Abstract: Systems and methods of monitoring solidification quality and automatic correcting any detected defect in additive manufacturing are described. The present disclosure includes a build station for manufacturing one or more parts and a controller having one or more computer-vision based system coupled to the build station. One or more camera is provided to obtain a plurality of images of the solidified parts at predetermined settings. The present disclosure introduces a predictive model trained by machine learning algorithm, the predictive model calculates level of solidification quality of a manufactured part and build parameters value to be adjusted. The present disclosure introduces a plurality of validation coupons having various shapes to enhance more accuracy in manufacturing, wherein the validation coupons further include block data which is distributed to electronic ledger system.

Abstract: A support fixture is provided for forming a three dimensional article of manufacture onto a lower build surface thereof. The formation of the three dimensional article occurs in a resin vessel containing photocurable resin. The resin vessel includes a transparent sheet that forms a lower bound for the resin. The support fixture includes an interface fixture and a replaceable support. The interface fixture includes an upper portion having alignment and gripping features, a lower portion surrounding a central opening and including a plurality of attachment features, and a side wall coupling the upper and lower portions. The replaceable support includes a planar portion having a lower surface (providing the lower build surface) for attachment of the three dimensional article of manufacture and a peripheral support portion including complementary attachment features engaging the attachment features when the peripheral support portion is mounted to the lower portion of the interface fixture.

Abstract: A three dimensional printing system includes a vertical support, a support plate, a resin vessel, and an interface mechanism. The support plate extends away from the vertical support along a first lateral axis from a proximal end to a distal end. The resin vessel is disposed above the support plate and includes a pair of latch features disposed at opposing ends of the resin vessel relative to a second lateral axis. The interface mechanism includes a pair of latches and a movable plate. The pair of latches are disposed adjacently to the opposed ends of the resin vessel. The movable plate is configured to engage the pair of latches with a single downward movement of the movable plate. In response to the engagement by the movable plate, the latches engage the latch features of the resin vessel.

Abstract: A three dimensional (3D) printing system includes a print engine, a first powder handling module, a sieve, a second powder handling module, and a controller. The controller operates the print engine to fabricate 3D articles of manufacture. The controller operates the first powder handling module to transfer excess powder from the print engine to the first powder handling module and to receive new powder. The first powder handling module dispenses powder to the sieve. The controller operates the second handling module to transfer powder from the sieve to the second powder handling module. The second powder handling module provides powder to the print engine.

Abstract: A device is provided for layered manufacture of at least a three-dimensional product by an additive manufacturing technique based on a powder. The invention therefore relates to a device for the layered manufacturer of a product based on a powder, in particular a metal powder. This device is fitted with a build chamber with a vertically movable build platform on which said product is manufactured and contains a powder dispenser for application of the successive powder layers on the build platform in a horizontal build surface. The powder dispenser can be moved back and forth over the build surface along a horizontal dispensing direction in order to apply said powder layers. Moreover, the device contains a hopper that must contain said powder in order to supply powder to the powder dispenser. This hopper has a bottom with a dosing opening that lets out into the build chamber and that works in combination with a dosing valve.

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: A three dimensional printing system includes a resin vessel, a light engine, and a fluid spill containment vessel. The resin vessel is for containing resin and has a transparent sheet on a lower side that provides a lower bound for the resin. The light engine is disposed below the resin vessel for projecting pixelated light up through the transparent sheet. The fluid spill containment vessel is disposed between the resin vessel and the light engine to capture resin that spills from the resin vessel. The fluid spill containment vessel includes a housing for containing the spilled resin, a transparent window for allowing the pixelated light to project up through the fluid spill containment vessel and to the transparent sheet, and a fluid barrier wall surrounding at least part of the clear window and configured to reduce an amount of spilled resin required to occlude the pixelated light.

Abstract: Methods for volume rendering of 3D object data are provided. The methods can include classifying 3D object data and determining a transfer function to use to render the 3D object data. based on the classification; incrementally determining voxels to render from the 3D object data; and/or determining a grid that represents the voxels and rendering based on the voxel grid.

Abstract: A three dimensional printing system includes a plurality of light engines, an alignment article, a camera, and a controller. The plurality of light engines define a corresponding plurality of build fields which overlap and define a build plane. The alignment article carries an alignment calibration image and is configured to be mounted in the three dimensional printing system with the alignment calibration image proximate to the build plane and in facing relation with the plurality of light engines. The alignment calibration image defines a dark field with an array of reflective alignment targets. The camera is mounted to be in facing relation to the alignment calibration image. The controller is configured to operate at least the light engines and the camera to individually align the light engines to the alignment calibration image.

Abstract: Methods for volume rendering of 3D object data are provided. The methods can include classifying 3D object data and determining a transfer function to use to render the 3D object data based on the classification; incrementally determining voxels to render from the 3D object data; and/or determining a grid that represents the voxels and rendering based on the voxel grid.

Abstract: Thermoplastic 3D objects are printed directly onto permeable materials with a high strength bond. The 3D object can be attached to the permeable material at one side where the bottom layer of the 3D object can be attached to the permeable material or alternatively, at an internal layer where portions of the 3D object are on opposite sides of the permeable material. In order to improve the adhesion of the 3D object to the permeable material, the bonding layer of the liquid thermoplastic material that is printed directly onto the permeable material can be deposited at modified 3D printer settings that can include a hotter than normal material deposition temperature. Additional build layers of the liquid thermoplastic material are printed on the bonding layer to complete the 3D objects.

