Abstract: A 3D printing system includes a build vessel, a carriage, and a light engine. The build vessel includes a vessel base having a downward extending tension ring that tensions a transparent sheet. The transparent sheet laterally bounds a build plane that is defined over orthogonal lateral axis X and Y. The carriage includes a roller that extends between two opposing sides of the tension ring. The roller exerts an upward force on the transparent sheet and the two opposing sides of the tension ring. The vertical constraint of the roller biased against the tension ring provides a location and improved planarity of a supported portion of the transparent sheet adjacent to the roller. The light engine light engine is configured to selectively apply radiation to a projected area of the build plane through the supported portion of the transparent sheet.

Abstract: A method of manufacturing a 3D article includes operating a 3D printing system including an elevator coupled to a vertical movement mechanism, and a distance sensor. The elevator includes an elevator actuator. The vertical movement mechanism is coupled to the elevator. The build platform includes a build plate having a lower surface. The method includes loading the build platform onto the elevator, operating the vertical movement mechanism to lower the lower surface of the build platform into a measurement range with the distance sensor, scanning the distance sensor along a lateral axis, concurrent with scanning the distance sensor, receiving a signal from the distance sensor indicative of a plurality of vertical locations along the lateral axis of the lower surface of the build platform, and operating the elevator actuator to adjust a height of the lower surface of the build platform.

Abstract: A three-dimensional (3D) printing system includes a print engine and a resin vessel. The print engine includes a pair of support plates in facing relation that define a receiving space therebetween. The pair of support plates include a pair of profiled ramps and a pair of hooks extending into the receiving space. An outer surface of the resin vessel includes a plurality of fixed rollers and a pair of cam rollers. The plurality of fixed rollers are configured to partially engage the pair of profiled ramps when the resin vessel is translated into the receiving space. In response to being revolved about the horizontal axis, the pair of cam rollers are configured to engage the pair of hooks and to lift and translate the plurality of fixed rollers into complete engagement with the pair of profiled ramps.

Abstract: A manufacturing system includes an additive manufacturing (AM) system and a fluid supported molding system. The AM system is configured to produce a plastic mold. The fluid supported molding system includes a pressure vessel surrounding a pressure chamber. The pressure vessel is configured to contain a fluid surrounding the mold. The fluid supported molding system also includes a mold material injector configured to inject a mold material into the mold. During the injection of mold material into the mold, the fluid surrounding the mold is configured to resist defection of an outer surface of the mold.

Abstract: A three-dimensional (3D) printing system is configured to print a 3D article in a layer-by-layer manner and includes a vertical beam, an elevator, and a build platform. The elevator is configured for vertical translation along the vertical beam and includes an upper support and a lower support. The lower support includes at least one elevator actuator extending upward from an upper side. The upper support has a lower side including a datum surface in engagement with the actuator. The elevator actuator is configured to modulate a position of the upper side of the upper support. The build platform includes a build plate coupled below a support plate. The build plate has a lower side for formation of the 3D article. The support plate has a lower side that engages the upper side of the upper support of the elevator to support the build platform.

Abstract: In one aspect, inks for use with a three-dimensional printing system are described herein. In some embodiments, an ink described herein is a composite ink. Such a composite ink, in some cases, comprises an optically transparent or substantially transparent carrier ink comprising a curable material; and a colorant dispersed in the carrier ink in an amount of about 0.01 to 5 weight %, based on the total weight of the composite ink.

Abstract: A method of manufacturing a 3D article includes providing a 3D printing system including a rigid base with a vertical beam, an elevator for translation along the vertical beam, the elevator containing an elevator actuator and a force sensor, a vertical movement mechanism, a build platform including a build plate having a lower surface, a build vessel containing photocurable resin, and a controller. The method includes loading the build platform onto the elevator, operating the vertical movement mechanism to translate the lower surface of the build plate through the resin, the photocurable resin exerting a torque upon the elevator, receiving a signal from the force sensor, operating the controller to compute a force-induced angular discrepancy between the lower surface of the build plate and the horizontal plane, and operating the elevator actuator according to the angular discrepancy to level the lower surface of the build plate.

Abstract: Polymerizable liquids are described herein which, in some embodiments, can produce 3D printed articles of high resolution and desirable mechanical properties. In one aspect, a polymerizable liquid comprises an acrylate component, a polymeric additive, and a monomeric curing agent, wherein the acrylate component and monomeric curing agent are copolymerizable upon exposure to light. In being copolymerizable, the acrylate component and monomeric curing agent can form a copolymer. As described father herein, the monomeric curing agent can enable further reaction of the copolymer with one or more crosslinking species to link the copolymer with one more polymeric networks.

Abstract: A surgical guide includes a metal guide and a plastic reference formed by additive manufacturing. The metal guide is configured to engage a bone surface of a first body area. The metal guide includes a main plate and an arm. The main plate has an inner surface customized and shaped to the bone surface. The main plate defines mounting guides for securing the main plate to the bone surface and defines a machining guide for drilling or cutting through the bone surface. The arm is formed to the main plate at a proximal end and extends to a distal end. The plastic reference has a reference surface customized and shaped to a surface of a second body area that is physically separated from the first body area.

