Abstract: Techniques are described for generating a support structure that connects to a part while avoiding connecting to regions that include one or more less desirable features, such as at edges, corners and/or high detail regions. A computing device may be configured to identify regions of the surface of a part that contain less desirable surface features, and exclude and/or disfavor those regions for connection to a support structure when generating the support structure. In some embodiments, regions containing less desirable surface features can be defined by a user, such as via a graphical user interface displaying a three-dimensional (3D) representation of a part to be fabricated.
Abstract: Techniques are described to gather information from an end user relating to fabrication process failures in a standardized manner. This information may be provided to an additive fabrication device manufacturer and analyzed by the manufacturer. Analysis may include identifying patterns in the data to identity problems relating to an additive fabrication device, software used to operate the device and/or user operations. Identification of such patterns may aid in selecting and/or generating support solutions to be provided the end user, or to improve the additive fabrication device and/or software.
Type:
Application
Filed:
November 5, 2025
Publication date:
March 5, 2026
Applicant:
FORMLABS, INC.
Inventors:
Edward Tekeian, Benjamin FrantzDale, Jacob A. Misra, Kyle P. McNulty
Abstract: Techniques are described for consistently moving powder from a hopper into a trough for subsequent delivery into a build area of an additive fabrication system. A powder conveyer may be arranged at least partially within the hopper and configured to be actuated to transfer powder to the trough. The powder conveyer may be formed as a screw conveyor, for example. Such techniques do not require complex closed-loop control systems and may be effective irrespective of the flowability of the powder. In at least some cases, there may be no production of excess powder because the amount of powder that is metered into the trough may be precisely controlled to be the amount needed for recoating.
Type:
Grant
Filed:
March 28, 2023
Date of Patent:
March 3, 2026
Assignee:
Formlabs, Inc.
Inventors:
Luke Plummer, Maria Rosa Ruiz, Carlos Ruiz-Vargas, Robert Morgan, Joseph Johnson, Gregory Connor Evans
Abstract: Techniques are described to gather information from an end user relating to fabrication process failures in a standardized manner. This information may be provided to an additive fabrication device manufacturer and analyzed by the manufacturer. Analysis may include identifying patterns in the data to identity problems relating to an additive fabrication device, software used to operate the device and/or user operations. Identification of such patterns may aid in selecting and/or generating support solutions to be provided the end user, or to improve the additive fabrication device and/or software.
Type:
Grant
Filed:
December 22, 2023
Date of Patent:
November 25, 2025
Assignee:
Formlabs, Inc.
Inventors:
Edward Tekeian, Benjamin FrantzDale, Jacob A. Misra, Kyle P. McNulty
Abstract: Techniques for preventing contamination of an electronic component via gas flow are described. According to some aspects, an electronic component module is configured to provide gas flow past and away from an electronic component such that thermal and material exchange is limited between the electronic component module and a coupled system. In some embodiments, the coupled system may be a portion of an additive fabrication device. As a result, a reduced number of contaminants may adhere to the electronic component, extending its lifespan and reducing maintenance.
Abstract: Techniques for improved efficiency of sintering in additive fabrication are described. According to some aspects, mechanisms for depositing and leveling source material are combined with a mechanism for heating the material. In some embodiments, one or more heating elements may be arranged to lead and/or follow a material deposition mechanism such that heat may be applied to the build region in concert with deposition of material. As a result of this technique, the heating and depositing steps may be performed closer together in time and/or heat may be applied more directly to the material than in conventional systems. As a result, greater control over material temperature may be achieved, thereby avoiding excess temperature exposure and subsequent undesirable changes to the material.
Type:
Application
Filed:
March 27, 2025
Publication date:
August 7, 2025
Applicant:
FORMLABS, INC.
Inventors:
Eduardo Torrealba, Steven Thomas, Christopher Auld
Abstract: A curing system for an additive fabrication system includes a light source, a liquid crystal cell, and a first polarizer. The light source is configured to emit light at a wavelength suitable for curing a material. The liquid crystal cell is configured to receive the light from the light source. The first polarizer comprises a polyvinyl alcohol (PVA) matrix and organic dyes impregnated into the PVA matrix.
Type:
Application
Filed:
March 24, 2025
Publication date:
July 3, 2025
Applicant:
FORMLABS, INC.
Inventors:
Andrew Goldman, Hayley Whelan, Henry Whitney, Maxim Lobovsky, Mehmet Dogan
Abstract: An improved additive fabrication device and a build platform are provided. The additive fabrication device is configured to form layers of material on a build surface. The additive fabrication device comprising: a build platform comprising: a rigid structure; an actuation structure attached to the rigid structure, wherein the actuation structure comprises one or more sheet handles and a flexible sheet, and wherein a first surface of the flexible sheet forms a build surface on which the additive fabrication device is configured to form layers of materials; and the one or more sheet handles are configured to be actuated to apply a force to the flexible sheet while at least a part of the actuation structure remains attached to the rigid structure, to deform at least a part of the flexible sheet away from the rigid structure.
