SLA additive manufacturing using frozen supports of non-SLA material
Methods and apparatuses for additive manufacturing using stereolithography (“SLA”) materials. The apparatus includes a platform for holding an assembly of SLA resin layers. The apparatus also includes a platform for holding an assembly of SLA resin layers. The apparatus also includes a first movable stage for depositing and curing a portion of the liquid SLA resin on the platform, forming a pattern of cured SLA resin. The apparatus also includes a second movable stage for depositing a low-viscosity non-SLA material in voids in the pattern of cured SLA resin. The apparatus also includes a cooler for cooling the low-viscosity non-SLA material below its freezing point until solidified.
1. A method for stereolithography (SLA) additive manufacturing, the method comprising:
depositing a layer of liquid SLA resin over one of a base surface or an underlying layer of cured SLA resin;
curing a portion of the liquid SLA resin to form a pattern of cured SLA resin;
removing uncured liquid SLA resin from the pattern of cured SLA resin to leave one or more voids;
depositing water into the one or more voids; and
cooling the water below its freezing point until the water solidifies.
2. The method of claim 1 , further comprising repeating the depositing the layer of liquid SLA resin, the curing, the removing, the depositing the water, and cooling the water to form a multi-layer structure of cured SLA resin and frozen water.
3. The method of claim 2 , wherein multiple layers of the liquid SLA resin are deposited and cured between successive operations of depositing and cooling the water.
4. The method of claim 2 , further comprising warming the multi-layer structure of cured SLA resin and frozen water until the frozen water entirely melts.
5. The method of claim 4 , further comprising removing the melted water, leaving a multi-layer structure substantially including cured SLA resin.
6. The method of claim 5 , wherein the water expands upon freezing, creating an excess of frozen water.
7. The method of claim 6 , further comprising removing the excess of frozen water.
8. The method of claim 6 , wherein removing the excess comprise extractor over the pattern of cured SLA resin.
9. The method of claim 7 , further comprising preceding the extractor with a heater.
10. The method of claim 1 , further comprising enclosing a perimeter of the pattern of cured SLA resin to prevent runoff of the water.
11. The method of claim 9 , wherein enclosing the perimeter comprises curing a perimeter wall pattern in the layer of liquid SLA resin.
12. The method of claim 1 , wherein cooling the water comprises energizing a thermoelectric material that is thermally coupled to the water that is deposited in the one or more voids.