Abstract: A method of forming a three-dimensional object includes: providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; filling the build region with a polymerizable liquid, irradiating the build region with light through the optically transparent member to form a solid polymer from the polymerizable liquid, and advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer. The irradiating step includes projecting focused light at the build region, and the advancing step is carried out at a rate that is dependent on an average light intensity of the focused light.

Abstract: The invention relates to a method for manufacturing a sensor element or an active component of a sensor element. The sensor element is applied in a field device of automation technology. The method comprises the following method steps: predetermining at least two materials with different physical and chemical properties depending on a functionality of the sensor element or the active component of the sensor element; predetermining an outer shape, into which the at least two materials should be formed, the outer shape being divided into a plurality of virtual spatial regions, wherein in each virtual spatial region the material distribution of the at least two materials occurs homogeneously and periodically according to predetermined rules corresponding to a microstructure. The method also includes steps of ascertaining the predetermined rules via a computer supported method depending on the predetermined functionality of the sensor element or the active component of the sensor element.

Abstract: There is provided a method of manufacturing a 3D object from a plurality of media layers including processing a media layer to define a layer of the 3D object, said processing including: cutting the media layer to define the profile of the layer; printing the media layer to define the colour of the layer. The processing including the cutting and printing of the media layer is done in a common reference plane and a plurality of media layers are processed and assembled at the build location to form the object.

Abstract: A method for producing micromechanical components is provided. A liquid starting material which can be cured by means of irradiation is applied onto a substrate. A partial volume of the starting material is cured by means of a local irradiation process using a first radiation source in order to produce at least one three-dimensional structure. The three-dimensional structure delimits at least one closed cavity in which at least one part of the liquid starting material is enclosed. Alternatively or in addition, a micromechanical component is provided that contains a liquid starting material, which is partly cured by means of irradiation, and at least one cavity in which the liquid starting material is enclosed.

Abstract: A chip-on film and a display device including the same are disclosed. The chip-on film includes a first base film, a second base film positioned on the first base film, a film pad portion positioned on at least one side of the second base film and exposed to the outside of the first base film, and a coating layer positioned on one surface of the first base film.

Abstract: A method of forming a three-dimensional object includes: providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; filling the build region with a polymerizable liquid, irradiating the build region with light through the optically transparent member to form a solid polymer from the polymerizable liquid, and advancing said carrier away from said build surface to form said three-dimensional object from said solid polymer. The irradiating step includes projecting focused light at the build region, and the advancing step is carried out at a rate that is dependent on an average light intensity of the focused light. An apparatus to perform the method is also disclosed.

Abstract: A method of forming a three-dimensional object includes: providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween, filling the build region with a polymerizable liquid, irradiating the build region with light through the optically transparent member to form a solid polymer from the polymerizable liquid, and advancing the carrier away from the build surface to form the three-dimensional object from the solid polymer. The irradiating step is carried out with a plurality of tiled images projected into the build region, and each tiled image includes an array of projected pixels. An apparatus to perform the method is also discloses.

Abstract: A functional polymeric cutting edge structure and methods for the manufacturing of cutting edge structures comprised of polymeric materials are provided. The cutting edge structures may be produced on a substrate having a blade body or blade support type. The polymeric material is produced by curing a precursor material by electromagnetic radiation wherein a wavelength of said radiation is about double a wavelength required to cure the precursor material. A razor blade for use in a razor cartridge or a blade box may be formed using the present invention.

Abstract: An embodiment method includes forming a patterned etch mask over a target layer and patterning the target layer using the patterned etch mask as a mask to form a patterned target layer. The method further includes performing a first cleaning process on the patterned etch mask and the patterned target layer, the first cleaning process including a first solution. The method additionally includes performing a second cleaning process to remove the patterned etch mask and form an exposed patterned target layer, the second cleaning process including a second solution. The method also includes performing a third cleaning process on the exposed patterned target layer, and performing a fourth cleaning process on the exposed patterned target layer, the fourth cleaning process comprising the first solution.

