EP-4735233-A1 - STEREOLITHOGRAPHY APPARATUS FOR IMPROVING PLANARITY OF A TRANSPARENT SHEET

Abstract

A 3D printing system includes a build vessel (8), a carriage (58), and a light engine. The build vessel includes a vessel base having a downward extending tension ring that tensions a transparent sheet (34). The transparent sheet laterally bounds a build plane that is defined over orthogonal lateral axis X and Y. The carriage includes a roller (52) that extends between two opposing sides of the tension ring. The roller exerts an upward force on the transparent sheet and the two opposing sides of the tension ring. The vertical constraint of the roller biased against the tension ring provides a location and improved planarity of a supported portion of the transparent sheet adjacent to the roller. The light engine light engine is configured to selectively apply radiation to a projected area of the build plane through the supported portion of the transparent sheet.

Inventors

• CLINTON, Nickolas, M.
• HULL, CHARLES, W.
• DRAPER, Grant
• SABO, DAVID
• ROHRBACH, Samuel, David

Assignees

• 3D Systems, Inc.

Dates

Publication Date

20260506

Application Date

20240625

Claims (20)

1. 1 . A three-dimensional (3D) printing system configured to manufacture a 3D article comprising: a machine chassis including a vessel support; a build vessel supported by the vessel support, the build vessel including: a vessel base having a downward extending tension ring; and a transparent sheet that is tensioned over the tension ring and laterally bounds a build plane, the build plane is defined along orthogonal lateral axes X and Y; a carriage including a roller that laterally extends below two opposing sides of the tension ring, the roller engages and exerts an upward force upon the two opposing sides of the tension ring with the transparent sheet between the roller and the tension ring, the upward force of the roller against the tension ring constrains a vertical location and improves planarity of a supported portion of the transparent sheet adjacent to the roller; and a light engine configured to selectively apply radiation to a projected area of the build plane through the supported portion of the transparent sheet.
2. 2. The 3D printing system of claim 1 wherein the vessel base defines a recess that extends around the tension ring and further comprising a support frame within the recess that clamps a peripheral edge of the transparent sheet.
3. 3. The 3D printing system of claim 1 wherein the carriage is slidingly mounted to the vessel base by a pair of linear bearings to constrain motion of the carriage along the lateral axis X.
4. 4. The 3D printing system of claim 3 further comprising a lateral movement mechanism configured to translate and position the carriage along the lateral axis X, the roller extends along the lateral axis Y.
5. 5. The 3D printing system of claim 4 wherein the light engine is configured to be positioned with the carriage along the lateral axis X.
6. 6. The 3D printing system of claim 5 wherein the roller includes two rollers, the supported portion of the transparent sheet is between the two rollers.
7. 7. The 3D printing system of claim 5 wherein the light engine is configured to translate relative to the carriage along the lateral axis Y.
8. 8. The 3D printing system of claim 1 wherein roller is coupled to the carriage at two ends by a pair of circular bearings, the circular bearings are biased upward to provide the upward force of the roller upon the tension ring.
9. 9. The 3D printing system of claim 1 further comprising a source of pressurized gas configured to apply fluid pressure to a lower surface of the transparent sheet.
10. 10. The 3D printing system of claim 1 wherein the light engine is configured to project a pixelated radiation field through the supported portion of the transparent sheet and to the build plane and further comprising: a lateral movement mechanism including: an X motor configured to move the carriage along the lateral axis X; and a Y motor configured to move the light engine relative to the carriage along the lateral axis Y; a build plate; and a vertical movement mechanism configured to vertically position the build plate.
11. 11 . The 3D printing system of claim 10 further comprising a controller configured to fabricate the 3D article through the sequential formation of layers, for individual layers the controller is further configured to: operate the vertical movement mechanism to position a lower face of the build plate or the 3D article in a partially fabricated state at the build plane; operate the X motor to sequentially position the carriage at a plurality of X-stop locations along the lateral axis X, for individual X stop locations: operate the Y motor to scan the light engine along the lateral axis Y; and operate the light engine to selectively illuminate a column along the build plane as the light engine is being scanned.
12. 12. A method of manufacturing the 3D article using the 3D printing system of claim 10 comprising: operating the vertical movement mechanism to position a lower face of the build plate or the 3D article in a partially fabricated state at the build plane; operating the X motor to sequentially position the carriage at a plurality of X-stop locations along the lateral axis X, for individual X-stop locations: operating the Y motor to scan the light engine along the lateral axis Y; and operating the light engine to selectively illuminate a column along the build plane as the light engine is being scanned.
13. 13. The 3D printing system of claim 1 wherein the roller has an outer surface that has a lower scratch resistance than a lower surface of the transparent sheet.
14. 14. The 3D printing system of claim 1 wherein the roller includes a coating of a material selected from the group consisting of a polymer and an oil.
15. 15. A three-dimensional (3D) printing system configured to manufacture a 3D article comprising: a machine chassis including a vessel support; a build vessel supported by the vessel support, the build vessel including: a vessel base having a downward extending tension ring; and a transparent sheet that is tensioned over the tension ring and laterally bounds a build plane, the build plane is defined along orthogonal lateral axes X and Y; a carriage mounted to the vessel base by a linear bearing, the carriage including a roller mounted to the carriage by a pair of roller bearings located at opposed ends of the roller, the carriage including a spring that biases the roller bearing upward, the roller spans the build plane and presses upon laterally opposed portions of the tension ring that are laterally outside the build plane; and a light engine configured to selectively apply radiation to an area of the build plane adjacent to the roller.
16. 16. The 3D printing system of claim 15 wherein the vessel base defines a recess that extends around the tension ring and further comprising a support frame that within the recess that clamps a peripheral edge of the transparent sheet.
17. 17. The 3D printing system of claim 15 further comprising a lateral movement mechanism coupled to the projector and the carriage and configured to: position the carriage and the light engine together along the lateral axis X; and position and translate the light engine relative to the carriage along the lateral axis Y.
18. 18. The 3D printing system of claim 17 further including a controller configured to: operate the vertical movement mechanism to position a lower face of the build plate or the 3D article in a partially fabricated state at the build plane; and operate the lateral movement mechanism to position the carriage at a plurality of locations along the lateral axis X, at an individual one of the plurality of adjacent locations the rollers bound a column of the build plane so that the plurality of adjacent locations correspond to a plurality of adjacent columns, the adjacent columns contiguously cover a region of the build plane to be selectively irradiated, at a column: operate the lateral movement mechanism to scan the light engine over the column along the lateral axis Y; and operate the light engine to selectively irradiate the column.
19. 19. A method of manufacturing the 3D article using the 3D printing system of claim 17 comprising: operating the vertical movement mechanism to position a lower face of the build plate or the 3D article in a partially fabricated state at the build plane; operating the lateral movement mechanism to position the carriage at a plurality of locations along the lateral axis X, at an individual one of the plurality of adjacent locations the rollers bound a column of the build plane so that the plurality of adjacent locations correspond to a plurality of adjacent columns; the adjacent columns contiguously cover a region of the build plane to be selectively irradiated, at a column: operating the lateral movement mechanism to scan the light engine over the column along the lateral axis Y; and operating the light engine to selectively irradiate the column.
20. 20. The three-dimensional (3D) printing system of claim 15 wherein the roller has an outer surface that has a lower scratch resistance than a lower surface of the transparent sheet, the outer surface is formed from a material that is one or more of a polymer, an oil, and a felt material.

