Stereolithographic Shaping From Liquid Precursor Patents (Class 264/401)
  • Patent number: 11833762
    Abstract: Direct ink write (DIW) printing of reactive resins presents a unique challenge due to the time-dependent nature of the rheological and chemical properties of the ink. As a result, careful print optimization or process control is important to obtain consistent, high quality prints. The present invention uses a flow-through characterization cell for in situ chemical monitoring of a resin ink during DIW printing. Additionally, in-line extrusion force monitoring can be combined with off-line post inspection using machine vision. By combining in-line spectroscopy and force monitoring, it is possible to follow reaction kinetics (for example, curing of a reactive resin) and viscosity changes during printing, which can be used for a closed-loop process control. Additionally, the capability of machine vision to automatically identify and quantify print artifacts can be incorporated on the printing line to enable real-time, AI-assisted quality control of the printed products.
    Type: Grant
    Filed: October 17, 2022
    Date of Patent: December 5, 2023
    Assignee: National Technology & Engineering Solutions of Sandia, LLC
    Inventors: Adam W. Cook, Mathias C. Celina, Carl Erik Linde, Leah N. Appelhans, Devin J. Roach
  • Patent number: 11833742
    Abstract: A method and system for microscale 3D printing achieve high-fidelity fabrication through the control of the light exposure time. A single pulse of light is used to initiate polymerization of a pre-polymer solution to minimize scattering-induced resolution deterioration. The printed object is fabricated in a layer-by-layer construction where each layer is formed through exposure to a single light pulse.
    Type: Grant
    Filed: June 28, 2021
    Date of Patent: December 5, 2023
    Assignee: The Regents of the University of California
    Inventors: Shangting You, Shaochen Chen
  • Patent number: 11833743
    Abstract: A 3D printing apparatus includes a synthetic resin bath for a photosensitive synthetic resin and a lifting apparatus. The photosensitive synthetic resin at the lifting apparatus is polymerizable by light of a specified wavelength. The 3D printing apparatus further includes a carrier medium having a coupling-in region and a coupling-out region, and an illumination apparatus to emit light onto the coupling-in region. The coupling-in region includes a coupling-in deflection structure to couple light of the specified wavelength incident on the coupling-in deflection structure from the illumination apparatus, into the carrier medium in a direction of the coupling-out region, and the coupling-out region is disposed below the synthetic resin bath and includes a coupling-out deflection structure configured to couple the light of the specified wavelength that is incident on the coupling-out deflection structure, as an exposure pattern, out of the carrier medium onto the photosensitive synthetic resin.
    Type: Grant
    Filed: April 30, 2020
    Date of Patent: December 5, 2023
    Assignee: AUDI AG
    Inventors: Markus Klug, Tobias Moll, Johannes Scheuchenpflug
  • Patent number: 11833760
    Abstract: A laser conformal manufacturing method of a flexible sensor comprises: obtaining morphology data of a curved surface, and constructing a Standard Triangle Language (STL) model of the curved surface; introducing into a 3D modeling software, and combining the curved surface with a clamper holder; manufacturing to obtain the clamper with the curved surface; coating material to be manufactured on a 3D curved surface of the clamper with the curved surface; positioning to a processing platform of a laser device; constructing a model of a pattern to be manufactured by laser based on the STL model of the curved surface, and constructing an STL model or a dwg model of the pattern to be manufactured; introducing into the laser device, turning on the laser device, and running a 3D dynamic focus system; repeating the steps 4-8, and stripping the flexible sensor from the 3D curved surface.
    Type: Grant
    Filed: February 14, 2023
    Date of Patent: December 5, 2023
    Assignee: Xiamen University
    Inventors: Wei Zhou, Rui Chen, Xinning Zhu, Tao Luo, Weisong Ling, Chiqian Xiao
  • Patent number: 11828438
    Abstract: A method for producing a 3D item (1) by means of fused deposition modelling, the method comprising a 3D printing stage comprising layer-wise depositing an extrudate (321) comprising 3D printable material (201), to provide the 3D item (1) comprising 3D printed material (202), wherein the 3D item (1) comprises a plurality of layers (322) of 3D printed material (202), and an opening (405) in the 3D printed material (202), the opening (405) having an opening edge (410) that is at least partly defined by one or more interruptions (1410) in a subset (1322) of one or more layers (322) of the plurality of layers (322), wherein the method comprises providing each interruption (1410) by 3D printing a layer (322) of the subset (1322) with oppositely arranged turns (415), wherein each turn (415) connects a first layer part (3221) and a second layer part (3222), the first layer part (3221) and the second layer part (3222) forming legs of a U-turn (435), wherein, for each turn (415), the first layer part (3221) has a first
    Type: Grant
    Filed: July 1, 2020
    Date of Patent: November 28, 2023
    Assignee: SIGNIFY HOLDING B.V.
