Plate-based additive manufacturing apparatus and method

A method for producing a component layer-by-layer, comprising the steps of:

• depositing a radiant-energy-curable resin on a build plate oriented parallel to a plane extending in an x-direction and a y-direction from a material depositor by translating the material depositor over the build plate through actuation of a first actuator positioned on a first side of the build plate in the y-direction, wherein the build plate includes at least a portion which is transparent, and wherein the build plate is positioned vertically above one or more lateral surfaces that bound the build surface;
• leveling the resin;
• selectively curing the resin while the build plate is positioned in a build zone defined between a stage above the build plate and a radiant energy apparatus below the build plate, using an application of radiant energy, from the radiant energy apparatus, in a specific pattern to define a geometry of a cross-sectional layer of the component;
• moving the stage relatively apart from the build plate in a z-direction to separate the component from the build plate;
• translating a cleaning apparatus over the build plate through actuation of a second actuator positioned on a second side of the build plate in the y-direction to remove the resin that remains on the build plate, wherein the second side of the build plate is opposite the first side in the y-direction, and wherein each of the first and second actuators extends beyond each of first and second opposing peripheral walls of the build plate in the x-direction;
• and
• repeating the steps of depositing, defining, curing, moving, and cleaning for a plurality of layers until the component is complete.

A method for producing a component layer-by-layer, comprising the steps of:

• activating a pump to pump a radiant-energy-curable resin onto a build plate from a supply container, the build plate including a transparent portion positioned above one or more lateral surfaces of the build plate that bound the transparent portion;
• leveling the resin;
• selectively curing the resin while the build plate is positioned in a build zone defined between a stage above the build plate and a radiant energy apparatus below the build plate, using an application of radiant energy, from the radiant energy apparatus, in a specific pattern to define a geometry of a cross-sectional layer of the component;
• moving the build plate and the stage relatively apart to separate the component from the build plate;
• collecting excess resin in a trough positioned along at least first and second opposing lateral sides of the build plate by translating a cleaning apparatus within the build zone and over the trough, wherein the trough is defined between a lateral surface of the build plate and a peripheral wall of the build plate;
• and
• repeating the steps of depositing, defining, curing, moving, and cleaning for a plurality of layers until the component is complete.