Integrated additive manufacturing systems

Abstract

An integrated additive manufacturing system includes: (a) at least one resin supply; (b) a plurality of additive manufacturing machines on which parts may be produced, each of the additive manufacturing machines operatively associated with the at least one resin supply; and (c) at least one peripheral machine operatively associated with each of the additive manufacturing machines and the at least one resin supply.

We claim: 
     
         1 . An integrated additive manufacturing system, comprising:
 (a) at least one resin supply;   (b) a plurality of additive manufacturing machines on which parts may be produced, each of said additive manufacturing machines operatively associated with said at least one resin supply; and   (c) at least one peripheral machine operatively associated with each of said additive manufacturing machines and said at least one resin supply.   
     
     
         2 . The system of  claim 1 , wherein said at least one resin supply comprises a single-use resin supply or a bulk resin supply,
 each of which can be associated with either one of or a plurality of said additive manufacturing machines,   and each of which can optionally include an automated resin feed system configured to supply resin to one of, or a plurality of, said additive manufacturing machines.   
     
     
         3 . The system of  claim 1 , wherein said at least one peripheral machine comprises:
 at least one part post-production machine, such as at least one of a part washing machine, a part penetrant bath apparatus, a part oven, a part cutting, grinding, and/or texturing machine, a part painting machine, or a combination thereof; and/or   at least one maintenance machine configured to maintain or replace a component of said additive manufacturing machines, such as a build plate cleaning machine.   
     
     
         4 . The system of  claim 1 , wherein said at least one peripheral machine comprises a part washing machine. 
     
     
         5 . The system of  claim 1 , further comprising:
 (d) a database operatively associated with each of said plurality of additive manufacturing machines, said database configured to record part configuration data for each part produced on each additive manufacturing machine.   
     
     
         6 . The system of  claim 5 , wherein:
 said database is further configured to contain specific resin data for each of a plurality of different resins;   said at least one resin supply comprises a resin container having a resin therein and a resin unique identifier operatively associated therewith, said resin unique identifier associated with specific resin data for the contained resin; and   each of said plurality of additive manufacturing machines comprises a resin unique identifier reader operatively associated therewith and a resin reservoir configured to receive resin from said resin container; with each of said plurality of additive manufacturing machines configured to carry out a part production process with said resin based on both part configuration data and said specific resin data.   
     
     
         7 . The system of  claim 5 , wherein:
 each of said additive manufacturing machines includes a releasable carrier plate on which a part is produced from said resin, each of said carrier plates having a carrier plate unique identifier operatively associated therewith;   said database is further configured to record both part configuration data and resin data, and optionally time of production, for each part produced on each carrier plate;   said part washing machine includes a carrier plate unique identifier reader operatively associated therewith;   said part washing machine is configured to select and carry out a part washing process on each part from a plurality of different part washing processes (optionally while each said part remains on the carrier plate on which the part was produced) based on: (i) part configuration data, (ii) specific resin data, or (iii) both part configuration data and specific resin data; and   optionally with said database configured to record washing process data, and optionally time of wash, for each part washed in said part washing machine.   
     
     
         8 . The system of  claim 7 , wherein:
 at least one of said peripheral machines is configured to releasably secure said carrier plate.   
     
     
         9 . The system of  claim 7 , further comprising:
 (e) an oven operatively associated with each said additive manufacturing machine;   optionally with said oven configured to select and carry out a baking process on each part from a plurality of different baking processes (optionally while each said part remains on the carrier plate on which the part was produced) based on: (i) part configuration data, (ii) specific resin data, or (iii) both part configuration data and specific resin data; and   optionally with said database configured to record baking process data, and optionally time of bake, for each part baked in said oven.   
     
     
         10 . The system of  claim 5 , each of said additive manufacturing machines configured to apply a part unique identifier to each part produced thereon;
 with said database further configured to record said part unique identifier from each of said additive manufacturing machines.   
     
