An additive manufacturing apparatus includes a vat with multiple chambers and at least one of the chambers is a resin chamber configured to receive a radiant-energy-curable resin. A build surface is defined by the resin chamber within the vat, wherein at least a portion of the build surface is transparent. The additive manufacturing apparatus includes a stage that is positioned facing the vat and the build surface and the stage is configured to hold a stacked arrangement of one or more cured layers of the radiant-energy-curable resin.

An additive manufacturing apparatus includes a vat with multiple chambers and at least one of the chambers is a resin chamber configured to receive a radiant-energy-curable resin. A build surface is defined by the resin chamber within the vat, wherein at least a portion of the build surface is transparent. The additive manufacturing apparatus includes a stage that is positioned facing the vat and the build surface and the stage is configured to hold a stacked arrangement of one or more cured layers of the radiant-energy-curable resin.

According to examples, a build module may include a housing, a build material chamber, and a build chamber. The build material chamber may be positioned beneath the build chamber in the housing and may include a moveable support member, in which a build material distributor is to supply successive layers of build material onto the moveable support member from the build material chamber. The build module may be removably insertable into a build receiver of an additive manufacturing system to allow the additive manufacturing system to solidify a portion of the successive layers received onto the moveable support member during the solidification process of the build material. The moveable support member may separate the build material chamber from the build chamber to block build material from the above the build material chamber from being received into the build material chamber during a solidification process of the build material.

A method of forming a three-dimensional object includes providing a carrier and an optically transparent member having a build surface. The carrier and the build surface define a build region therebetween. The method further includes filling said build region with a polymerizable liquid; continuously or intermittently irradiating said build region with light through said optically transparent member to form a solid polymer from said polymerizable liquid; applying a reduced pressure and/or polymer inhibitor-enriched gas to the polymerizable liquid through the optically transparent member to thereby reduce a gas content of the polymerizable liquid; and continuously or intermittently advancing (e.g., sequentially or concurrently with said irradiating step) said carrier away from said build surface to form said three-dimensional object from said solid polymer.

A method of forming a three-dimensional object includes providing a carrier and an optically transparent member having a build surface. The carrier and the build surface define a build region therebetween. The method further includes filling said build region with a polymerizable liquid; continuously or intermittently irradiating said build region with light through said optically transparent member to form a solid polymer from said polymerizable liquid; applying a reduced pressure and/or polymer inhibitor-enriched gas to the polymerizable liquid through the optically transparent member to thereby reduce a gas content of the polymerizable liquid; and continuously or intermittently advancing (e.g., sequentially or concurrently with said irradiating step) said carrier away from said build surface to form said three-dimensional object from said solid polymer.

A method of step-wise exposing a voxel of a resist to radiation for forming a three-dimensional structure, the method comprising setting a step size to a first resolution; setting a voxel volume to a first volume; exposing a first set of voxels of said first volume to radiation using said first resolution; setting the step size to a second resolution being smaller than said first resolution, or, respectively, greater than said first resolution; setting the voxel volume to a second volume being smaller than said first volume, or, respectively, greater than said first volume; and exposing a second set of voxels of said second volume to radiation using said second resolution.

A method of step-wise exposing a voxel of a resist to radiation for forming a three-dimensional structure, the method comprising setting a step size to a first resolution; setting a voxel volume to a first volume; exposing a first set of voxels of said first volume to radiation using said first resolution; setting the step size to a second resolution being smaller than said first resolution, or, respectively, greater than said first resolution; setting the voxel volume to a second volume being smaller than said first volume, or, respectively, greater than said first volume; and exposing a second set of voxels of said second volume to radiation using said second resolution.

The invention relates to a method for manufacturing molded articles consisting of at least one molded article layer, said method comprising the steps of a) putting a layer support in place for accommodating at least one molded article layer; b) applying a molded article layer to a printing plate using a shaping tool; c) positioning the printing plate and the layer support or a previously produced molded article layer relative to one another; d) curing the molded article layer such that said layer becomes a previously molded article layer, and transferring the molded article layer; e) if necessary, putting the printing plate in place for accommodating additional molded article layers and repeating steps b) to d). The invention further relates to an apparatus for carrying out the disclosed method as well as to the use of molded articles obtained thereby.

An additive manufacturing (AM) method includes using an AM tool to fabricate a plurality of workpiece products; measuring qualities of the first workpiece products respectively; performing a temperature measurement on each of the melt pools on the powder bed; performing photography on each of the melt pools on the powder bed; extracting a length and a width of each of the melt pools; performing a melt-pool feature processing operation; first converting each of the workspace images to a gray level co-occurrence matrix (GLCM); building a conjecture model by using a plurality of sets of first process data and the actual metrology values of the first workpiece products in accordance with a prediction algorithm; and predicting a virtual metrology value of the second workpiece product by using the conjecture model based on a set of second process data.

An additive manufacturing (AM) method includes using an AM tool to fabricate a plurality of workpiece products; measuring qualities of the first workpiece products respectively; performing a temperature measurement on each of the melt pools on the powder bed; performing photography on each of the melt pools on the powder bed; extracting a length and a width of each of the melt pools; performing a melt-pool feature processing operation; first converting each of the workspace images to a gray level co-occurrence matrix (GLCM); building a conjecture model by using a plurality of sets of first process data and the actual metrology values of the first workpiece products in accordance with a prediction algorithm; and predicting a virtual metrology value of the second workpiece product by using the conjecture model based on a set of second process data.