    Inventors: Rifat Ata Mustafa Hikmet, Jacobus Petrus Johannes Van Os
  • Patent number: 11820072
    Abstract: Provided herein is a resin product useful for the production of three-dimensional objects by additive manufacturing, and methods using the same. The resin may include a reactive blocked prepolymer comprising a prepolymer blocked with reactive blocking groups; a polyol; a photoinitiator; and at least one organometallic catalyst. A packaged product useful for the production of three-dimensional objects by additive manufacturing, the product comprising a single container having a single chamber and a resin in the chamber with all components mixed together, is also provided.
    Type: Grant
    Filed: December 22, 2021
    Date of Patent: November 21, 2023
    Assignee: Carbon, Inc.
    Inventors: Robert K Pinschmidt, Jr., Andrew Gordon Wright, Jason P. Rolland
  • Patent number: 11820079
    Abstract: The present invention relates to a stereolithography apparatus for generating a three-dimensional object, comprising: an optical unit for projecting an image towards the photocurable substance for hardening the photocurable substance deposited in the focus layer; a control unit, characterized by further comprising: a detection unit which comprises: a detection means movably arranged in a detection region for detecting during the generation process or in a generation-pause the image projected by the optical unit and for outputting a detection signal; and a first driving means for moving the detection means into or out of the detection region, wherein the optical unit comprises: a second driving means linked to the optical unit for moving the focus layer into or out of the detection region, wherein the control unit adjusts the optical unit and/or modifies the image to be projected based on the signal indicative of the detected image.
    Type: Grant
    Filed: March 11, 2020
    Date of Patent: November 21, 2023
    Assignee: DENTSPLY SIRONA INC.
    Inventors: Thomas Michalica, Christian Schmidt, Franz Basler
  • Patent number: 11813797
    Abstract: In an example, mesh model data representing at least a portion of a print job to be generated by an additive manufacturing apparatus by solidifying build material is received at a processor. Using a processor and based on the mesh model data, it is validated whether the three-dimensional print job described by the mesh model data conforms with at least one of material-dependent shape constraints and apparatus-dependent shape constraints of the additive manufacturing apparatus. If the result of the validation is positive, the mesh model data is rendered, using a processor for manufacturing the three-dimensional print job by an additive manufacturing apparatus. If the result of the validation is negative, a predetermined action is performed.
    Type: Grant
    Filed: October 8, 2018
    Date of Patent: November 14, 2023
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Sergio Gonzalez Martin, Jordi Roca Vila, Manuel Freire Garcia
  • Patent number: 11813799
    Abstract: An additive manufacturing apparatus includes a first print module includes a first stage configured to hold a first component and a first radiant energy device. The resin support is configured to be positioned between the first stage and the first radiant energy device. A second print module includes a second stage configured to hold a second component and a second radiant energy device. The resin support is configured to be positioned between the second stage and the second radiant energy device. A control system is configured to translate the resin support based on a condition of the first print module and the second print module through the first print module and the second print module.
    Type: Grant
    Filed: August 9, 2022
    Date of Patent: November 14, 2023
    Assignee: General Electric Company
    Inventors: Christopher David Barnhill, Robert Edgar Estes, William Joseph Steele, Trent William Muhlenkamp, Zhen Liu, John Thomas Sterle, Victor Wayne Fulton
  • Patent number: 11813669
    Abstract: Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.
