Abstract: A machine vision system and method uses photoluminescence light response of micro-LEDs to identify micro-LEDs (e.g., red, green, or blue) that are used to assemble a micro-LED display. Excitation light (e.g., ultraviolet excitation light) in a wavelength range is illuminated on a random pool of heterogeneous micro-LEDs consisting of materials, for example, that photoluminesce in three different colors-red, green, or blue. The micro-LED is optically excited and will emit either red, green, or blue, photoluminescence light based on the type of the micro-LED. The machine vision system uses a camera device including color response sensors to distinguish micro-LED types. The orientation of the micro-LED can also be detected. The machine vision system, based on the type, location, and orientation of the heterogeneous micro-LEDs, provides image-data based optical feedback to a microassembler system to move the micro-LEDs on a planar working surface according to an electrostatic template.

Abstract: A machine vision system uses lensless near-contact imaging with coherent illumination, or incoherent illumination, and high pixel count large format sensors (e.g., equivalent to at least 20 to 65 mega-pixels) to produce diffraction patterns of the micro-objects or the gray scale images of the micro-objects over a large overall field-of-view of the machine vision system. The machine vision system provides feedback to a microassembler system to position, orient, and assemble microscale devices, such as micro-LEDs, over large working areas. The effective resolution of the machine vision system can be further improved by using grayscale and super-resolution image processing techniques.

Abstract: A machine vision system and method uses photoluminescence light response of micro-LEDs to identify types of micro-LEDs (e.g., red, green, or blue) that are used to assemble a micro-LED display. Excitation light (e.g., ultraviolet excitation light) in a certain wavelength range is illuminated on a random pool of heterogeneous micro-LEDs consisting of materials, for example, that photoluminesce in three different colors-red, green, or blue. The micro-LED is optically excited and will emit either red, green, or blue, photoluminescence light based on the type of the micro-LED. The machine vision system uses a camera device that includes color response sensors to differentiate the type of micro-LED. The orientation of the micro-LED can also be detected. The machine vision system, based on the type, location, and orientation of the heterogeneous micro-LEDs, provides image-data based optical feedback to a microassembler system to move the micro-LEDs on a planar working surface according to an electrostatic template.

Abstract: A machine vision system and method use lensless near-contact imaging with coherent illumination, or incoherent illumination, and high pixel count large format sensors (e.g., equivalent to at least 20 to 65 mega-pixels) to produce diffraction patterns of the micro-objects or the gray scale images of the micro-objects over a large overall field-of-view of the machine vision system. The machine vision system provides feedback to a microassembler system to position, orient, and assemble microscale devices like micro-LEDs over large working areas. The effective resolution of the machine vision system can be further improved through the use of gray scale and super-resolution image processing techniques.

Abstract: A 3D printer includes an ejector device including a substrate and a plurality of ejector conduits on the substrate. Each ejector conduit includes: a first end positioned to accept a print material and a second end including an ejector nozzle. The ejector nozzle includes a first electrode and a second electrode, and a passageway for allowing the print material to flow from the first end to the second end. A current pulse generating system is in electrical connection with the first electrode and the second electrode of the plurality of ejector conduits. A magnetic field source is proximate the second end of the plurality of ejector conduits so as to generate a flux region disposed within the ejector nozzle of the plurality of ejector conduits during operation of the 3D printer.

Abstract: What is disclosed is a micro-assembler backplane that has a backplane having a first surface and a number of controlled electrodes, wherein each is selectively activatable to manipulate micro-objects on the backplane. The micro-assembler backplane also has at least one trap location that is separate from the controlled electrodes. The at least one trap location is configured to hold, independently of activation of the controlled electrodes, at least one micro-object that is manipulated into a trap location.

Abstract: A machine vision system and method uses photoluminescence light response of micro-LEDs to identify types of micro-LEDs (e.g., red, green, or blue) that are used to assemble a micro-LED display. Excitation light (e.g., ultraviolet excitation light) in a certain wavelength range is illuminated on a random pool of heterogeneous micro-LEDs consisting of materials, for example, that photoluminesce in three different colors-red, green, or blue. The micro-LED is optically excited and will emit either red, green, or blue, photoluminescence light based on the type of the micro-LED. The machine vision system uses a camera device that includes color response sensors to differentiate the type of micro-LED. The orientation of the micro-LED can also be detected. The machine vision system, based on the type, location, and orientation of the heterogeneous micro-LEDs, provides image-data based optical feedback to a microassembler system to move the micro-LEDs on a planar working surface according to an electrostatic template.

