US 12,214,553 B2Granted

System for window separation in an additive manufacturing process

AssigneeStratasys, Inc.

InventorsChristopher Prucha, Joel Ong, John Paton

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Abstract

An additive manufacturing system including a base assembly and a tray assembly. The base assembly includes a build window, substantially transparent to electromagnetic radiation; a projection system configured to project electromagnetic radiation toward an upper surface of the build window; and a tray seat arranged around a perimeter of the build window. The tray assembly is configured to engage with the base assembly in an engaged configuration and includes: a tray structure defining a registration feature configured to engage the tray seat to locate an aperture proximal to the upper surface of the build window in the engaged configuration; and a separation membrane that is configured to laminate across the upper surface of the build window in response to an evacuation of gas from an interstitial region and configured to separate from the build window in response to injection of gas into the interstitial region.

Claims20

Dependent claims

An additive manufacturing system comprising:

a build window:
facing a projection system;
defining a lamination surface opposite the projection system;
and
configured to pass radiation, emitted by the projection system, through the lamination surface;
and
a tray assembly comprising:
a tray:
comprising a perimeter support edge inwardly offset from an outer edge of the tray and defining an aperture;
and
configured to locate over and engage the build window with the aperture arranged about the build window and with the perimeter support edge offset above the lamination surface;
and
a separation membrane:
extending across the aperture;
tensioned over and against the perimeter support edge;
operable in:
a laminated position, the separation membrane laminated against the lamination surface, below the perimeter support edge, in the laminated position, responsive to evacuation of fluid from an interstitial region between the separation membrane and the lamination surface, to form a build surface offset below the perimeter support edge, and the perimeter support edge offset above the lamination surface by a first height in the laminated position;
and
an expanded position, the separation membrane forming a convex geometry offset above the perimeter support edge and offset above the lamination surface, in the expanded position to promote separation of the separation membrane from a layer of a resin polymerized over the build surface via radiation emitted by the projection system, and the perimeter support edge offset above the lamination surface by the first height in the expanded position;
a fluid distribution port fluidly coupled to the interstitial region;
and
a fluid distribution channel circumscribing the build window and intersecting the fluid distribution port.

19 more elements

A tray assembly configured to interface with a build window arranged in an additive manufacturing system, facing a projection system, and defining a lamination surface opposite the projection system, the tray assembly comprising:

a tray:
comprising a perimeter support edge defining an aperture inwardly offset from an outer edge of the tray and;
and
configured to locate over and engage the build window with the aperture arranged about the build window and with the perimeter support edge offset above the lamination surface of the build window;
and
a separation membrane:
extending across the aperture;
tensioned against the perimeter support edge of the tray;
and
operable in:
a laminated position, the separation membrane laminated against the lamination surface in the laminated position, responsive to evacuation of fluid from an interstitial region between the separation membrane and the lamination surface, to form a build surface offset below the perimeter support edge, and the perimeter support edge offset above the lamination surface by a first height in the laminated position;
and
an expanded position, the separation membrane forming a convex geometry offset above the perimeter support edge and offset above the lamination surface in the expanded position to promote separation of the separation membrane from a layer of a resin polymerized over the build surface via radiation emitted by the projection system, and the perimeter support edge offset above the lamination surface by the first height in the expanded position;
a fluid distribution port fluidly coupled to the interstitial region;
and
a fluid distribution channel circumscribing the build window and intersecting the fluid distribution port.

13 more elements

A tray assembly comprising:

a tray:
configured to locate over and engage a build window of an additive manufacturing system, the additive manufacturing system comprising a projection system configured to project radiation through the build window, the build window defining a lamination surface opposite the projection system;
and
comprising:
a lower member defining:
an aperture;
a perimeter support edge facing the aperture and configured to seat offset above the lamination surface;
and
a perimeter relief encircling and inwardly offset from the perimeter support edge;
and
an upper member:
comprising a perimeter tongue;
and
configured to assemble over the lower member with the perimeter tongue inserted into the perimeter relief and extending below the perimeter support edge;
and
a separation membrane:
extending across the aperture, the perimeter support edge, and the perimeter relief, a portion of the separation membrane interposed between the perimeter relief and the perimeter tongue;
tensioned across the aperture by the perimeter support edge and the perimeter relief via assembly of the upper member onto the lower member;
and
operable in:
a laminated position, the separation membrane laminated against the lamination surface in the laminated position, responsive to evacuation of fluid from an interstitial region between the separation membrane and the lamination surface, to form a build surface offset below the perimeter support edge, and the perimeter support edge offset above the lamination surface by a first height in the laminated position;
and
an expanded position, the separation membrane forming a convex geometry above the lamination surface and the perimeter support edge in the expanded position to promote separation of the separation membrane from a layer of a resin polymerized over the build surface via radiation emitted by the projection system and transmitted through the build window and the separation membrane, and the perimeter support edge offset above the lamination surface by the first height in the expanded position;
a fluid distribution port fluidly coupled to the interstitial region;
and
a fluid distribution channel circumscribing the build window and intersecting the fluid distribution port.

23 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/965,699Filed 13 Oct 2022 · continuation
Priority: 1 Nov 2018
Published: US 2023/0035689 A12 Feb 2023
Granted: 4 Feb 2025
Term ends: Not estimatedThe source records don’t support an estimate.

Classification14 codes

B29C 64/364
Auxiliary operations or equipment: conditioning of environment
B01D 63/081
Flat membrane modules: manufacturing thereof
B01D 71/32
Polyalkenyl halides: containing fluorine atoms
B29C 64/135
Characterised by the energy source therefor, e.g. by global irradiation combined with a mask: the energy source being concentrated, e.g. scanning…

Family

Application62/754,430Us provisional application · filed 1 Nov 2018
Application16/672,415Parent of this continuation · filed 1 Nov 2019
Application17/388,598Parent of this continuation · filed 29 Jul 2021
US 2023/0035689 A1Pre-grant publication · published 2 Feb 2023
US 11,878,472 B2Parent of this continuation
US 11,104,075 B2Parent of this continuation
US 2020/0139630 A1Published application
US 2021/0354392 A1Published application
US 12,214,553 B2This patent

From the US filing history. Foreign family members aren’t listed.

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