Abstract: A stereolithography color 3D printing method applied to a stereolithography color 3D printer (1) having a light module (11), a coloring module (12) and a curing platform (17) is provided. The method is to lower the curing platform (17) a default height (h), operate the light module (11) to irradiate stereolithography materials (180) on the curing platform (17) for curing the stereolithography materials (180) and manufacturing one layer of slice physical model (182, 30, 31) according to one layer of object print data, operate the coloring module (12) to color the slice physical model (182, 30, 31), and perform above-mentioned operations repeatedly until a color 3D physical model has been manufactured. Therefore, better printing performance can be achieved and colored 3D physical model with high definition can be manufactured by combining the stereolithography technology with the auto-coloring technology.

Abstract: There is described herein a method and system for inspecting various fabrication features of composite components, such as tow/ply location, angle deviation, and gap size, using a laser-vision assembly. In some embodiments, a tolerance for that fabrication feature is provided as an inspection feature and a laser projecting device projects the inspection feature onto the material. Alternatively or in combination thereof, a calibration feature is projected onto the material, the calibration feature comprising known dimensional information. An image acquisition device acquires an image of the material with the inspection/calibration feature(s) projected thereon. The images can be analysed automatically or manually to detect whether the fabrication features are compliant and/or to obtain measurement data of the fabrication features.

Abstract: A control device reads a slice image, positions a boundary line in an overlapped area in the slice image, extracts first and second image segments from the slice image, converts luminance values in the boundary line and an area in the first image segment to zero, converts luminance values in the boundary line and an area in the second image segment to zero, and outputs picture signals according to the image segments to projectors, respectively. The control device displaces the boundary line every time when it positions the boundary line in repeating such operations.

Abstract: A system for releasing an additive manufactured part from a build location is disclosed having a cure inhibitor transport system to resupply a cure inhibitor at a cure inhibited photopolymer resin layer where the additive manufactured part is built, the transport system comprises a cure inhibiting reservoir to initially hold the cure inhibitor, a cure inhibiting distributor layer adjacent to the cure inhibiting reservoir through which the cure inhibitor passes from the cure inhibitor reservoir to the cure inhibited photopolymer resin layer and into the adjacent photopolymer creating a cure inhibited photopolymer resin layer. Another system and method are also disclosed.

Abstract: Systems and processes for enabling an off-site expert to interact with an on-site technician during repair of composite structure. The off-site expert can provide real-time guidance to an on-site technician before and during the performance of repair procedures to avoid errors. The off-site expert is also able to monitor the repair procedures in real time to verify that correct procedures are being employed. In particular, the systems and processes disclosed herein can provide direct visual guidance, feedback, and out-of-plan warnings for manual or automated scarfing and other operations during repair of composite structure. In some embodiments, the repair process combines optical three-dimensional surface measurement, illumination by at least one of visible, ultraviolet and infrared light, and digital light processing projection to provide step-by-step monitoring of the repair.

Abstract: A method of forming a three-dimensional object is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween, with the carrier positioned adjacent and spaced apart from the build surface at a start position; then (b) forming an adhesion segment of the three-dimensional object (c) optionally but preferably forming a transition segment of the three dimensional object; and then (d) forming a body segment of the three dimensional object. In each case, the segment can be formed by: (i) filling the build region with a polymerizable liquid, (ii) continuously or intermittently irradiating the build region with light through the optically transparent, and (iii) continuously or intermittently advancing the carrier away from the build surface, to thereby form that segment from the polymerizable liquid.

Abstract: A three dimensional object may be formed by forming voxels on a sheet of material and positioning the voxels together to form the three dimensional object by rolling up the sheet.

Abstract: A system for making three dimensional objects. The system may have a frame, a build platform movably coupled to the frame, a vat removably secured so that the build platform may be lowered within the vat, and a movable radiation source capable of movement along an x and y-axis. The vat may have a radiation permeable flat bottom. The build platform may have a work surface disposed thereon. There may be at least one stepper motor capable of moving the radiation source, the build platform, or both the radiation source and the build platform. There may also be a power source, a data reader device and or computer communication device, and a microcontroller in communication with the at least one stepper motor and at least one of the data reader device or computer communication device.