Abstract: A machine vision system and method use lensless near-contact imaging with coherent illumination, or incoherent illumination, and high pixel count large format sensors (e.g., equivalent to at least 20 to 65 mega-pixels) to produce diffraction patterns of the micro-objects or the gray scale images of the micro-objects over a large overall field-of-view of the machine vision system. The machine vision system provides feedback to a microassembler system to position, orient, and assemble microscale devices like micro-LEDs over large working areas. The effective resolution of the machine vision system can be further improved through the use of gray scale and super-resolution image processing techniques.

Abstract: A machine vision system and method uses high resolution telecentric, or non-telecentric, machine vision macro lenses with high pixel count large format sensors (e.g., equivalent to at least 20 to 65 mega-pixels) at magnifications that increase the native resolution of the machine vision system, while allowing the overall field-of-view (FOV) of the vision system to be large enough relative to the optics and cameras to enable side-by-side, feathered or staggered stitching of images from individual optical camera modules, which can produce an overall system working FOV image greater than or equal to 12 inches in width. The effective resolution of the machine vision system can be further improved through the use of microlens arrays, gray scale imaging, super-resolution imaging, and pixel shifting.

Abstract: A method of making an ejector device. The method includes providing a substrate and forming one or more ejector conduits on the substrate. The one or more ejector conduits comprise: a first end configured to accept a print material; a second end comprising an ejector nozzle, the ejector nozzle comprising a first electrode pair that includes a first electrode and a second electrode, at least one surface of the first electrode being exposed in the ejector nozzle and at least one surface of the second electrode being exposed in the ejector nozzle; and at least one passageway for allowing the print material to flow from the first end to the second end. A method of printing a three-dimensional object and a method for jetting print material from a printer jetting mechanism are also disclosed.

Abstract: A method of making an ejector device. The method includes providing a substrate and forming one or more ejector conduits on the substrate. The one or more ejector conduits comprise: a first end configured to accept a print material; a second end comprising an ejector nozzle, the ejector nozzle comprising a first electrode pair that includes a first electrode and a second electrode, at least one surface of the first electrode being exposed in the ejector nozzle and at least one surface of the second electrode being exposed in the ejector nozzle; and at least one passageway for allowing the print material to flow from the first end to the second end. A method of printing a three-dimensional object and a method for jetting print material from a printer jetting mechanism are also disclosed.

Abstract: A 3D printer includes an ejector device for mixing and ejecting print material. The ejector device includes a substrate and a plurality of ejector conduits on the substrate. The ejector conduits are arranged in an array. Each ejector conduit includes a first passageway fluidly connecting a first end of the ejector conduit to a conduit junction. The first end is configured to accept a first print material. Each ejector conduit also includes a second passageway fluidly connecting a second end of the ejector conduit to the conduit junction. The second end is configured to accept a second print material. Each ejector conduit also includes a third passageway fluidly connecting a third end of the ejector conduit to the conduit junction. The third end includes an ejector nozzle. The ejector nozzle includes a first electrode and a second electrode.

Abstract: System and method that allow utilize machine learning algorithms to move a micro-object to a desired position are described. A sensor such as a high speed camera or capacitive sensing, tracks the locations of the objects. A dynamic potential energy landscape for manipulating objects is generated by controlling each of the electrodes in an array of electrodes. One or more computing devices are used to: estimate an initial position of a micro-object using the sensor; generate a continuous representation of a dynamic model for movement of the micro-object due to electrode potentials generated by at least some of the electrodes and use automatic differentiation and Gauss quadrature rules on the dynamic model to derive optimum potentials to be generated by the electrodes to move the micro-object to the desired position; and map the calculated optimized electrode potentials to the array to activate the electrodes.

