Abstract: A three-dimensional (3D) printing system configured to manufacture a three-dimensional (3D) article includes a vessel configured to contain a photocurable resin, a build plate coupled to the vertical movement mechanism, an imaging subsystem configured to selectively image over a build plane that is above the build plate, a coating subsystem including a plurality (N) of coater blades coupled to a horizontal movement mechanism, the N coater blades defining lateral regions therebetween, and a controller. The controller is configured to operate the vertical movement mechanism to position an upper surface of the build plate or the 3D article one layer thickness below the build plane, operate the horizontal movement mechanism to translate the N coater blades over the build plane and to provide a new layer of resin over the upper surface, and operate the imaging subsystem to selectively irradiate the new layer of resin in the lateral regions.

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 three-dimensional (3D) printing system includes a vessel configured to contain a photocurable resin, a coating subsystem including a coater blade, a build plate coupled to a vertical movement mechanism, an imaging system configured to selectively image the photocurable resin at a build plane, and a controller. The controller is configured to operate the vertical movement mechanism to position an upper surface of the build plate at the build plane, translate a lower edge of the coater blade over the build plane along a scan direction, and concurrent with translating the lower edge of the coater blade, operate the imaging system to selectively image the build plane while maintaining an exclusion zone that includes a digital shadow that translates with the coater blade, the digital shadow includes an area of the coater blade and a fluidic wake area that follows the coater blade.

Abstract: A three-dimensional (3D) printing system includes a vessel, a coating subsystem, a calibration block, and a controller. The vessel is configured to contain a photocurable resin having a resin upper surface. The coating subsystem includes a coater module including a coater blade, a lateral movement mechanism coupled to the coater module, a sensor mounted to the coater module, and a vertical actuator system. The calibration block has a calibration surface. The controller is configured to operate the lateral movement mechanism to position the coater blade over the calibration block, operate the vertical actuator system to lower the coater blade into engagement with the calibration surface of the calibration block, operate the sensor to measure a distance to the calibration block, and store the distance as indicative of a vertical position of a lower edge of the coater blade.

Abstract: A three-dimensional (3D) printing system includes a resin vessel containing photocurable resin, an imaging system, a build plate with a plate upper surface, a vertical positioner, a volume compensator (VC), and a controller. The controller is configured to: (a) operate the VC to maintain a resin upper surface proximate to a build plane, (b) operate the imaging system and the vertical positioner to generate a plurality of base layers upon the plate upper surface, (c) receive a first signal responsive to vertical motion of the resin upper surface, (d) analyze the first signal to determine a metric that is related to an extent of immersion of the plate upper surface below the resin upper surface during formation of the base layers, and (e) operate the imaging system and the vertical positioner to begin generation of the 3D article after the metric has reached a predefined threshold.

Abstract: A three-dimensional (3D) printing system includes a vessel, a coating subsystem, a calibration block, and a controller. The vessel is configured to contain a photocurable resin having a resin upper surface. The coating subsystem includes a coater module including a coater blade, a lateral movement mechanism coupled to the coater module, a sensor mounted to the coater module, and a vertical actuator system. The calibration block has a calibration surface. The controller is configured to operate the lateral movement mechanism to position the coater blade over the calibration block, operate the vertical actuator system to lower the coater blade into engagement with the calibration surface of the calibration block, operate the sensor to measure a distance to the calibration block, and store the distance as indicative of a vertical position of a lower edge of the coater blade.

Abstract: A three-dimensional (3D) printing system includes a vessel, a coating subsystem, a calibration block, and a controller. The vessel is configured to contain a photocurable resin having a resin upper surface. The coating subsystem includes a coater module including a coater blade, a lateral movement mechanism coupled to the coater module, a sensor mounted to the coater module, and a vertical actuator system. The calibration block has a calibration surface. The controller is configured to operate the lateral movement mechanism to position the coater blade over the calibration block, operate the vertical actuator system to lower the coater blade into engagement with the calibration surface of the calibration block, operate the sensor to measure a distance to the calibration block, and store the distance as indicative of a vertical position of a lower edge of the coater blade.

Abstract: A three-dimensional (3D) printing system includes a vessel, a coating subsystem, a calibration block, and a controller. The vessel is configured to contain a photocurable resin having a resin upper surface. The coating subsystem includes a coater module including a coater blade, a lateral movement mechanism coupled to the coater module, a sensor mounted to the coater module, and a vertical actuator system. The calibration block has a calibration surface. The controller is configured to operate the lateral movement mechanism to position the coater blade over the calibration block, operate the vertical actuator system to lower the coater blade into engagement with the calibration surface of the calibration block, operate the sensor to measure a distance to the calibration block, and store the distance as indicative of a vertical position of a lower edge of the coater blade.

