Abstract: Methods and processes are provided by which inhibited-crystallization polymers may be employed as feedstock materials in thermoplastic extrusion-type additive manufacturing systems. Counteracting the tendency of such polymers to uncontrolledly settle into an amorphous state upon cooling under typically used conditions, techniques are disclosed for controlling process temperatures, exposure times and feed rates to produce parts with uniform crystallinity, high mechanical strength and efficient throughput.

Abstract: A three dimensional printing system includes a controller that is configured to (1) receive an incoming slice data array that defines an initial two dimensional object having an initial outer boundary; (2) process the incoming slice data array to define a simple outer boundary whereby if the object has two portions defining a channel therebetween, the channel is reduced or eliminated thereby reducing a perimeter of the outer boundary. In one embodiment the object is two objects. If the channel is defined between the two objects, then the processing merges the two objects. If the channel is a concave recess within one object, then the processing reduces the depth of or eliminates the concave recess.

Abstract: A three-dimensional printing system for fabricating a three-dimensional article includes a resin vessel, a motorized build plate, an imaging bar, and a movement mechanism. The resin vessel is for containing a photocurable resin, the photocurable resin having an upper resin surface. The motorized build plate is for supporting the three-dimensional article in the photocurable resin. The imaging bar includes a plurality of light emitting devices arranged along a transverse axis for emitting light generally downwardly and a transparent sheet disposed below the plurality of light emitting devices. The transparent sheet has a lower surface to contact the resin and define a build plane below the upper surface of the resin. The movement mechanism is for imparting movement of the imaging bar along a scan axis.

Abstract: A method of manufacturing using an additive manufacturing process includes providing a deposition system, the deposition system configured to provide a plurality of cells to form a blank of a part, depositing a first layer of the blank, the first layer comprising a first deposited cell, a second deposited cell spaced apart from the first deposited cell, and a third deposited cell spaced apart from the first deposited cell and the second deposited cell, and depositing a second layer of the part on the first layer, the second layer comprising a fourth deposited cell, a fifth deposited cell spaced apart from the fourth deposited cell, and a sixth deposited cell spaced apart from the fourth deposited cell and the fifth deposited cell. Each of the first layer and the second layer are formed using non-continuous deposition to form the blank.

Abstract: A three dimensional printing system includes a light engine having a spatial light modulator for curing individual layers of a photocure resin to form a three dimensional article of manufacture. The light engine is configured to: (1) receive a slice image that defines an array of energy values for curing a layer, (2) process the slice image to define an image frame compatible with the spatial light modulator, (3) receive an on signal, (4) activate the first light source in response to the on signal; (5) repeatedly send the first defined image frame to the first spatial light modulator during a defined cure time for the single layer of resin; (6) receive an off signal; (7) deactivate the first light source in response to the off signal; and (8) repeat steps (1)-(7) until the three dimensional article of manufacture is formed.

Abstract: Build materials for 3D printing applications are described herein which, in some embodiments, comprise monomeric species operable for producing articles with high Tg and/or high heat deflection temperature while maintaining shelf stability. In one aspect, a polymerizable liquid comprises at least 20 weight percent isocyanurate polyacrylate; a photoinitiator component; and a crystallization inhibitor component comprising monomeric curable material, oligomeric curable material or mixtures thereof, wherein the polymerizable liquid does not exhibit crystallization over a period of 28 days at a storage temperature of 5-10° C.

Abstract: A method for manufacturing a three-dimensional (3D) article includes: (1) receiving a solid model defining a 3D article, (2) receiving information defining an information bearing image which can includes machine and/or human readable indicia, (3) defining a solid model of a 3D tag to be attached to the article, the 3D tag having thick sections and thin sections that define the information bearing image, (4) merging the solid model of the 3D article with the solid model of the 3D tag to provide a composite solid model defining the 3D article integral with the 3D tag, (5) sending the composite solid model to an additive manufacturing system, and (6) operating the additive manufacturing print engine to integrally fabricate the 3D article and 3D tag from a single material.

