Patents by Inventor Charles W. Hull

Charles W. Hull has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11833757
    Abstract: A three-dimensional (3D) printing system for manufacturing a 3D article includes a resin vessel, a build tray, a movement mechanism, a light engine, a housing, a gas handling system, and a controller. The resin vessel includes a transparent sheet on a lower side. The housing defines two chambers including an upper chamber and a lower chamber. The upper chamber is in fluidic communication with the resin contained by the resin vessel. The lower chamber is in fluid communication with a lower surface of the transparent sheet. The controller is configured to (a) operate the gas handling system to reduce and control a partial pressure of oxygen in the upper and lower chambers, (b) operate the movement mechanism and the light engine to form the 3D article in a layer-by-layer manner.
    Type: Grant
    Filed: April 14, 2022
    Date of Patent: December 5, 2023
    Assignee: 3D SYSTEMS, INC.
    Inventors: John Stockwell, Pingyong Xu, Peter Scott Turner, Charles W. Hull
  • Patent number: 11718030
    Abstract: Methods and apparatus are provided for controlling the temperature of powders in a powder-based additive manufacturing system using spatial light modulation. Powder layer temperatures can be measured and selectively controlled using a radiation source comprising a spatial light modulator. The spatial light modulator applies a visible light radiation and/or IR radiation. In addition to controlling the pre-fused temperature of the powder in the image plane, the spatial light modulator can also apply the radiation to fuse the powder.
    Type: Grant
    Filed: December 18, 2017
    Date of Patent: August 8, 2023
    Assignee: 3D SYSTEMS, INC
    Inventor: Charles W. Hull
  • Publication number: 20220339873
    Abstract: A three-dimensional (3D) printing system for manufacturing a 3D article includes a resin vessel, a build tray, a movement mechanism, a light engine, a housing, a gas handling system, and a controller. The resin vessel includes a transparent sheet on a lower side. The housing defines two chambers including an upper chamber and a lower chamber. The upper chamber is in fluidic communication with the resin contained by the resin vessel. The lower chamber is in fluid communication with a lower surface of the transparent sheet. The controller is configured to (a) operate the gas handling system to reduce and control a partial pressure of oxygen in the upper and lower chambers, (b) operate the movement mechanism and the light engine to form the 3D article in a layer-by-layer manner.
    Type: Application
    Filed: April 14, 2022
    Publication date: October 27, 2022
    Inventors: John Stockwell, Pingyong Xu, Peter Scott Turner, Charles W. Hull
  • Patent number: 11305480
    Abstract: There is provided a 3D printing system, methods, and materials for the 3D printing of objects that include a cured hydrogel material, an uncured hydrogel material, and a support material. The cured hydrogel material may define a scaffold for organs or other biological structures. The 3D printing system selectively deposits the hydrogel material and support material, dries the hydrogel material, and selectively applies a catalyst to the hydrogel material to selectively cure the hydrogel material. Once the 3D printing has completed, the uncured hydrogel material may be drained and the support material may be melted or dissolved leaving a scaffold of cured hydrogel material that may be infused with living cells of the desired organ or biological structure.
    Type: Grant
    Filed: April 8, 2020
    Date of Patent: April 19, 2022
    Assignee: 3D Systems, Inc.
    Inventor: Charles W. Hull
  • Patent number: 11241823
    Abstract: A three dimensional printing system for manufacturing a three dimensional article includes a build platform, a light engine, and a controller. The build platform is coupled to a vertical positioning apparatus. The light engine is configured to generate and scan a columnar array of light spots across a build plane. The columnar array of light spots are arranged along a second axis. The light spots are scanned along a first axis. The build plane is laterally defined by mutually perpendicular X and Y axes. In the build plane, the first axis is parallel to the X-axis.
    Type: Grant
    Filed: July 10, 2019
    Date of Patent: February 8, 2022
    Assignee: 3D Systems, Inc.
    Inventors: Evgeny Korol, Charles W. Hull
  • Publication number: 20200230939
    Abstract: There is provided a 3D printing system, methods, and materials for the 3D printing of objects that include a cured hydrogel material, an uncured hydrogel material, and a support material. The cured hydrogel material may define a scaffold for organs or other biological structures. The 3D printing system selectively deposits the hydrogel material and support material, dries the hydrogel material, and selectively applies a catalyst to the hydrogel material to selectively cure the hydrogel material. Once the 3D printing has completed, the uncured hydrogel material may be drained and the support material may be melted or dissolved leaving a scaffold of cured hydrogel material that may be infused with living cells of the desired organ or biological structure.
