Apparatus and method for forming 3D objects

A method for printing a three-dimensional (3D) object using a printer apparatus comprising an elongated container having a length, a build platform having a top-side, upward-facing build surface, a means for conveying the build platform along the length of the elongated container, a matrix of light emitters, positioned over the elongated container and along the length of the conveying means, and a computer with programming to selectively control the movement of the build platform and a pattern of reactive light emitted from the matrix of light emitters, the method comprising a step of passing the upward-facing build surface through a series of stages along a pathway that is angled relative to an upper surface of a build fluid contained in the elongated container, wherein the angled pathway descends down into and proceeds along a length of the build fluid, and printing a layer of build material at each stage, comprising the steps of:

• a) advancing the build surface by an increment length along the angled pathway;
• b) flooding at least one of the build surface and a previously-printed layer of build material with a surface layer of the build fluid;
• and
• c) exposing the upper surface layer of the build fluid to a predetermined pattern of the reactive light emitted toward the top-side build surface, to at least partially polymerize or agglomerate a selected portion of the surface layer of the build fluid into a printed layer of build material having a build pattern.

A printer apparatus for printing a three-dimensional (3D) object, comprising:

• A) an elongated container having a length and including a light-transparent bottom, for containing build fluid comprising a monomer,
• B) a build platform having an under-side build surface,
• C) a means for conveying the build platform along the length of the container, and along a pathway that is angled relative to the light-transparent bottom, and wherein the angled pathway ascends up through the build fluid and proceeds along a length of the elongated container,
• D) a matrix of light emitting elements positioned under the light-transparent bottom and along the length of the conveying means, for emitting a predetermined pattern of a reactive light through the light-transparent bottom of the container and toward the under-side build surface, the reactive light being effective for at least partially polymerizing or agglomerating a portion of the build fluid adjacent the light-transparent bottom into a layer of build material having a build pattern, and
• E) a computer with programming to selectively control the movement of the build platform and the pattern of light emitted from the matrix of light emitters at and along the build fluid adjacent the light-transparent bottom, for printing the 3D object onto the under-side build surface.

A printer apparatus for printing a three-dimensional (3D) object, comprising:

• A) an elongated container including a light-transparent bottom, for containing build fluid comprising a monomer,
• B) a plurality of under-side, downward-facing, planar build surface segments for printing a plurality of 3D objects,
• C) a conveying apparatus for conveying the plurality of under-side, downward-facing, planar build surface segments along a pathway that is angled relative to the light-transparent bottom, and wherein the angled pathway ascends up through the build fluid and proceeds along a length of the elongated container, wherein the plurality of under-side, downward-facing, planar build surface segments are removably connected along a length of a structure of the conveyor apparatus,
• D) a matrix of light emitting elements for emitting a predetermined pattern of a reactive light through the light-transparent bottom of the container and toward the under-side build surface, the reactive light being effective for at least partially polymerizing or agglomerating a portion of the build fluid adjacent the light-transparent bottom into a layer of build material having a build pattern, and
• E) a computer with programming to selectively control the movement of the build platform and the pattern of light emitted from the matrix of light emitters at and along the build fluid adjacent the light-transparent bottom, for printing the 3D object onto the under-side build surface;
• and wherein the plurality of under-side, downward-facing planar build surface segments are either:
• (1) angled relative to the light-transparent bottom, or (2) parallel with the light-transparent bottom, or at an angle relative to the angled pathway.