Additive manufacturing device and method

Abstract

Disclosed is an additive manufacturing device, comprising: a vessel for containing a material which is polymerisable on exposure to radiation; a build platform having a build surface, the build platform being mounted or mountable for movement relative to the vessel; and a programmable radiation module comprising an array of individually addressable radiation emitting or transmitting elements, the array being configurable to produce radiation having a predetermined pattern by selective activation of elements of the array; wherein the programmable radiation module is positioned or positionable to irradiate uncured material adjacent the build surface, or adjacent a previously cured structure on the build surface, with the predetermined pattern without magnification. Also disclosed is an additive manufacturing method which employs the additive manufacturing device.

1 - 15 . (canceled) 
     
     
         16 . An additive manufacturing method, comprising:
 providing a vessel for containing a material which is polymerisable on exposure to radiation;   providing a build platform having a build surface arranged to have an object formed thereon, the build platform being configured for movement relative to the vessel; and   providing a programmable radiation module to produce patterned radiation;   providing a rigid transparent member such that the rigid transparent member is disposed between a bottom of the vessel and the programmable radiation module;   positioning the build platform relative to the vessel; and   irradiating the material contained in the vessel with the patterned radiation such that, on curing, a layer of the material is in contact with at least the build surface to form a layer of the object.   
     
     
         17 . The additive manufacturing method of  claim 16 , wherein providing the programmable radiation module comprises providing a programmable radiation module that comprises a dynamic mask component, and a radiation source for irradiating through the dynamic mask component. 
     
     
         18 . The additive manufacturing method of  claim 17 , wherein the dynamic mask component comprises a liquid crystal display (LCD). 
     
     
         19 . The additive manufacturing method of  claim 18 , wherein the LCD is a monochrome LCD. 
     
     
         20 . The additive manufacturing method of  claim 17 , wherein providing the rigid transparent member comprises enabling attachment of the rigid transparent member and the dynamic mask component to the vessel. 
     
     
         21 . The additive manufacturing method of  claim 17 , wherein providing the vessel comprises providing a vessel that has sidewalls and a transparent lower wall at the bottom of the vessel. 
     
     
         22 . The additive manufacturing method of  claim 21 , wherein providing the programmable radiation module comprises enabling attachment of the programmable radiation module to the transparent lower wall of the vessel. 
     
     
         23 . The additive manufacturing method of  claim 21 , wherein providing the programmable radiation module comprises enabling attachment of the programmable radiation module to the sidewalls of the vessel. 
     
     
         24 . The additive manufacturing method of  claim 16 , wherein providing the programmable radiation module comprises providing a programmable radiation module that comprises an array of individually addressable radiation emitting or transmitting elements, the array being configurable, by selective activation of the elements of the array, to produce the patterned radiation. 
     
     
         25 . The additive manufacturing method of  claim 24 , wherein the array comprises an array of individually addressable radiation emitting elements, the array being configurable, by selective activation of the elements of the array, to emit the patterned radiation. 
     
     
         26 . The additive manufacturing method of  claim 16 , wherein providing the vessel comprises providing a vessel that comprises a non-stick layer or polymerization-inhibiting layer at the bottom of the vessel. 
     
     
         27 . The additive manufacturing method of  claim 26 , wherein the non-stick layer is formed from a silicone-based material, polyurethane, polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), or latex. 
     
     
         28 . The additive manufacturing method of  claim 16 , wherein providing the programmable radiation module comprises disposing the programmable radiation module underneath the bottom of the vessel. 
     
     
         29 . An additive manufacturing method, comprising:
 providing a vessel for containing a material which is polymerisable on exposure to radiation;   providing a build platform having a build surface arranged to have an object formed thereon, the build platform being configured for movement relative to the vessel; and   providing a programmable radiation module that is configured to produce a dynamic curing pattern, wherein providing the programmable radiation module comprises disposing the programmable radiation module below the vessel to irradiate a layer of uncured material using the dynamic curing pattern such that, on curing, the layer is in contact with at least the build surface to form a layer of the object;   providing a rigid transparent member such that the rigid transparent member is disposed between a bottom of the vessel and the programmable radiation module, wherein the programmable radiation module comprises a dynamic mask component and a radiation source for irradiating through the dynamic mask component, and wherein providing the rigid transparent member comprises attaching the rigid transparent member and the dynamic mask component to the vessel;   positioning the build platform relative to the vessel; and   irradiating the material contained in the vessel.   
     
     
         30 . The additive manufacturing method of  claim 29 , wherein the dynamic mask component comprises a liquid crystal display (LCD). 
     
     
         31 . The additive manufacturing method of  claim 30 , wherein the LCD is a monochrome LCD. 
     
     
         32 . The additive manufacturing method of  claim 29 , wherein providing the vessel comprises providing a vessel that has sidewalls and a transparent lower wall at the bottom of the vessel. 
     
     
         33 . The additive manufacturing method of  claim 32 , wherein attaching comprises attaching the rigid transparent member and the dynamic mask component to the transparent lower wall of the vessel. 
     
     
         34 . The additive manufacturing method of  claim 29 , wherein providing the vessel comprises providing a vessel that comprises a non-stick layer or polymerization-inhibiting layer at the bottom of the vessel. 
     
     
         35 . The additive manufacturing method of  claim 34 , wherein the non-stick layer is formed from a silicone-based material, polyurethane, polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), or latex.