Abstract: Devices, systems, methods and computer program products are disclosed that facilitate part layer curing by an additive manufacturing device wherein each element of the part layer is exposed to light from a light source until the element receives sufficient energy to cure. In an aspect, received energy is calculated based on both the light received directly from the light source and light received from surrounding elements due to dispersion and other effects. The present disclosure enables consistent curing across a part layer, facilitate the creation of sharp outer structures, and allow fragile structures to be built alongside larger structures without a loss of quality, clarity, or resolution.

Abstract: The present invention relates to a method for preserving a mark on a metallic workpiece prior to a chemical etching process to remove a surface material from a surface of the workpiece carrying the mark, the method comprising the steps of: deepening the mark relative to the surface to form a first depth; and depositing a filling material into the first depth, wherein the filling material is adapted to be removed during the chemical process, such that a second depth is obtained at the mark after the chemical process.

Abstract: A method and an apparatus of three-dimensional (3D) printing and an electronic apparatus are provided. The 3D printing method is adapted for printing a 3D object and includes the following. A plurality of layer objects of a 3D model are obtained, and a plurality of two-dimensional images, which correspond to a slice plane, of each of the layer objects are generated. The layer objects include a first layer object and a second layer object. When a comparison relationship between a two-dimensional image of the first layer object and a two-dimensional image of the second layer object matches a stack condition, the first layer object and the second layer object are stacked to generate thickness stack information of a stack object. A printing mechanism is initiated according to the thickness stack information so as to print a 3D object associated with the 3D model.

Abstract: Aspects of this disclosure relate generally to relief sculptures, and more particularly to methods of creating relief sculptures, kits for creating relief sculptures, and the relief sculptures themselves. A relief sculpture may include, for example, a transparent plate, a sculpting medium contacting a portion of the transparent plate, and a pliable sheet having a first surface comprising an image and a second surface that is adhered to the transparent plate, the sculpting medium, or both, wherein the image comprises an image feature that corresponds to the portion of the transparent plate to which the sculpting medium is contacted.

Abstract: Techniques are disclosed for converting a stereolithographic model into an STL data file that defines logically related components and subcomponents of an object. A user can categorize elements of an object to form logically related components and subcomponents of the object. Each element is represented by a triangle. All triangles representing each of these components and subcomponents are then reordered and listed sequentially within the STL. Each list is delimited at the beginning and end by two hidden triangles, one or both of which store unique identification values that are associated with the respective individual components. Additionally, a reference table can be added to the STL. The reference table includes instructions, operations or other information that is specifically associated with each component and subcomponent using the unique identification values. These instructions and operations enable users to have better control over 3D print quality than is possible using existing techniques.

Abstract: Devices, methods, and computer program products for facilitating the assembly of three-dimensional parts in a layer-wise fashion are disclosed, wherein separation forces between the assembler device and the parts are minimized at certain interfaces. Parts may be produced from polymers, photopolymers, metals, or other materials. In some aspects of the present disclosure, separation forces are minimized via the utilization of a cure inhibiting layer on a top surface of the image plate and via sliding the part from contact with a portion of the image plate having high elevation to above a portion of the image plate with low elevation. In some aspects, the assembler device further comprises a sweeper configured to expose the cure inhibiting layer to a source of cure inhibitor after a cure cycle.

Abstract: A method and apparatus for reworking an inconsistency on a part. Information about the inconsistency on the part may be identified using data generated by a nondestructive evaluation system. A portion of a section of the part in which the inconsistency is located may be removed based on the information about the inconsistency. A profile for the section of the part may be identified. Rework image data may be generated using the profile in which the rework image data comprises a number of patch images. The number of patch images may be projected onto a rework material as a number of patch projections for use in forming a patch to be applied over the section of the part.

Abstract: A Cartridge (2; 2?; 2?) for a stereolithography machine (1), including a container (3) provided with an access opening (4), a reservoir (5) for containing a base material (6), liquid or pasty, suited to be solidified through exposure to a predefined radiation (7), said reservoir (5) being permanently associated with said container (3), feeding means (8) suited to feed said base material (6) from said reservoir (5) towards said container (3), characterized in that the bottom (9) of said container (3) is at least partially transparent to said predefined radiation (7) and is situated opposite said access opening (4).