Type:
Application
Filed:
December 4, 2024
Publication date:
May 29, 2025
Applicant:
FORMLABS, INC.
Inventors:
Mark J. Frykman, Mark J. Ripoll, Lawrence Cheung, Nathan Jeffrey, Yoav Reches, Derek J. Vilim
Abstract: Techniques for improved efficiency of sintering in additive fabrication are described. According to some aspects, mechanisms for depositing and leveling source material are combined with a mechanism for heating the material. In some embodiments, one or more heating elements may be arranged to lead and/or follow a material deposition mechanism such that heat may be applied to the build region in concert with deposition of material. As a result of this technique, the heating and depositing steps may be performed closer together in time and/or heat may be applied more directly to the material than in conventional systems. As a result, greater control over material temperature may be achieved, thereby avoiding excess temperature exposure and subsequent undesirable changes to the material.
Type:
Grant
Filed:
August 16, 2021
Date of Patent:
April 29, 2025
Assignee:
Formlabs, Inc.
Inventors:
Eduardo Torrealba, Steven Thomas, Christopher Auld
Abstract: Techniques are described for fabricating parts in an additive fabrication device from a light-scattering build material, such as ceramic build materials. An additive fabrication device may comprise a container for holding a photo-polymerizable build material containing a light-scattering species such as ceramic particles. The bottom of the tank may comprise one or more light-absorbing additives that absorb a portion of the actinic radiation used to cure the build material. The one or more light-absorbing additives may include an absorptive dye, including inorganic pigments like carbon black, organic dyes, or other species.
Abstract: According to some aspects, techniques are provided for identifying contamination in additive fabrication devices by measuring light interacting with the contamination using one or more light sensors. Contamination located between a light source and a target of a light source can affect the uniformity and intensity of the light source when incident upon the target. For instance, in an inverse stereolithography device, contamination located between a light source and a liquid photopolymer resin that is to be cured can affect the quality of the fabricated object when the light is scattered or blocked by the contamination. Identifying the presence of contamination between the light source and the liquid photopolymer resin and alerting the user prior to initiating a fabrication process may increase the quality of the resulting fabricated object and improve the user experience by saving time and photocurable liquid.
Type:
Grant
Filed:
June 20, 2023
Date of Patent:
April 1, 2025
Assignee:
Formlabs, Inc.
Inventors:
Shane Wighton, Andrew M. Goldman, Henry Whitney, Justin Keenan
Abstract: According to some aspects, an additive fabrication device and a build platform suitable for use within an additive fabrication device are provided. The build platform may include a build surface on which material may be formed by the additive fabrication device when the build platform is installed within the additive fabrication device. According to some embodiments, the build platform may include a flexible build layer and at least one removal mechanism configured to be actuated to apply a force to the flexible build layer. Such actuation may cause the flexible build layer to deform, thereby enabling separation of material adhered to the build surface from the build platform. According to some embodiments, the build platform may comprise a restorative mechanism that acts to return the flexible build layer to a flat state so that subsequent additive fabrication may form material on a flat build surface.
Abstract: A method and system for tensioning film tank in a liquid photopolymer container designed for use in a stereolithography (SLA) additive fabrication device is disclosed. The liquid photopolymer container comprises a tank frame, a film clamp that attaches to the tank frame and secures a film between the clamp and the tank frame, and a film positioned between the clamp and the bottom surface of the tank frame. The film clamp and the tank frame include raised-features and recesses that mate together to increase the grip on the film.
Abstract: An improved additive fabrication device and a build platform are provided. The additive fabrication device is configured to form layers of material on a build surface. The additive fabrication device comprising: a build platform comprising: a rigid structure; an actuation structure attached to the rigid structure, wherein the actuation structure comprises one or more sheet handles and a flexible sheet, and wherein a first surface of the flexible sheet forms a build surface on which the additive fabrication device is configured to form layers of materials; and the one or more sheet handles are configured to be actuated to apply a force to the flexible sheet while at least a part of the actuation structure remains attached to the rigid structure, to deform at least a part of the flexible sheet away from the rigid structure.
Type:
Grant
Filed:
December 11, 2023
Date of Patent:
December 31, 2024
Assignee:
Formlabs, Inc.
Inventors:
Mark J. Frykman, Mark J. Ripoll, Lawrence Cheung, Nathan Jeffery, Yoav Reches, Derek J. Vilim
Abstract: Techniques to allow an additive fabrication device to dynamically adjust the size of a post metering volume for adjusting pressure of source material in the volume. These techniques may allow for greater control of material extrusion through an orifice and thereby mitigate or avoid issues of lag time between starting and/or stopping extrusion and/or in which there is unwanted emission of source material through the orifice. In some cases, techniques for adjusting the size of the post metering volume may include operating an actuator arranged in a channel that is coupled to the post metering volume. In some cases, techniques for adjusting the size of the post metering volume may include having a stator that is at least partially arranged within a chamber that defines the post metering volume and is free to move within the chamber.