Abstract: A three dimensional printing system includes a powder delivery system and a controller. The powder delivery system includes a cartridge, a powder transfer assembly, a vacuum source, and source of inert gas. The cartridge includes a lower portion defining a lower cavity containing powder and an upper portion. The powder transfer assembly includes a cowling and a loader suction tube that extends through the cowling. The controller is configured to: (1) lower the cowling into sealing engagement with the upper portion of the cartridge whereby an upper cavity is defined between the cowling and the upper portion of the cartridge, (2) operate the source of inert gas to positively pressurize the upper cavity, and (3) lower the loader suction tube into the powder while operating the vacuum source to extract the powder.

Abstract: A three dimensional printing system includes a vertical support, a support plate, a resin vessel, a carriage, and a support fixture. The support plate has a proximal end affixed to the vertical support and extends along a first lateral axis to a distal end. The resin vessel is supported by the support plate and has a rear side that is proximate to the proximal end of the support plate. The resin fluid outlet is supported over the rear side of the resin vessel. The carriage is configured to be translated vertically along the vertical support. A pair of fixture receiving arms extend from the carriage along the first lateral axis from a proximal to a distal end. The fixture receiving arms are spaced apart along a second lateral axis that is perpendicular to the first lateral axis. The support fixture is supported by the two fixture receiving arms.

Abstract: A system is configured to form a three dimensional (3D) object having multiple zones within the three dimensional object. The zones differ from each other according to system operational parameters. The system is operable to perform a method including: (1) receiving a solid model file, (2) generating a shell of the 3D object based on the file, (3) dividing the shell into zones, (4) defining or selecting parameters for forming the zones, (5) forming layer data defining layers of the 3D object, and creating a tool path from the layer data including merging layer data for the zones.

Abstract: A three dimensional printing system includes a support plate, a resin vessel, and one or more mechanical features. The support plate includes a ridge surrounding a first central opening. The resin vessel includes a vessel body defining an inner edge surrounding a second central opening and a transparent sheet that closes the central opening to define a lower bound for a body of resin to be contained within the resin vessel. The one or more mechanical features are configured to align and secure the resin vessel relative to the support plate whereby the ridge engages a lower surface of the transparent sheet to tension the transparent sheet and the ridge is laterally recessed inwardly relative to the inner edge of the vessel body.

Abstract: A support fixture is provided for forming a three dimensional article of manufacture onto a lower build surface thereof. The formation occurs in a resin vessel containing photocurable resin. The resin vessel includes a transparent sheet that forms a lower bound for the resin. The support fixture includes a lower planar portion, an upper portion, and a side wall coupling the lower planar portion to the upper portion. The lower planar portion defines a dense array of small openings that minimize a fluid drag of lateral resin motion when the lower build surface is proximate to the transparent sheet. The upper portion is for providing alignment and support within the three dimensional printing system. A plurality of large openings formed along the side wall that individually have a cross sectional area that is equal to a combined cross sectional area of a plurality of the small openings.

Abstract: A three dimensional (3D) printing system includes an ink cartridge providing ink to a printhead and a controller. The ink cartridge also includes a flag material and a sensor component. The ink has a low dielectric constant and defines an upper surface having a vertical position defining an ink level. The flag material has a high dielectric constant and is disposed upon the upper surface of the ink. The sensor component includes a vertical arrangement of electrodes proximate to the ink. The controller is coupled to the sensor electrodes and is configured to: (1) scan sensor electrodes to determine a capacitance between adjacent pairs of electrodes, (2) identify at least one pair of electrodes having a peak capacitance value relative to capacitance values of remaining pairs of electrodes, and (3) estimate the ink level based upon the identification.

Abstract: A three dimensional printing system includes a vertical support, a support plate, a resin vessel, a resin handling module, a latch, and an interface mechanism. The support plate has a proximal end affixed to the vertical support and extends along a first lateral axis to a distal end. The resin vessel is supported by the support plate and includes a vessel body and a transparent sheet. The vessel body has a latch feature formed therein. The resin handling module includes a fluid outlet for dispensing resin into the resin vessel. The interface mechanism is configured to move the latch into engagement with the latch feature and to move the resin handling module from a non-operating position to an operating position whereby the fluid outlet is operably positioned over a portion of the resin vessel.

Abstract: In one aspect, methods of printing a color 3D article are described herein. In some embodiments, a method described herein comprises receiving data representing a surface colorization of the article, and transforming the data representing the surface colorization of the article into voxel data of the article. The voxel data comprises (a) location values and at least one of (b) color values and (c) transparency values for a plurality of columns of voxels normal or substantially normal to a surface of the article. The method further comprises selectively depositing layers of one or more build materials onto a substrate to form the article in accordance with the voxel data. In addition, at least one column of the plurality of columns of voxels exhibits a surface color resulting from a combination of colors of a plurality of voxels of the column.

Abstract: In one aspect, inks for use with a 3D printer are described herein. In some embodiments, an ink described herein comprises a cyclic carbonate monomer and an amine monomer. Further, in some instances, an ink described herein also comprises an ethylenically unsaturated monomer such as a (meth)acrylate. Additionally, an ink described herein, in some cases, further comprises a colorant, such as a molecular dye, a particulate inorganic pigment, or a particulate organic colorant. An ink described herein may also comprise one or more additives selected from the group consisting of inhibitors, stabilizing agents, photoinitiators, and photosensitizers.