Abstract: A three-dimensional printing system for fabricating a three-dimensional article includes a resin vessel, a motorized platform, an imaging bar, a movement mechanism, a servicing module, and a controller. The motorized platform has an upper surface for supporting the three-dimensional article. The imaging bar has an array of light emitters arranged along a transverse axis which emitting light downwardly from an exit surface. The controller is configured to: operate the motorized build plate, the movement mechanism, and the imaging module to complete fabrication, and periodically during fabrication operate the movement mechanism to position the imaging bar in the servicing module to clean resin residue from the imaging bar.

Abstract: A three dimensional printing system includes a print engine, a fluid processing station, a fixture, a transport mechanism, and a controller. The fluid processing station includes a fluid injector port coupled to a fluid source. The fixture has a lower portion with a lower face and a first fluid conduit coupled to the lower face. The controller is configured to: (a) Operate the print engine to form a three dimensional article of manufacture onto the lower face and thereby defining an internal cavity and an inlet port that couples the internal cavity to the first fluid conduit of the fixture. (c) Transfer the fixture to the fluid processing station. (d) Couple the fluid injector port of the fluid processing station to the first fluid conduit of the fixture. (e) Operate the fluid source to inject fluid out of the fluid injector port and into the internal cavity.

Abstract: A three-dimensional printing system includes a support plate and a resin vessel. The support plate defines a central opening and an upper surface. The resin vessel is disposed upon the upper surface of the support plate and includes a substructure and a transparent sheet. The substructure includes a vertical wall and a tension ring that extends inwardly and downwardly from the vertical wall. The tension ring impinges downwardly upon an upper surface of the transparent sheet and tensions the transparent sheet.

Abstract: A three dimensional printing system for manufacturing a three dimensional article includes a print engine, a receptacle, a pump motor system, a removable conduit assembly, and a resin container. The receptacle includes an upper portion with an opening and a lower interface portion. The removable conduit assembly includes: a fluid inlet extending upwardly from the lower interface portion; a pump head removably coupled to the pump motor system; a fluid outlet for supplying resin to the print engine. The resin container includes an internal reservoir and a leading and trailing end relative to a direction of insertion of the resin container into the receptacle. The resin container includes a fluid outlet that extends downwardly from the leading end. Installation of the resin container includes passing the leading end through the opening and lowering and coupling the leading end to the lower interface portion.

Abstract: A three-dimensional printing system includes an array of platen sections, a plurality of compressive sheets, a chassis, a plurality of actuators, a powder dispenser, and an energy beam source. The array of platen sections individually have a top surface and a plurality of vertical side surfaces intersecting the top surface. The plurality of platen sections are positioned with adjacent pairs of platen sections having a pair of the vertical side surfaces in facing relation with each other and defining a vertical gap therebetween. Thus they define a plurality of vertical gaps over the array of platen sections. The plurality of compressible sheets fill the plurality of vertical gaps. The chassis supports the array of platen sections. The plurality of actuators is for individually and vertically positioning the platen sections.

Abstract: A three-dimensional printing system is for fabricating or manufacturing a three-dimensional article. The three-dimensional printing system includes a substrate, a light engine, a radiation sensor, and a controller. The substrate has a surface positioned proximate to a build field. The surface supports a calibration target which includes or defines elongate light modulating bars disposed at two different orientations and including a Y-bar aligned with a Y-axis and an X-bar aligned with an X-axis. The light engine includes a plurality of projection modules including at least a first projection module and a second projection module. The first projection module configured to project an array of pixels onto a first image field. The second projection module configured to project an array of pixels onto a second image field.