Abstract: A replenishing device in an additive manufacturing system is disclosed having a sweeper that extends to a base of a reservoir that holds a liquid resin and horizontally across at least a portion of a cure inhibiting layer located on the base of the reservoir that functions as an imaging plate, with the sweeper positioned across at least a portion of a side of the cure inhibiting layer to at least one of retard a flow of the liquid resin across a portion of a top surface of the cure inhibiting layer by providing a physical barrier to the liquid resin, remove debris from the cure inhibiting layer, and agitate the liquid resin. Other devices are also disclosed.

Abstract: A method of forming a structural assembly may include providing a first component and a second component to be joined together. The method may additionally include scanning a contour of a first mating surface of the first component and scanning a contour of a second mating surface of the second component. The method may further include producing a thermoplastic element having opposing first and second element surfaces substantially matching a contour of the first mating surface and the second mating surface.

Abstract: Magnetic devices, and methods of manufacturing the same, include a stack structure including at least one magnetic layer, etched using an etching gas including at least 70 volume percent of a hydrogen-containing gas and at least 2 volume percent of CO gas.

Abstract: An area of a composite laminate structure is reworked by scarfing the area, generating a 3-D map of the scarfed area, and installing a rework patch that is built based on the 3-D map.

Abstract: A repair process for a composite material panel that forms part of a fuselage, wings, or stabilizers of an aircraft, with the panel having large dimensions and including irregular contours in some areas and edges prone to damages occurring from handling and assembly of the panel. The process a) locates the damage in the element of the composite material panel; b) sands the area that includes the damage in an area larger than the damage, makes a cut in the panel, having the cut of a same form as a piece that will serve to repair panel; c) places the piece in the cut, so that it is perfectly flush with the panel to be repaired; and d) attaches the piece to the composite material panel.

Abstract: Embodiments of the invention include providing a figurine, a film for application to a surface of the figurine, wherein the film is to receive an image from a digital photograph provided by a user, and wherein the figurine is customizable by applying the film with the image from the digital photograph provided by the user to the surface of the figurine.

Abstract: A composite repair system and method for assisting in the repair of a cured composite part in which a damaged portion has been cut out and removed, exposing a plurality of composite plies and their corresponding composite ply edges. The composite repair system may comprise a light source to illuminate the ply edges, an image capturing device to obtain an image of the ply edges, and a computing device for processing the image of the ply edges and creating a map of the ply edges based on the image. The map may be used to manufacture filler plies having peripheral edges shaped to correspond with the composite ply edges for replacing the damaged portion of the composite part.

Abstract: A manufacturing method of a three-dimensional structure includes (a) placing a second porous sheet on top of a first porous sheet that has a predetermined external shape and at least part of which contains a first functional liquid, (b) bonding at least a range surrounded by a predetermined shape of the second porous sheet onto the first porous sheet, (c) processing the second porous sheet in the predetermined shape, and (d) after step (b), causing a second functional liquid to be contained in at least part of the range of the second porous sheet so that the first functional liquid and the second functional liquid are brought into contact through the first porous sheet and the second porous sheet.

Abstract: A method of producing an electroluminescent display is provided. A medium is obtained from a stream of commerce. The medium is activated to form a pattern such that the medium emits light by electroluminescence according to the pattern in response to electrical energization.

Abstract: A stereolithography method capable of accurately forming a three-dimensional model with a desired shape. In the stereolithography method, liquid photocurable resin is selectively exposed to light to form a cured resin layer and cured resin layers are sequentially laminated to form a three-dimensional model. The light exposure is performed on projection regions with an arbitrary area of, for example, 100 mm2 or less, and the position of the regions are changed while the exposure is performed. In the projection regions are overlap regions at the boundaries between adjacent projection regions.

Abstract: The process in accordance with the invention for producing a three-dimensional surface structure in a paper poster or paper photograph is used especially for the plastic reproduction of paintings. A paper poster or paper photograph is thereby placed face down onto a structured matrix and fixed, the paper poster or paper photograph being equal in size to or smaller than the matrix. A canvas is then adhered onto the back surface of the poster or photograph and the resulting stack of layers cold pressed. After the pressing, the structured laminate of paper poster or paper photograph and adhered canvas is then removed from the matrix, mounted under tension onto a frame, and sealed. In the preferred embodiment, the matrix is an imprint of the original painting and the paper poster is a print of the original painting in the original size.