Description

Stereolithography Apparatus for Improving Planarity of a Transparent Sheet Cross Reference to Related Applications [0001] This non-provisional patent application claims priority to U.S. Provisional Application Serial Number 63/510,962, Entitled “Stereolithography Apparatus for Improving Planarity of a Transparent Sheet” by Charles W. Hull et al., filed on June 29, 2023, incorporated herein by reference under the benefit of U.S.C. 119(e). This non-provisional patent application also claims priority to U.S. Provisional Application Serial Number 63/620,328, Entitled “Stereolithography Apparatus for Improving Planarity of a Transparent Sheet” by Nickolas M. Clinton et al., filed on January 12, 2024, incorporated herein by reference under the benefit of U.S.C. 119(e). Field of the Invention [0002] The present disclosure concerns an apparatus and method for manufacture of solid three dimensional (3D) articles from radiation curable materials in a layer-by-layer manner. More particularly, the present disclosure concerns an improved mechanism for obtaining high resolution 3D articles by controlling flatness of a transparent sheet which forms part of an optical path. Background [0003] Three dimensional (3D) printers are in rapidly increasing use for manufacturing customized 3D articles. One class of 3D printers includes stereolithography printers having a general principle of operation including the selective curing and hardening of radiation curable (i.e. , photocurable) liquids. One type of stereolithography system includes a containment vessel holding the photocurable liquid, a movement mechanism coupled to a support tray, and a light engine. The stereolithography system manufactures or fabricates a 3D article by selectively curing layers of the photocurable liquid along a build plane above a transparent sheet. There is a desire to produce articles having features sizes that are 10 microns or smaller in size. One challenge is the weight of a column of photocurable liquid distorting the transparent sheet which in turn impacts dimensional accuracy of a 3D article. Another challenge is an ability to create a thin layer of photocurable liquid to enable the small feature sizes. Summary [0004] In an aspect of the disclosure a three-dimensional (3D) printing system is configured to manufacture or fabricate a 3D article. The 3D printing system includes a machine chassis including a vessel support, a build vessel, a carriage, and a light engine. The build vessel is supported by the vessel support. The build vessel includes a vessel base having a downward extending tension ring and a transparent sheet that is tensioned over the tension ring. The transparent sheet laterally bounds a build plane that is defined over orthogonal lateral axis X and Y. The carriage includes a roller that extends between two opposing sides of the tension ring. The roller exerts an upward force on the transparent sheet and the two opposing sides of the tension ring. The upward force of the roller against the tension ring - with the transparent sheet therebetween - constrains a vertical location and improves planarity of a supported portion of the transparent sheet adjacent to the roller. The light engine is configured to selectively apply radiation to a projected area of the build plane through the supported portion of the transparent sheet. [0005] In one implementation the vessel base includes a recess that extends around the tension ring. A support frame clamps a peripheral edge of the transparent sheet. The support frame is mounted within the recess. The transparent sheet extends downward from the support frame, over a lower edge of the tension ring, and laterally between opposing sides of the tension ring. The transparent sheet provides a lower bound for photocurable liquid that is disposed within the build vessel. [0006] In another implementation the carriage is slidingly mounted to the vessel base by a pair of linear bearings to constrain motion of the carriage along the lateral axis X. The carriage includes a lateral movement mechanism configured to translate and position the carriage along the lateral axis X. The roller extends along the lateral axis Y. The light engine generates a pixelated radiation field that is configured to translate and be positioned with the carriage along the lateral axis X. The pixelated radiation field of the light engine is configured to translate and be positioned along the lateral axis Y. [0007] In yet another implementation the roller is individually coupled to the carriage at two ends by a pair of circular bearings. The circular bearings are biased upward to provide the upward force of the roller upon the transparent sheet and the tension ring. In a further implementation, the 3D printing system includes a lateral movement mechanism coupled to the carriage and the light engine and configured to: (1 ) position the carriage and light engine together along the lateral axis X and (2) position and translate