Abstract: A three-dimensional printing system for manufacturing a three-dimensional article includes a transparent substrate, a fluid handling system, a support tray, and a light engine. The transparent substrate slopes downwardly from an upper end toward a lower end. The fluid handling system is configured to input photocurable resin at the upper end and to receive the photocurable resin at the lower end. The fluid handling system thereby forms a gravity-driven flowing sheet of resin over an upper surface of the transparent sheet. The support tray is mounted to a movement mechanism. The support tray has a lower face for supporting the three-dimensional article. The lower face is generally parallel to the upper surface of the transparent substrate. The light engine is positioned below the transparent substrate for selectively illuminating the resin along a build plane that is within the resin and parallel to the upper surface of the transparent substrate.

Abstract: A three-dimensional (3D) printing system includes a resin vessel containing photocurable resin, an imaging system, a build plate with a plate upper surface, a vertical positioner, a volume compensator (VC), and a controller. The controller is configured to: (a) operate the VC to maintain a resin upper surface proximate to a build plane, (b) operate the imaging system and the vertical positioner to generate a plurality of base layers upon the plate upper surface, (c) receive a first signal responsive to vertical motion of the resin upper surface, (d) analyze the first signal to determine a metric that is related to an extent of immersion of the plate upper surface below the resin upper surface during formation of the base layers, and (e) operate the imaging system and the vertical positioner to begin generation of the 3D article after the metric has reached a predefined threshold.

Abstract: A three-dimensional printing system is for manufacturing and post-processing a three-dimensional article. The system includes a housing, a blower, and a residue trap. The housing is for surrounding the three-dimensional article during the post process and includes an air inlet and an air outlet. The blower includes an inlet and an outlet. The outlet supplies pressurized air to the air emitting nozzle. The residue trap is coupled between the housing air outlet and the inlet of the blower. The air circulates around a loop from the blower outlet, to the air inlet of the housing, out of the air outlet of the housing, and to the inlet of the blower.

Abstract: A three-dimensional printing system for manufacturing a three-dimensional article includes a transparent substrate, a fluid handling system, a support tray, and a light engine. The transparent substrate slopes downwardly from an upper end toward a lower end. The fluid handling system is configured to input photocurable resin at the upper end and to receive the photocurable resin at the lower end. The fluid handling system thereby forms a gravity-driven flowing sheet of resin over an upper surface of the transparent sheet. The support tray is mounted to a movement mechanism. The support tray has a lower face for supporting the three-dimensional article. The lower face is generally parallel to the upper surface of the transparent substrate. The light engine is positioned below the transparent substrate for selectively illuminating the resin along a build plane that is within the resin and parallel to the upper surface of the transparent substrate.

Abstract: A three-dimensional printing system is for manufacturing and post-processing a three-dimensional article. The system includes a housing, a blower, and a residue trap. The housing is for surrounding the three-dimensional article during the post process and includes an air inlet and an air outlet. The blower includes an inlet and an outlet. The outlet supplies pressurized air to the air emitting nozzle. The residue trap is coupled between the housing air outlet and the inlet of the blower. The air circulates around a loop from the blower outlet, to the air inlet of the housing, out of the air outlet of the housing, and to the inlet of the blower.

Abstract: A post-processing system is configured to receive full support trays from a print engine subsystem. The full support trays individually include an upper rim coupled to a lower face. A three-dimensional article fabricated by the print engine subsystem is attached to the lower face. The post processing subsystem includes a continuous transport mechanism and a plurality of post-process modules. The continuous transport mechanism extends along a lateral Y-axis and includes a pair of synchronized belts that are separated along an X-axis. The pair of belts are for receiving portions of the upper rims of the support trays. The plurality of post-process modules are disposed along the continuous transport mechanism in sequence and at least include a resin removal module followed by a post-cure module.

Abstract: A module for cleaning a three-dimensional article supported by a support tray includes: (1) a housing having an entrance door and an exit door; (2) a continuous transport mechanism that transports the support tray along a lateral Y-axis through the entrance door, through a chamber within the housing, and out the exit door; (3) one or more nozzles configured to apply one or more fluid jets to remove residue from the three-dimensional article.

Abstract: A mounting assembly for accurately positioning, attaching, and supporting a circuit board such as a midplane board within a chassis. The assembly's design facilitates an improved assembly method that includes fastening the board to the chassis so to provide reliable connector mate and rapid assembly. The mounting assembly includes a clamp member) and a spring assembly that act in combination to secure a circuit board onto datum features provided on a chassis and/or its modified and/or lightweight alignment bulkhead, which is part of the new assembly. The new assembly design enables a tight tolerance loop between mating components while also providing a more consistent connector engagement when compared with many prior device designs. In some embodiments, a single fastener (e.g., a nut) is used to attach the clamped and captured circuit board to the chassis. The board is “captured” as it is sandwiched between the modified bulkhead and the clamp.

Abstract: A roller assembly for use in a printer includes a shaft with two ends and a pair of conical rollers. Each of the conical rollers is disposed on the shaft near each of the ends. The roller assembly guides a medium within the printer without damaging a freshly-printed surface of the medium. A printer including the roller assembly and a belt in contact with the roller assembly is also described and claimed.