Methods, systems, and devices for three-dimensional object generation and physical mask curing

Abstract

An additive manufacturing device can include a light source configured to emit light; a vessel configured to container a photopolymer, a bed having a surface disposed at least partially within the vessel. The surface is movable in a first direction relative to the light source. A mask carrier is configured to support a mask and is movable during operation in a plane parallel with the surface. The mask has a plurality of orifices formed thereon that are configured to transmit the light therethrough.

What is claimed is: 
     
         1 . An additive manufacturing system comprising:
 a light source configured to emit light;   a vessel configured to contain a photopolymer;   a bed having a surface disposed at least partially within the vessel, the surface being movable in a first direction relative to the light source;   a mask carrier that is movable during operation in a plane parallel with the surface; and   a mask disposed within the mask carrier, mask having a plurality of orifices formed thereon, the orifices being configured to transmit the light therethrough.   
     
     
         2 . The system of  claim 1 , further comprising a membrane disposed between the mask carrier and the bed. 
     
     
         3 . The system of  claim 2 , wherein the membrane is sized to have a taut portion adjacent the mask carrier and at least one slack portion. 
     
     
         4 . The system of  claim 3 , wherein the membrane is configured in operation to release from a cured photopolymer as the mask carrier moves in the plane. 
     
     
         5 . The system of  claim 1 , wherein the plurality of orifices increase in size from a first end of the mask to a second end of the mask. 
     
     
         6 . The system of  claim 1 , wherein the light source is configured to emit light in the ultraviolet spectrum. 
     
     
         7 . The system of  claim 1 , further comprising a wash tank disposed adjacent the vessel, wherein the bed is configured to move a formed photopolymer object from the vessel to the wash tank. 
     
     
         8 . The system of  claim 1 , further comprising a cure tank having at least one evaporation element operably disposed thereon, the cure tank being disposed adjacent the vessel and the wash tank, the bed being configure to move the formed photopolymer object from the wash tank to the cure tank. 
     
     
         9 . The system of  claim 1 , the mask carrier further comprising:
 a housing having features to allow the mask carrier to move within the plane;   a mask reel coupled to the housing;   a mask movably coupled to the mask reel, the mask having at least a first orifice and a second orifice, the mask reel being configured to move the mask from a first position to a second position;   a light source operably coupled to the housing to direct light towards the mask; and   a window positioned adjacent the mask opposite the light source.   
     
     
         10 . The mask carrier of  claim 9 , wherein the first orifice is positioned between the light source and the window when in the mask is in the first position and the second orifice is positioned between the light source and the window when the mask is in the second position. 
     
     
         11 . The mask carrier of  claim 9 , wherein the features further comprise linear bearings. 
     
     
         12 . The mask carrier of  claim 9 , further comprising a structure configured to couple with a belt. 
     
     
         13 . The mask carrier of  claim 9 , wherein the window is at least partially made from a low friction material. 
     
     
         14 . The mask carrier of  claim 13 , wherein the material is one of polydimethylsiloxane (PDMS), fluorinated ethylene propylene (FEP), polymethyl methacrylate (PMMA), polyethylene (PET), or polypropylene (PP). 
     
     
         15 . A method of fabricating an object, the method comprising:
 providing a vessel containing a photopolymer, with a bed positioned a first layer thickness away from a bottom surface;   moving a mask carrier to a first position, the mask carrier having a movable first mask disposed therein, the first mask having at least a first orifice and a second orifice;   directing a first light through one of the first orifice or the second orifice through the bottom surface into the photopolymer, the first light being generated by a light source operably coupled to a mask carrier;   curing a first portion of the photopolymer between the bottom surface and the bed with the first light;   moving the mask carrier to a second position;   directing a second light through one of the first orifice or the second orifice through the bottom surface with the mask carrier in the second position;   curing a second portion of the photopolymer between the bottom surface and the bed with the second light; and   moving the bed in a direction away from the bottom surface.   
     
     
         16 . The method of  claim 15 , further comprising separating the first portion from the bottom surface when the mask carrier moves from the first position to the second position. 
     
     
         17 . The method of  claim 16 , wherein the separating is caused by a mass of the photopolymer on the bottom surface. 
     
     
         18 . The method of  claim 15 , further comprising moving the first mask from a third position to a fourth position when the mask carrier moves from the first position to the second position. 
     
     
         19 . The method of  claim 18 , wherein the first light is directed through the first orifice when the first mask is in the third position and through the second orifice when the first mask is in the fourth position. 
     
     
         20 . The method of  claim 15 , further comprising replacing the first mask in the mask carrier with a second mask, the second mask having at least a third orifice and a fourth orifice.