Additive manufacturing method for functionally graded material

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

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