    Type: Application
    Filed: April 8, 2020
    Publication date: July 23, 2020
    Inventor: Charles W. Hull
  • Publication number: 20200016824
    Abstract: A three dimensional printing system for manufacturing a three dimensional article includes a build platform, a light engine, and a controller. The build platform is coupled to a vertical positioning apparatus. The light engine is configured to generate and scan a columnar array of light spots across a build plane. The columnar array of light spots are arranged along a second axis. The light spots are scanned along a first axis. The build plane is laterally defined by mutually perpendicular X and Y axes. In the build plane, the first axis is parallel to the X-axis.
    Type: Application
    Filed: July 10, 2019
    Publication date: January 16, 2020
    Inventors: Evgeny Korol, Charles W. Hull
  • Publication number: 20180186074
    Abstract: Methods and apparatus are provided for controlling the temperature of powders in a powder-based additive manufacturing system using spatial light modulation. Powder layer temperatures can be measured and selectively controlled using a radiation source comprising a spatial light modulator. The spatial light modulator applies a visible light radiation and/or IR radiation. In addition to controlling the pre-fused temperature of the powder in the image plane, the spatial light modulator can also apply the radiation to fuse the powder.
    Type: Application
    Filed: December 18, 2017
    Publication date: July 5, 2018
    Inventor: Charles W. Hull
  • Publication number: 20170217091
    Abstract: There is provided a 3D printing system, methods, and materials for the 3D printing of objects that include a cured hydrogel material, an uncured hydrogel material, and a support material. The cured hydrogel material may define a scaffold for organs or other biological structures. The 3D printing system selectively deposits the hydrogel material and support material, dries the hydrogel material, and selectively applies a catalyst to the hydrogel material to selectively cure the hydrogel material. Once the 3D printing has completed, the uncured hydrogel material may be drained and the support material may be melted or dissolved leaving a scaffold of cured hydrogel material that may be infused with living cells of the desired organ or biological structure.
    Type: Application
    Filed: January 27, 2017
    Publication date: August 3, 2017
    Inventor: Charles W. Hull
  • Publication number: 20160332368
    Abstract: A solid imaging apparatus and method employing levels of exposure varied with gray scale or time or both of digitally light projected image of a cross-section of a three-dimensional object on a solidifiable photopolymer build material. The gray scale levels of exposure of projected pixels permits the polymerization boundaries in projected boundary pixels to be controlled to achieve preserved image features in a three-dimensional object and smooth out rough or uneven edges that would otherwise occur using digital light projectors that are limited by the number of pixels in an image projected over the size of the image. Software is used to control intensity parameters applied to pixels to be illuminated in the image projected in the cross-section being exposed in the image plane.
    Type: Application
    Filed: July 28, 2016
    Publication date: November 17, 2016
    Inventors: Thomas Alan Kerekes, Jouni P. Partanen, Yong Chen, Charles W. Hull
  • Patent number: 9415544
    Abstract: A solid imaging apparatus and method employing levels of exposure varied with gray scale or time or both of digitally light projected image of a cross-section of a three-dimensional object on a solidifiable photopolymer build material. The gray scale levels of exposure of projected pixels permits the polymerization boundaries in projected boundary pixels to be controlled to achieve preserved image features in a three-dimensional object and smooth out rough or uneven edges that would otherwise occur using digital light projectors that are limited by the number of pixels in an image projected over the size of the image. Software is used to control intensity parameters applied to pixels to be illuminated in the image projected in the cross-section being exposed in the image plane.
    Type: Grant
    Filed: August 29, 2006
    Date of Patent: August 16, 2016
    Assignee: 3D Systems, Inc.
    Inventors: Thomas Alan Kerekes, Jouni P. Partanen, Yong Chen, Charles W. Hull
  • Patent number: 8703037
    Abstract: A solid imaging apparatus and method employing sub-pixel shifting in multiple exposures of the digitally light projected image of a cross-section of a three-dimensional object on a solidifiable liquid medium. The multiple exposures provide increased resolution, preserving image features in a three-dimensional object and smoothing out rough or uneven edges that would otherwise be occur using digital light projectors that are limited by the number of pixels in an image projected over the size of the image. Algorithms are used to select pixels to be illuminated within the boundary of each image projected in the cross-section being exposed.
    Type: Grant
    Filed: June 9, 2010
    Date of Patent: April 22, 2014
    Assignee: 3D Systems, Inc.