Abstract: In the context of additively manufacturing a solid object using extrusion deposition, closed-loop control of flow rate is achieved using a distance measuring tool to scan a surface of a layer that has been deposited using a first flow rate, comparing data from the scan to a desired target value and using a control algorithm to calculate a corrected second flow rate to be applied when depositing a subsequent layer. In some embodiments, the control algorithm is a proportional-integral control algorithm. In some embodiments, a solid object shape may result in some layers having multiple isolated regions and separate closed-loop control instances may be applied to the separate regions.

Abstract: A three-dimensional (3D) printing system includes a build vessel, a build plate, a vertical movement mechanism, a lower light engine, an upper light engine, and a controller. The build vessel is configured to contain a column of photocurable liquid above a transparent sheet. The vertical movement mechanism is configured to vertically position the build plate. The controller is configured to operate the vertical movement mechanism, the lower light engine, and the upper light engine to fabricate: (a) a lower 3D article upon a lower surface of the build platform by selective solidification of the photocurable liquid at the lower build plane using the lower light engine, and (b) an upper 3D article upon an upper surface of the build platform by selective solidification of the photocurable liquid at the upper build plane using the upper light engine.

Abstract: A three-dimensional (3D) printing includes a rigid base, a build vessel supported on the rigid base, and an imaging module. The build vessel includes a lower frame structure, a transparent plate supported by the lower frame structure, a transparent sheet supported above the transparent plate, a vented housing supported by the lower frame structure, a desiccant disposed within the vented housing, and a vessel wall coupled to the lower frame structure. A fixed or variable fluidic region is defined between the transparent plate and the transparent sheet. The vented housing includes openings fluidically communicating with the fluidic region to allow the desiccant to deplete vapor from the fluidic region. The vessel wall and transparent sheet are configured to provide an upward facing reservoir. The imaging module is supported by the rigid base and configured to selectively image the photocurable liquid over a build plane above the transparent sheet.

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: Additives for three-dimensional build materials or inks are described herein which, in some embodiments, can impart one or more structural enhancements to articles printed from the build materials. In one aspect, a polymerizable liquid comprises at least one additive including a plurality of cyclopolymerizable functionalities separated by an aliphatic linker or alkylene oxide linker.

Abstract: In one aspect, waxy build material inks are described herein which, in some embodiments, exhibit desirable print quality and associated mechanical properties for three-dimensional printing applications. A build material ink, in some embodiments, comprises 20-40 wt. % rosin component, 5-35 wt. % non-polar wax component, and 40-65 wt. % alcohol wax component comprising one or more waxes of the formula (CnH2n+1)OH wherein n is an integer from 15 to 40. In another aspect, a build material ink comprises a eutectic mixture including rosin component, a non-polar wax component, and an alcohol wax component comprising one or more waxes of the formula (CnH2n+1)OH wherein n is an integer from 15 to 40.

Abstract: In one aspect, build materials for use with a three-dimensional (3D) printing system are described herein. In some embodiments, a build material described herein comprises an acrylate component, a photoinitiator component, a non-curable absorber component, and water. The photoinitiator component of the build material is operable to initiate curing of the acrylate component and/or other curable materials that may optionally be present when the photoinitiator is exposed to incident curing radiation having a Gaussian distribution of wavelengths and a peak wavelength ?. The build material has a penetration depth (Dp) and a critical energy (Ec) at the wavelength ?. In some embodiments, the Dp is greater than 200 ?m and less than 300 ?m, and the Ec is 3-12 mJ/cm2. In other embodiments, the Dp is greater than 10 ?m and less than 50 ?m, and the Ec is 5-40 mJ/cm2.

Abstract: Compositions for additive manufacturing applications are described herein which, in some embodiments, impart flame resistant and/or flame retardant properties to articles printed or formed from the compositions. The compositions may also impart desirable mechanical properties to the articles. In some embodiments, a composition comprises a sinterable powder or a thermoplastic polymer in an amount of 10-99 wt. %, based on the total weight of the composition, and an intumescent additive in an amount of up to 30 wt. %, based on the total weight of the composition. The intumescent additive comprises a phosphinate component and at least one of (a) a heptazine or melamine-derived component, and (b) a proton donor component.

Abstract: Additives for three-dimensional build materials or inks are described herein which, in some embodiments, can impart flame retardant properties and/or structural enhancements to articles printed from the build materials. In some embodiments, such an additive comprises a compound of Formula I herein, wherein L and Z are ring substituents comprising at least one polymerizable point of unsaturation, and wherein R1 and R2 are independently selected from the group consisting of alkylene and alkenylene, and R3-R6 each represent one to four optional ring substituents, each one of the one to four ring substituents independently selected from the group consisting of alkyl, heteroalkyl, haloalkyl, halo, hydroxyl, alkoxy, amine, amide, and ether, and wherein n is an integer from 1 to 7.

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: In one aspect, inks for use with a three-dimensional (3D) printing system are described herein. In some embodiments, an ink described herein comprises up to 80 wt. % oligomeric curable material; up to 80 wt. % monomeric curable material; up to 10 wt. % photoinitiator; up to 1 wt. % non-curable absorber material; and up to 10 wt. % one or more additional components, based on the total weight of the ink, and wherein the total amount of the foregoing components is equal to 100 wt. %. Additionally, the photoinitiator is operable to initiate curing of the oligomeric curable material and/or the monomeric curable material when the photoinitiator is exposed to incident curing radiation having a peak wavelength ?. Moreover, the ink has a penetration depth (Dp), a critical energy (Ec), and a print through depth (DPT) at the wavelength ? of less than or equal to 2×Dp.