Abstract: An additive manufacturing (AM) system and method configured to fabricate a 3D printed object from a composition is provided. The AM system comprises a vat assembly having a vat, a pump, and a density control reservoir and an AM assembly having a blade system and a build system. The pump system pumps the composition from the vat, having a first and second fluid outlet and at least one perforated outlet extension attached thereto, to the density control reservoir and then back into the vat through an inlet conduit. The at least one perforated outlet extension has a tube attachment mechanism and at least one elongated perforated tube assembly communicating therewith. The blade system has a dispersing blade and cutting blade, dispersing the composition from the inlet conduit toward and throughout a central top level of the composition and cutting a top surface of the composition, respectively.

Abstract: An additive manufacturing (AM) system and method configured to fabricate a 3D printed object from a liquid photocurable composition is provided. The AM system comprises a gas sphere assembly and an AM assembly. The gas sphere assembly comprises a prep chamber and a generation system having a generation chamber including a gas sphere generation unit, a jet source chamber including a sphere unit, and a gas chamber, a reservoir, and a gas cylinder. When a gas is fed to the gas chamber and the liquid photocurable composition is fed to the jet source chamber and generation chamber, the gas is pushed through a plurality of first openings of the sphere unit, and then a plurality of micro-openings of the gas sphere generation unit, to generate the plurality of closed-packed gas spheres. The plurality of closed-packed gas spheres are employed in the AM system for fabrication of the 3D printed object.

Abstract: An additive manufacturing (AM) system and method configured to fabricate a 3D printed object from a composition is provided. The AM system comprises a vat assembly having a vat, a pump, and a density control reservoir and an AM assembly having a blade system and a build system. The pump system pumps the composition from the vat, having a first and second fluid outlet and at least one perforated outlet extension attached thereto, to the density control reservoir and then back into the vat through an inlet conduit. The at least one perforated outlet extension has a tube attachment mechanism and at least one elongated perforated tube assembly communicating therewith. The blade system has a dispersing blade and cutting blade, dispersing the composition from the inlet conduit toward and throughout a central top level of the composition and cutting a top surface of the composition, respectively.

Abstract: An additive manufacturing (AM) system and method configured to fabricate a 3D printed object from a liquid photocurable composition is provided. The AM system comprises a gas sphere assembly and an AM assembly. The gas sphere assembly comprises a prep chamber and a generation system having a generation chamber including a gas sphere generation unit, a jet source chamber including a sphere unit, and a gas chamber, a reservoir, and a gas cylinder. When a gas is fed to the gas chamber and the liquid photocurable composition is fed to the jet source chamber and generation chamber, the gas is pushed through a plurality of first openings of the sphere unit, and then a plurality of micro-openings of the gas sphere generation unit, to generate the plurality of closed-packed gas spheres. The plurality of closed-packed gas spheres are employed in the AM system for fabrication of the 3D printed object.