Abstract: A method of patterning a layer of magnetic material to form isolated magnetic regions. The method forms a mask on a film stack comprising a layer of magnetic material such that the protected and unprotected regions are defined. The unprotected regions are etched in a high temperature environment to form isolated magnetic regions.

Abstract: The present invention relates to a method for thermally printing a pre-selected dye image onto a three dimensional object using an improved dye carrier sheet comprising a film substrate coated with a dye-receptive layer. The dye carrier sheet has high shrink-force, tensile strength, melt strength, and infrared (IR) absorption properties, and can conform tightly to the object. The film substrate is made from an ionomer copolymer of: i) &agr;-olefins of the formula R—CH═CH2, wherein R is a hydrogen atom or an alkyl radical having 1 to 8 carbon atoms, ii) &agr;,&bgr;-ethylenically unsaturated carboxylic acids having 3 to 8 carbon atoms, and iii) optionally an additional monoethylenically unsaturated comonomer compound, wherein 10% to 90% of the carboxylic acid functional groups are ionized by neutralization via metallic ions distributed over the copolymer.

Abstract: The invention relates to an image support medium for creation of an aesthetic image that is an work or object for display. This support medium includes a polymer in an amount sufficient to enable the image to have at least one aesthetic element. In different embodiments, the image support medium is an image support stabilizer, the polymer is a synthetic absorbent or conductive polymer, or the polymer is a transparent or synthetic translucent polymer and a property of this transparent or translucent polymer is enhanced to facilitate the creation or preservation of the image by at least one stabilizer. The invention also relates to a method for preparing this image support medium. The method includes forming a reaction mixture comprising a monomer in an amount sufficient to provide or enable the image to have an aesthetic element, and processing the reaction mixture into a 2- or 3-dimensional shape.

Abstract: A method of copying a three-dimensional surface having X, Y, and Z dimensions forms a translucent impression of the surface to be copied and then captures a two-dimensional image of the translucent impression. The captured image has X and Y dimensions and a grayscale value for each X, Y coordinate of the image. Then, the method converts each grayscale value of the image to a Z height value, thereby generating a digital file of X, Y, and Z values. The digital file may then be provided as an input to a numerically controlled machine, which can be operated to reproduce the surface to be copied. The method of the present invention finds particular application in digitizing handcrafted emboss dies and the like.

Abstract: A method and apparatus for fabricating a three-dimensional object from porous solid preform layers and at least a pore-filling material.

Abstract: A method for repairing a multi-layered damage area in a multi-layered composite structure. The method first includes obtaining depth measurement data, and obtaining topographical measurement data by laser scanning the surface of the damage area. This depth measurement data and topographical measurement data are inputted into a microprocessor along with thickness data of each layer. All inputted information is correlated among itself to thereby internally produce a three-dimensional damage area display-replica and interpolate a two-dimensional pattern of each layer of the damage area and of the surface of the damage area. The damage area is removed by first projecting a two-dimensional laser pattern of the damage area thereat on the surface of the structure, and thereafter manually removing the area to produce a void. Repair is accomplished by projecting onto respective replacement material a two-dimensional laser image pattern of each layer and manually cutting that layer according to the appropriate pattern.

Abstract: A method for engraving an image pattern onto an impression die plate utilizes laser engraving and acid attacking techniques. In one embodiment, a brass plate is provided having a nickel coating thereon. A laser removes selected portions of the nickel coating according to a preselected image pattern so as to expose the underlying portions of the brass plate. Upon immersion of the plate into an acid bath, the acid attacks the exposed plate portions so as to present depressions in the plate. Upon removal of the plate from the bath a series of depressions and remaining coating portions on the plate present undulations thereon corresponding to the desired pattern image. This image is then impressed onto a medium, e.g. as a foil or the like. Various materials may be used for the plate, coating and acid bath. An electrically charged chrome coating may also be used with a non-electrically charged chrome being the acid bath.