Abstract: Control loop latency can be accounted for in predicting positions of micro-objects being moved by using a hybrid model that includes both at least one physics-based model and machine-learning models. The models are combined using gradient boosting, with a model created during at least one of the stages being fitted based on residuals calculated during a previous stage based on comparison to training data. The loss function for each stage is selected based on the model being created. The hybrid model is evaluated with data extrapolated and interpolated from the training data to prevent overfitting and ensure the hybrid model has sufficient predictive ability. By including both physics-based and machine-learning models, the hybrid model can account for both deterministic and stochastic components involved in the movement of the micro-objects, thus increasing the accuracy and throughput of the micro-assembly.

Abstract: The system and method described allow for real-time control over positioning of a micro-object. A movement of at least one micro-object suspended in a medium can be induced by a generation of one or more forces by electrodes proximate to the micro-object. Prior to inducing the movement, a simulation is used to develop a model describing a parameter of an interaction between each of the electrodes and the micro-object. A function describing the forces generated by an electrode and an extent of the movement induced due to the forces is generated using the model. The function is used to design closed loop policy control scheme for moving the micro-object towards a desired position. The position of the micro-object is tracked and taken into account when generating voltage patterns in the scheme.

Abstract: Control loop latency can be accounted for in predicting positions of micro-objects being moved by using a hybrid model that includes both at least one physics-based model and machine-learning models. The models are combined using gradient boosting, with a model created during at least one of the stages being fitted based on residuals calculated during a previous stage based on comparison to training data. The loss function for each stage is selected based on the model being created. The hybrid model is evaluated with data extrapolated and interpolated from the training data to prevent overfitting and ensure the hybrid model has sufficient predictive ability. By including both physics-based and machine-learning models, the hybrid model can account for both deterministic and stochastic components involved in the movement of the micro-objects, thus increasing the accuracy and throughput of the micro-assembly.

Abstract: The system and method described allow for real-time control over positioning of a micro-object. A movement of at least one micro-object suspended in a medium can be induced by a generation of one or more forces by electrodes proximate to the micro-object. Prior to inducing the movement, a simulation is used to develop a model describing a parameter of an interaction between each of the electrodes and the micro-object. A function describing the forces generated by an electrode and an extent of the movement induced due to the forces is generated using the model. The function is used to design closed loop policy control scheme for moving the micro-object towards a desired position. The position of the micro-object is tracked and taken into account when generating voltage patterns in the scheme.

Abstract: A 3D printer includes an ejector device for mixing and ejecting print material, the ejector device comprising a substrate and a plurality of ejector conduits on the substrate. The ejector conduits are arranged in an array, each ejector conduit comprising: a first passageway fluidly connecting a first end of the ejector conduit to a conduit junction, the first end configured to accept a first print material; a second passageway fluidly connecting a second end of the ejector conduit to the conduit junction, the second end configured to accept a second print material; and a third passageway fluidly connecting a third end of the ejector conduit to the conduit junction. The third end comprises an ejector nozzle, the ejector nozzle comprising a first electrode and a second electrode, at least one surface of the first electrode being exposed in the third passageway and at least one surface of the second electrode being exposed in the third passageway.

Abstract: A 3D printer includes an ejector device comprising a substrate and a plurality of ejector conduits on the substrate, the ejector conduits being arranged in an array. Each ejector conduit includes: a first end positioned to accept a print material, a second end comprising an ejector nozzle, the ejector nozzle comprising a first electrode and a second electrode, and a passageway for allowing the print material to flow from the first end to the second end, at least one surface of the first electrode being exposed in the passageway and at least one surface of the second electrode being exposed in the passageway. A current pulse generating system is in electrical connection with the first electrode and the second electrode of the plurality of ejector conduits. A magnetic field source is sufficiently proximate the second end of the plurality of ejector conduits so as to generate a flux region disposed within the ejector nozzle of the plurality of ejector conduits during operation of the 3D printer.

Abstract: A method of making an ejector device. The method includes providing a substrate and forming one or more ejector conduits on the substrate. The one or more ejector conduits comprise: a first end configured to accept a print material; a second end comprising an ejector nozzle, the ejector nozzle comprising a first electrode pair that includes a first electrode and a second electrode, at least one surface of the first electrode being exposed in the ejector nozzle and at least one surface of the second electrode being exposed in the ejector nozzle; and at least one passageway for allowing the print material to flow from the first end to the second end. A method of printing a three-dimensional object and a method for jetting print material from a printer jetting mechanism are also disclosed.