Abstract: An additive manufacturing system, and associated methods, comprise an image projection system comprising a plurality of image projectors that project a composite image onto a build area within a resin pool. The composite image comprises a plurality of sub-images arranged in an array. The properties of a sub-image and the alignment of the position of the sub image within the composite image can be adjusted using a set of filters comprising an irradiance mask that normalizes irradiance, and a gamma adjustment mask that adjusts sub-image energy based on a reactivity of the resin.

Abstract: Methods of creating additive manufactured parts include selectively dispensing a second composition onto a top surface of a first composition in a vat. The second composition is dispensed in a shape area according to a layer of a part to be created by additive manufacturing. Polymerization components for formation of the layer are kept separate from each other until the dispensing, with at least one of the polymerization components being in the second composition. The top surface is illuminated to expose the first composition and the second composition to light having a polymerization wavelength, thereby causing polymerization of the layer of the part only in the shape area where the second composition was dispensed.

Abstract: An additive manufacturing system, and associated methods, comprise an image projection system comprising a plurality of image projectors that project a composite image onto a build area within a resin pool. The composite image comprises a plurality of sub-images arranged in an array. The properties of each sub-image and the alignment of the position of each sub image within the composite image can be adjusted using a set of filters comprising: 1) an irradiance mask that normalizes irradiance, 2) a gamma adjustment mask that adjusts sub-image energy based on a reactivity of the resin, and 3) a warp correction filter that provides geometric correction.

Abstract: In some embodiments, the techniques described herein relate to photoreactive 3D printing systems and methods. The 3D printing system can include: a moveable print platform; a resin tub with a membrane; resin contained within the resin tub; an illumination system; a force sensor, and a print recipe including information for layers in a 3D printed part to be built on the print platform. The photoreactive 3D printing system can be configured to: project an image through the membrane into the volume of resin using the illumination system; move the print platform in a z-direction; measure a force on the print platform using the force sensor, and update a print platform movement in the print recipe during a printing run based on the force on the print platform.

Abstract: In some embodiments, a photoreactive 3D printing system includes: a moveable print platform; a resin tub comprising a membrane; a tension apparatus; a volume of resin contained within the resin tub; an illumination system; a print platform force sensor; and a print recipe comprising information for layers in a 3D printed part to be built on the print platform. In some embodiments, the photoreactive 3D printing system is configured to: project an image through the membrane at a polymer interface using the illumination system; moving the print platform in a z-direction; apply a tensioning force using the tension apparatus to induce a membrane tension on the membrane; measure an amount of print platform force using the print platform force sensor; and update the print platform movement in the print recipe during a printing run based on the amount of print platform force measured by the print platform force sensor.

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: Methods of producing an additive manufactured part with a smooth surface finish and customized properties include creating a compensated design that serves as a print recipe for an additive manufacturing process for a part, where the creating comprises modifying a desired design with a geometric offset correction to compensate for a first portion of an uncured surface finish material to be retained on the part. A spinning device is provided that has a platform. The part is formed with the additive manufacturing process and secured to the platform, where the part is at least partially wetted with the uncured surface finish material. The platform is rotated, where a second portion of the uncured surface finish material is removed due to forces imparted by the rotating. The uncured surface finish material is chosen to customize a property of the part.

Abstract: Methods of creating additive manufactured parts from expanding foam material include printing a part made of an expandable foam, using an additive manufacturing system. The foam is printed in an unexpanded state and has a closed layer at an external surface of the part. Expansion of the part is controlled, using the additive manufacturing system, wherein the expansion is performed after the printing. Methods also include modeling an expansion of a part made of an expandable foam, and printing the part made of the expandable foam, using an automated additive manufacturing system and according to the modeling. The foam is printed in an unexpanded state and has a closed layer at an external surface of the part.

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: In some embodiments, a photoreactive 3D printing system includes: a moveable print platform; a resin tub comprising a membrane; a tension apparatus; a volume of resin contained within the resin tub; an illumination system; a print platform force sensor; and a print recipe comprising information for layers in a 3D printed part to be built on the print platform. In some embodiments, the photoreactive 3D printing system is configured to: project an image through the membrane at a polymer interface using the illumination system; moving the print platform in a z-direction; apply a tensioning force using the tension apparatus to induce a membrane tension on the membrane; measure an amount of print platform force using the print platform force sensor; and update the print platform movement in the print recipe during a printing run based on the amount of print platform force measured by the print platform force sensor.

Abstract: The present disclosure provides techniques for calibration systems and methods for additive manufacturing systems with multiple image projection. In some embodiments, a method of calibrating two or more image projectors of a photoreactive 3D printing system (PRPS) includes: projecting a sub-image from each of the two or more image projectors; measuring light from an image projector using a light sensor of a calibration system; receiving a signal from the light sensor; processing information from the light sensor; and changing a parameter of a sub-image based on the processed information. In some cases, a PRPS includes a calibration fixture comprising the light sensor. In some cases, a PRPS can be calibrated using a modular calibration fixture comprising the light sensor, wherein the modular calibration fixture can be coupled to the PRPS, leveled and height adjusted, and then a calibration routine can be performed.