Abstract: The invention relates to a system for the layered manufacture of a three-dimensional product starting from a powder, in particular a metal powder. More specifically, the invention relates to a system in which selective laser melting is applied to manufacture a product. Here, successive powder layers are covered by an energy beam, such as a laser beam, in order to melt the powder in this layer in whole or in part and subsequently to solidify or sinter it and to create successive layers of the product in this way.

Abstract: A three-dimensional printing system includes a resin vessel containing resin, an imaging bar, a movement mechanism coupled to the imaging bar, and a controller. The imaging bar includes an arrangement of light emitting devices that selectively emit radiation from an exit surface of the imaging bar to define a build plane in the resin. The exit surface of the imaging bar is preferably less than 10 millimeters from the build plane. The controller is configured to scan the imaging bar along a scan axis and, concurrent with scanning, operate the imaging bar to selectively image a layer of resin at the build plane.

Abstract: A three-dimensional printing system includes a print engine, a storage subsystem, and a controller. The print engine includes a resin vessel having a lower side with a transparent sheet, a light engine that defines a build field above the transparent sheet, and a motorized carriage for holding a support tray with a lower surface above the resin vessel. The storage subsystem is configured to store support trays. The controller is configured to: receive a build order including a plurality of incoming files individually defining a three-dimensional article to be fabricated, process and determine breakage-related risk factors for the processed files, define a build plan for at least some of the plurality of processed files based at least partly upon the determined risk factors, and operate the print engine and the storage subsystem to build and store three-dimensional articles according to the defined build plan.

Abstract: There is provided a 3D printing system, methods, and materials for the 3D printing of objects that include a cured hydrogel material, an uncured hydrogel material, and a support material. The cured hydrogel material may define a scaffold for organs or other biological structures. The 3D printing system selectively deposits the hydrogel material and support material, dries the hydrogel material, and selectively applies a catalyst to the hydrogel material to selectively cure the hydrogel material. Once the 3D printing has completed, the uncured hydrogel material may be drained and the support material may be melted or dissolved leaving a scaffold of cured hydrogel material that may be infused with living cells of the desired organ or biological structure.

Abstract: A method of determining a type of support structure for a three-dimensional (3D) object formed by additive manufacturing includes receiving solid model of the 3D object; performing a geometric analysis of the solid model to identify a region of the 3D object requiring a support structure; performing stress and warping analyses of the solid model at the region so identified, including one or more heuristic algorithms applied to the solid model, and excluding finite element analysis of a corresponding finite element model of the 3D object; selecting a type of support structure to place at the region so identified, the type of support structure being selected based on the stress and warping analyses so performed; and generating a shell of the 3D object based on the solid model, and including the support structure at the region so identified and of the type so selected.

Abstract: A method of manufacturing a three-dimensional article includes (1) receiving a data file, (2) analyzing the data file, and (3) defining a support structure. The data file defines a hollow three-dimensional article to be formed from a build material. Analyzing the data file includes identifying an opening that converges to an apex along the sequence of layers. The opening is at least partly defined by an inside edge of the three-dimensional article. The support structure is attached to the edge and closes the opening. The support structure includes a structural sheet portion and an interface web portion. The structure sheet portion defines a majority of an area of the support structure except for a boundary contour between the structural sheet portion and the inside edge. The interface web portion closes the boundary contour and defines a weakness contour for removing the structural portion from the three-dimensional article.

Abstract: A method for detecting two dimensional sketch data from source model data for three dimensional reverse modeling. The method includes the steps of detecting optional model data, establishing X-axis, Y-axis and Z-axis of the model data depending upon a reference coordinate system information inputted from a user, and setting a work plane for detecting two dimensional section data of the model data; projecting, on the work plane, two dimensional section data to be detected from the model data or polylines detected by designating a detection position; detecting two dimensional projected section data of the model data projected on the work plane, and dividing the two dimensional projected section data into feature segments depending upon a curvature distribution; and establishing a constraint and numerical information in accordance with connection of the divided feature segments of the two dimensional projected section data, and creating two dimensional sketch data.