Abstract: Shaping elements are arranged and fixed according to an attribute data of voxels to produce a shaped article corresponding to the attribute data. A conversion unit 52 produces a shaping element information based on the attribute data from a three-dimensional cell attribute information memorizing unit 23 and stores it in a shaping element information memorizing unit 53. A solid object generator 51 controls a stacker 56, a transportation unit 57, and a picker 58 depending on the shaping element information to align the shaping elements in a shaping area. It also controls a coating unit 59 to apply an adhesive to the shaping elements to bond them to each other.

Abstract: A method is provided for producing a composite work from a single two-dimensional work having an image thereon. A flat backing member is provided having generally the same shape and size as the two-dimensional work. The work and the backing member are bonded together to form a work piece. The work piece is cut to define a geometrically shaped center section and a separate perimeter section, thereby breaking the image of the two-dimensional work regardless of individual sculptural components of the work so that each of the sections displays the respective portion of the broken image. The center section and border section are then assembled such that the continuity of the image formed by the sections is broken.

Abstract: A number of non specific, preexisting images are combined using an optical process of masking that (for purposes of clarity the following assumes 3 images are used) removes 2/3 of the first image in a sequential/lenticular pattern, replacing the removed image segments with 1/3 of each of the other two images also sequentially. These combined images are then separated by thin black separation lines using a special burning mask. This series of images and black lines is then visually decombined through the use of a clear thickness of material sandwiched together with the combined transparency and, using a non opaque adhesive, to a decombining mask in registration. This product is then able to be trimmed down and inserted into any preexisting light box. The product when back lit and viewed from the front creates the illusion of 3 complete, separate and sequential, non ghosting images that appear separately depending upon the viewers angle in relationship to the horizontal plane of the standing image.

Abstract: The 3-D Model Maker of the present invention is a device that builds three dimensional models of computer generated (e.g., CAD) structures by vector plotting layer-upon-layer applications of solidifiable substances. The layers are formed by expelling minuscule beads of the substances in liquid or flowable phase onto a platform from one or more jets, the jets and platform being relatively movable in X, Y and Z coordinate system. The beads are deposited along vectors, during X/Y relative movement, on the stage, one at a time, layer-upon-layer, to build the model. The jets and platform are moved relatively to one another in accordance with instructions from the computer (controller) to form each layer in the X-Y plane (in a manner analogous to an X-Y vector plotter) and either the stage or the jets may move in the Z direction to allow the jets to form subsequent layers.

Abstract: A photo-setting resin is shaped into a three-dimensional resin model by scanning successive resin solution layers of a photo-setting resin solution with a radiation beam to form a stack of scanned set layers of photo-setting resin, each of the successive resin solution layers having a shaped region of an isometric section. The radiation beam is scanned along a contour line of the shaped region to set the shaped region along the contour line, and scanned in a raster scanning mode to set the shaped region inwardly of the contour line. Specifically, the radiation beam is scanned along a first line which is spaced a first distance inwardly from the contour line thereby to set the shaped region along the first line, and the radiation beam is scanned inwardly of a second line which is spaced a second distance inwardly from the contour line thereby to set the shaped region inwardly of the second line. The first distance is smaller than the second distance.

Abstract: A photo-solidification modeling apparatus and a photo-solidification modeling method, wherein the reliability of an operation for coating the upper surface of a solidified layer with an unsolidified liquid is improved and the time required to carry out the same operation is reduced. To meet the purpose, a clearance is formed between the lower surface of a recoater travelling on a solidified layer and the upper surface of the solidified layer. When this condition is satisfied, an unsolidified liquid is introduced onto the solidified layer by virtue of both the force of the lower surface of the recoater which drags the unsolidified liquid and the nature of the unsolidified liquid entering the clearance. When recesses are provided in the lower surface of the recoater, the liquid adsorbed to the surfaces of the recesses is also introduced onto the unsolidified layer.

Abstract: A method for reducing curl in three dimensional computer generated models, created by the sequential exposure of adjacent layers of a photoformable composition, comprising exposing each layer twice, the first exposure being with an image modulated exposure further modulated to produce a series of isolated, anchored islets along the imaged areas, and the second exposure also being image modulated but without the additional modulation, so as to fuse the islets into a continuous solid image.