     
         11 . The system of  claim 5 , each of said additive manufacturing machines including an interchangeable build plate, said build plate including an optically transparent member and a build plate unique identifier,
 with each of said plurality of additive manufacturing machines further including a build plate unique identifier reader;   and with said database further configured to record build plate data for each part produced on each of said plurality of additive manufacturing machines.   
     
     
         12 . An integrated method for producing and washing parts by additive manufacturing, comprising:
 (a) providing a manufacturing system including a plurality of additive manufacturing machines operatively associated with a part washing machine, with said part washing machine configured to execute a plurality of different wash programs;   (b) generating at least one part on each of said plurality of additive manufacturing machines to produce a plurality of parts to be washed, each part of said plurality of parts produced from a resin and from part configuration data, and with each said part having residual resin thereon; and   (c) washing each of said plurality of parts in said part washing machine with the same wash liquid in a plurality of consecutive wash programs for each part, each wash program configured or selected based on: (i) part configuration data, (ii) specific resin data, or (iii) both part configuration data and specific resin data; and then   (d) optionally further curing each of said plurality of parts.   
     
     
         13 . The method of  claim 12 , wherein each said part is produced in step (b) on a carrier platform, said carrier platform comprises a carrier unique identifier, said washing of each of said plurality of parts is carried out with said part on the carrier platform on which it was produced, and said wash program is configured or selected based upon information associated with said carrier unique identifier. 
     
     
         14 . The method of  claim 12 , wherein each of said consecutive wash programs for each part is carried out in a total time of not more than 10 minutes. 
     
     
         15 . The method of  claim 12 , wherein each said wash program for each said part is carried out in a sequence of (i) agitating said part in wash liquid, (ii) separating or draining wash liquid from said part, (iii) agitating said part free of wash liquid to further separate residual resin; and (iv) optionally repeating steps (i) through (iii) at least once, all optionally in the same vessel, and all optionally with the same wash liquid. 
     
     
         16 . The method of  claim 12 , further comprising recording, in a database and in association with each part, at least one, any combination, or all of: wash liquid type, wash liquid batch, wash liquid usage history, day of wash, time of day of wash, wash machine identity, wash liquid temperature, wash program, interval between additive production and wash, and/or wash machine operator. 
     
     
         17 . A method of tracking production of parts from a resin, comprising:
 (a) providing a database comprising resin data, the resin data including: (i) at least one resin type data, and (ii) resin batch data for each of a plurality of batches of each resin type;   (b) producing a plurality of parts from one said resin type and from part configuration data with at least one additive manufacturing machine by a part production process, each of said parts having a part unique identifier applied thereto; and   (c) generating in said database a part record for each of said parts, the part record including resin type data, resin batch data, part production process data, and part unique identifier, the part record optionally including part configuration data.   
     
     
         18 . The method of  claim 17 , further comprising:
 (d) washing each said part in a washing machine with a wash liquid in accordance with a wash cycle, and also adding wash cycle data and wash liquid data to each part record for each part washed.   
     
     
         19 . The method of  claim 18 , further comprising generating a report from said database for at least one selected part based on said part unique identifier, said report including, for each selected part, at least one, or any combination, or all of:
 (i) resin type data, resin batch data, resin manufacturer identity;   (ii) part configuration data, part production program data, part production machine identity, build plate identity, time of part production, interval between resin manufacture and part production, interval between resin dispensing and/or blending and part production, part production machine operator identity; and/or   (iii) wash program data, wash liquid data, wash liquid batch, wash machine identity, time of wash, interval between time of production and time of wash, wash machine operator identity.   
     
     
         20 . The method of  claim 18 , further comprising generating a report from said database for all parts sharing at least one, or any combination of, or all of, the same:
 (i) resin type data, resin batch data, resin manufacturer identity; and/or   (ii) part configuration data, part production program data, part production machine identity, build plate identity, time of part production, interval between resin manufacture and part production, interval between resin dispensing and/or blending and part production, part production machine operator identity; and/or   (iii) wash program data, wash liquid data, wash liquid batch, wash machine identity, time of wash, interval between time of production and time of wash, wash machine operator identity.