanisms. 61. The method of claim 52, wherein the first layer and the second layer are applied by a single layering mechanism moving in a first direction to apply the first layer and moving in a second direction opposite the first direction to apply the second layer. 62. The method of claim 52, wherein each of the one or more layering mechanisms used further comprises an auxiliary roll rotatably mounted at least partially within the resin source such that a space is formed between the roll and the auxiliary roll, and each of a plurality of successive layers of resin is applied by selectively activating an irradiating device to emit electromagnetic waves in the direction of the initial irradiation site, located within the resin source and within the space between the roll and the auxiliary roll, to ensure that each layer is at least partially solidified, whereby the space between roller and auxiliary roller determines the thickness of the respective layer, before turning the roller to transfer the respective layer to the application site. 63. A source of resin in fluid form, containing: a supply tub configured to contain resin, the supply tub having first and second internal support walls located at opposite ends of the supply tub; the first outer support wall located outside the first inner support wall and located outside the supply bath, as a result of which a first space is formed between the first internal support wall and the first external support wall, while the first internal support wall contains the first opening extending through it between the tank supplies and first space; a roll located at least partially within the supply bath and configured to be in contact with the resin, while the roll extends through the first opening and is located at least partially within the first space; a first seal in contact with the roll along the entire periphery of the roll and located adjacent the first hole to prevent most of the leakage of resin through the first hole; and a drain system configured to remove parts of the resin that pass through the first hole from the first space. 64. The source according to claim 63, in which the drain system is additionally configured to return parts of the resin to the supply bath. 65. Source according to paragraph 63, additionally containing: a second outer support wall located outside the second inner support wall and located outside the supply tank, as a result of which a second space is formed between the second inner support wall and the second outer support wall, while the second inner support wall contains a second opening extending through it between the tank supply and the second space, while the roller continues through the second hole and is located at least partially within the second space; and a second seal in contact with the roll along the entire periphery of the roll and located adjacent to the second hole to prevent most of the leakage of resin through the second hole, wherein the drain system is further configured to remove additional portions of resin that pass through the second opening from the second space. 66. The source according to claim 63, in which the supply bath contains a bottom wall that extends between the first and second inner supporting walls and further extends between the first inner supporting wall and the first outer supporting wall through the first space, and the drain system contains a drain hole in the bottom wall within the first space. 67. The source according to claim 63, in which the drain system further comprises a drain hole within the first space and a reservoir in communication with the drain hole, and the drain system is designed in such a way that the removal of parts of the resin occurs by flowing through the drain hole and into the tank. 68. The source of claim 67, wherein the drain system further comprises a pumping mechanism configured to pump resin from the reservoir to the supply bath. 69. The source of claim. 68, in which the bottom wall of the supply pool contains an opening in communication with the pumping mechanism, whereby the pumping mechanism is configured to pump resin into the supply pool through the opening, and while the bottom wall of the supply pool is inclined down to the hole . 70. The source according to claim 63, further comprising a first bearing connected to the first outer support wall and an engagement roll for pivotally supporting the roll. 71. A device for creating a three-dimensional object on a build-up platform using resin using a layer-by-layer technique, the build-up area being defined adjacent to the build-up platform, comprising: a carriage configured to move along the build-up area; a supply tub mounted on a carriage and configured to contain fluid material, the supply tub having first and second internal support walls located at opposite ends of the supply tub; the first outer support wall located outside the first inner support wall and located outside the supply bath, as a result of which a first space is formed between the first internal support wall and the first external support wall, while the first internal support wall contains the first opening extending through it between the tank supplies and first space; a roll mounted on a carriage and located at least partially within the supply bath, and made with the possibility of contact with a fluid material, while the roll extends through the first hole and is located at least partially within the first space, and the roll is made with the ability to rotate to transfer the resin layer to the application site within the build-up area in order to apply to create a three-dimensional object as the carriage passes through the build-up area; a first seal in contact with the roll along the entire periphery of the roll and located adjacent the first opening to prevent most leakage of fluid material through the first opening; a drain system configured to remove parts of the fluid material that pass through the first opening from the first space; and an irradiating device mounted on the carriage and configured to radiate electromagnetic waves in the direction of the irradiation site within the build-up area in order to apply a layer to create a three-dimensional object.

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