Abstract: An additive manufacturing technique uses digital mask-based illumination and a polar-based build environment for increased throughput. In one embodiment, the build environment comprises a rotating element having a surface. A coater is configured to deposit photopolymer material on the rotating element at a given flow rate. As the element rotates and the coater deposits the photopolymer material, a radiation source of an image scanning system projects an array of point sources (an image) onto the photopolymer material for an exposure time to cure a given layer. As the photopolymer material is deposited layer-upon-layer, and for each layer, a control system adjusts a relative position of the coater with respect to the surface, adjusts a speed of rotation of the rotating element, and maintains the flow rate and the exposure time constant.

Abstract: SLA-based additive manufacturing using radiation-curable foams enables the production by 3D printing of lightweight parts having desirable physical and functional attributes. A representative method of manufacturing such items includes processing a radiation-curable resin in liquid form to produce a stable, non-aqueous radiation-curable foam, on-demand deposition of the foam at a build layer of a build surface within a 3D printer, and then curing the non-aqueous radiation-curable foam to produce a layer of a 3D build item. Processing the resin typically includes agitation, mixing, shaking, gas injection, ultrasonic stimulation, or combinations thereof. 3D articles of manufacture made by the above-described manufacturing process are also provided.

Abstract: A method of making a polyimide (PI)-based material. In one embodiment, the method begins by dispersing a polyamic acid (PAA) oligomer and photo-initiator into a photo-reactive monomer to form a liquid resin. In contrast to the above-described prior art, the liquid resin is substantially devoid of any non-reactive solvents. Electromagnetic radiation is then applied (e.g., in a 3D printing operation) to solidify the liquid resin and to substantially form a interpenetrating polymer network (IPN) in which the PAA oligomer is entangled within the network formed by the photo-reactive monomer but remains substantially independent and un-crosslinked from the PAA oligomer. Thereafter, the PAA-based IPN is thermally cycled to form a polyimide-based IPN.