Abstract: In some embodiments, a photoreactive 3D printing system and methods comprise providing a system with a resin tub comprising a membrane, wherein the membrane rests on a physical tension element such that increasing downward force on the resin tub induces increasing tension on the membrane. The system also comprises a plurality of sensors comprising a resin bulk temperature sensor, and a print recipe comprising information for each layer in a 3D printed part to be built on the print platform. In some embodiments, a resin bulk temperature is measured, and the information in the print recipe, including information related to the downward force on the resin tub, is updated during a printing run based on the resin bulk temperature measurement. In some embodiments, the print recipe can be updated during a printing run based on input from at least two sensors of the plurality of sensors.

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 stylus having an applied force-sensitive tip-switch is disclosed. The stylus includes a tip-switch responsive to a variable applied force. Control circuitry determines whether the tip-switch has made contact with an object and, if so, the magnitude of the applied force resulting from the contact. The circuitry then encodes a signal that varies with the magnitude of the applied force and transmits the encoded signal to a computing device, enabling the computing device to indicate the two- or three-dimensional path of the tip-switch in the stylus on a computer screen. The circuitry also monitors a manual override switch that activates an encoded override signal for interpretation and use by the computing device while indicating the path of the tip switch on a computer screen.

Abstract: An additive manufacturing system, and associated methods, comprise an image projection system comprising a plurality of image projectors that project a composite image onto a build area within a resin pool. The composite image comprises a plurality of sub-images arranged in an array. The properties of each sub-image and the alignment of the position of each sub image within the composite image can be adjusted using a set of filters comprising: 1) an irradiance mask that normalizes irradiance, 2) a gamma adjustment mask that adjusts sub-image energy based on a reactivity of the resin, and 3) a warp correction filter that provides geometric correction.

Abstract: An additive manufacturing system, and associated methods, comprise an image projection system comprising a plurality of image projectors that project a composite image onto a build area within a resin pool. The composite image comprises a plurality of sub-images arranged in an array. The properties of each sub-image and the alignment of the position of each sub image within the composite image can be adjusted using a stack of filters comprising: 1) an irradiance mask that normalizes irradiance, 2) a gamma adjustment mask that adjusts sub-image energy based on a reactivity of the resin, 3) a warp correction filter that provides geometric correction, and 4) an edge blending bar at one or more sub-image edges.

Abstract: Methods of creating additive manufactured parts include selectively dispensing a second composition onto a top surface of a first composition in a vat. The second composition is dispensed in a shape area according to a layer of a part to be created by additive manufacturing. Polymerization components for formation of the layer are kept separate from each other until the dispensing, with at least one of the polymerization components being in the second composition. The top surface is illuminated to expose the first composition and the second composition to light having a polymerization wavelength, thereby causing polymerization of the layer of the part only in the shape area where the second composition was dispensed.

Abstract: A method and corresponding system for reconstructing the surface geometry of a three-dimensional object is disclosed. The system comprises a cluster of heterogeneous sensors, including a two-dimensional high-resolution camera and a three-dimensional depth camera, and a turntable operable to rotate incrementally. In operation, the turntable is rotated to first and second positions and two-dimensional and three-dimensional data sets are obtained using the two-dimensional high-resolution camera and the three-dimensional depth camera. Corresponding features from the two-dimensional data sets are identified and used to identify the same corresponding features in the three-dimensional data sets. The three-dimensional corresponding features are used to calculate a three-dimensional homography, which is used to align the three-dimensional data sets. Following alignment, a three-dimensional mesh is generated from the aligned data sets.

Abstract: In some embodiments, a photoreactive 3D printing system and methods comprise providing a system with a resin tub comprising a membrane, wherein the membrane rests on a physical tension element such that increasing downward force on the resin tub induces increasing tension on the membrane. The system also comprises a plurality of sensors comprising a resin bulk temperature sensor, and a print recipe comprising information for each layer in a 3D printed part to be built on the print platform. In some embodiments, a resin bulk temperature is measured, and the information in the print recipe, including information related to the downward force on the resin tub, is updated during a printing run based on the resin bulk temperature measurement. In some embodiments, the print recipe can be updated during a printing run based on input from at least two sensors of the plurality of sensors.

Abstract: The present subject matter relates to examples of color calibration of image handling units. In an example, color settings of a flash light unit of a projector unit of a computing system may be calibrated with reference to a target calibration point. The flash light unit may function as an illumination source for an image capturing unit of the computing system. Further, based on the target calibration point and an image captured by the image capturing unit under illumination provided by the flash light unit, the color settings of the image capturing unit may be calibrated to synchronize the color settings of the image capturing unit to the color settings of the flash light unit.