    Inventors: Charles W. Hull, Jouni P. Partanen, Charles R. Sperry, Patrick Dunne, Suzanne M. Scott, Dennis F. McNamara, Chris R. Manners
  • Patent number: 8568646
    Abstract: There is provided methods and apparatus for compensation of intensity profiles of imagers used in three-dimensional modelers. The intensity profile of the actinic radiation projected from the imager is determined by a variety of techniques, including but not limited to manually operated sensors, exposed and scanned actinic radiation-sensitive paper, and intensity profilers. Once the intensity profile of the imager is determined, each layer of the solidifiable liquid material is cured by projecting a plurality of patterns (as opposed to a single pattern) defining the two-dimensional cross-section of the part being cured. The patterns vary in duration, number, and/or shape to correlate to the intensity profile so that a single layer of selectively cured solidifiable liquid material is cured with a substantially equivalent (or otherwise controlled) amount of actinic radiation per unit of surface area to provide generally controlled and consistent part quality.
    Type: Grant
    Filed: September 21, 2011
    Date of Patent: October 29, 2013
    Assignee: 3D Systems, Inc.
    Inventors: Hongqing V. Wang, Soon-Chun Kuek, Charles W. Hull, Richard Ora Gregory, II, Thomas Alan Kerekes
  • Patent number: 8465689
    Abstract: A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build.
    Type: Grant
    Filed: July 5, 2011
    Date of Patent: June 18, 2013
    Assignee: 3D Systems, Inc.
    Inventors: Charles R. Sperry, Dennis F. McNamara, Jr., Suzanne M. Scott, Charles W. Hull, Mehdi Mojdeh
  • Patent number: 8285411
    Abstract: Methods for generating supports (30) for parts (50) produced by solid freeform fabrication (“SFF”) are disclosed. The method includes defining a plurality of layers (L) that make up the part, and for each layer, determining those regions (R) that require support. The method also includes merging the regions for the different layers (L) into one or more common regions that require support, and providing at least one support for each of the one or more common regions. The result is that fewer supports are used as compared to conventional SFF fabrication methods.
    Type: Grant
    Filed: September 21, 2011
    Date of Patent: October 9, 2012
    Assignee: 3D Systems, Inc.
    Inventors: Charles W. Hull, Rajeev Kulkarni, Medhi Mojdeh, Hongqing V. Wang, John Corbin West
  • Patent number: 8221671
    Abstract: A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build.
    Type: Grant
    Filed: September 17, 2007
    Date of Patent: July 17, 2012
    Assignee: 3D Systems, Inc.
    Inventors: Charles W. Hull, Jouni Partanen, Charles R. Sperry, Suzanne M. Scott, Dennis F. McNamara, Jr.
  • Patent number: 8105066
    Abstract: A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build.
    Type: Grant
    Filed: September 17, 2007
    Date of Patent: January 31, 2012
    Assignee: 3D Systems, Inc.
    Inventors: Charles R. Sperry, Dennis F. McNamara, Jr., Suzanne M. Scott, Jason A. Rittenhour, Charles W Hull, Mehdi Mojdeh
  • Publication number: 20120007288
    Abstract: There is provided methods and apparatus for compensation of intensity profiles of imagers used in three-dimensional modelers. The intensity profile of the actinic radiation projected from the imager is determined by a variety of techniques, including but not limited to manually operated sensors, exposed and scanned actinic radiation-sensitive paper, and intensity profilers. Once the intensity profile of the imager is determined, each layer of the solidifiable liquid material is cured by projecting a plurality of patterns (as opposed to a single pattern) defining the two-dimensional cross-section of the part being cured. The patterns vary in duration, number, and/or shape to correlate to the intensity profile so that a single layer of selectively cured solidifiable liquid material is cured with a substantially equivalent (or otherwise controlled) amount of actinic radiation per unit of surface area to provide generally controlled and consistent part quality.
    Type: Application
    Filed: September 21, 2011
    Publication date: January 12, 2012
    Inventors: Hongqing V. Wang, Soon-Chun Kuek, Charles W. Hull, Richard Ora Gregory, II, Thomas Alan Kerekes
  • Publication number: 20120010741
    Abstract: Methods for generating supports (30) for parts (50) produced by solid freeform fabrication (“SFF”) are disclosed. The method includes defining a plurality of layers (L) that make up the part, and for each layer, determining those regions (R) that require support. The method also includes merging the regions for the different layers (L) into one or more common regions that require support, and providing at least one support for each of the one or more common regions. The result is that fewer supports are used as compared to conventional SFF fabrication methods.
    Type: Application
    Filed: September 21, 2011
    Publication date: January 12, 2012
    Inventors: Charles W. Hull, Rajeev Kulkarni, Medhi Mojdeh, Hongqing V. Wang, John Corbin West
  • Publication number: 20110272857
    Abstract: A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build.
    Type: Application
    Filed: July 5, 2011
    Publication date: November 10, 2011
    Inventors: Charles R. Sperry, Dennis F. McNamara, JR., Suzanne M. Scott, Charles W. Hull, Mehdi Mojdeh