    Type: Grant
    Filed: May 27, 2022
    Date of Patent: November 14, 2023
    Assignee: General Electric Company
    Inventors: James Herbert Deines, Brian David Przeslawski, Michael John McCarren, Gregory Terrence Garay, Douglas Gerard Konitzer, Mark Willard Marusko, Xi Yang, Brian Patrick Peterson
  • Patent number: 11813794
    Abstract: A 3D printing system may include a tank in which a bottom of the tank is formed by a radiation-transparent flexible membrane, a spill tray with an outer wall configured to contain liquid resin that inadvertently leaks out from the bottom of the tank, and a light source configured to project radiation towards the bottom of the tank. The spill tray may contain an inner opening that allows the radiation from the light source to pass through the spill tray to the tank. A 3D printing system may also include a mask assembly which comprises a mask with pixels configurable to be individually transparent or opaque to portions of the radiation projected from the light source and a mask assembly receiving member configured to receive the mask assembly. The mask assembly may also include a rigid guide portion that is insertable into a slot of the mask assembly receiving member.
    Type: Grant
    Filed: November 2, 2021
    Date of Patent: November 14, 2023
    Assignee: NEXA3D INC.
    Inventors: Matthew Buckby, Francis Kenyon Whetsell, Miguel Cuevas Sandoval, Avi N. Reichental
  • Patent number: 11804305
    Abstract: A fabrication system and method for prosthetic appliances employs imaging of a contralateral skeletal structure for designing a matched, patient specific replacement appliance based on the patient's own skeletal structure. Many skeletal structures are disposed on opposed sides, i.e. left and right sides. A contralateral bone or skeletal member often accurately depicts the individual bone shape of a particular patient more accurately than a generalized approximation. A scan such as a CT or MRI is segmented to apportion a skeletal member for replacement and reconstructed into a 3D (3 dimensional) model. The 3D model is inverted to define the contralateral side, and augmented for surgical connection features and comparison with an anatomic ideal to mitigate imperfections. 3D printing and/or additive manufacturing techniques are invoked with biocompatible materials to render the replacement prosthetic appliance based on the model.
    Type: Grant
    Filed: January 23, 2017
    Date of Patent: October 31, 2023
    Assignee: Mosaic Ventures, LLC
    Inventors: Ashok Seetharam, Adam E. Eltorai, Vishal J. Thomas
  • Patent number: 11801632
    Abstract: The present disclosure provides a multi-material photocuring 3D printer and a 3D printing method, wherein multi-material photocuring 3D printer comprises: a frame; a printing platform, arranged on frame; a lifting device, arranged on printing platform; a rotary motor, arranged on lifting device; a printing plate, arranged on rotary motor; wherein a bottom surface of printing plate is a printing plane; a plurality of resin slots, arranged on frame and located below printing plate; an optical engine, arranged on frame and located below printing plate. The present disclosure connects printing plate with rotary motor, after finishing printing with one material, it is possible to remove residual liquid resin on printed piece and printing plane by a method of high-speed centrifugation, to avoid any contaminations to printed piece, thereby ensuring printed piece in multi-material having a high precision and a high resolution.
    Type: Grant
    Filed: April 14, 2021
    Date of Patent: October 31, 2023
    Inventors: Qi Ge, Jianxiang Cheng
  • Patent number: 11801640
    Abstract: A post-processing system includes a rinse tank, a robot arm, a locking fixture, and a controller. The robot arm is configured to engage and move a workpiece. The locking fixture includes a platform support structure and a clamping assembly. The controller is in communication with the robot arm and the platform locking fixture. The controller is configured to instruct the robot arm to move the workpiece from a workstation to the rinse tank, instruct the robot arm to move the workpiece from the rinse tank to the platform support structure, and instruct the clamping assembly to secure the workpiece onto the platform support structure after the workpiece has been moved to the platform support.
    Type: Grant
    Filed: December 16, 2021
    Date of Patent: October 31, 2023
    Assignee: Ford Motor Company
    Inventors: Hadi Atwi, Richard Moore
  • Patent number: 11782417
    Abstract: A method of manufacturing a 3D modeled object, includes modeling including applying a modeling solution to powder laid in layers, hardening the powder to which the modeling solution applied to form modeling layers, and sequentially stacking the modeling layers to form a 3D modeled object; and immersing the 3D modeled object modeled at the modeling in a removal solution to remove the powder to which the modeling solution is not applied. At the modeling, the modeling solution is applied such that a density of the modeling solution in an inside of the 3D modeled object is smaller than a density of the modeling solution in a surface of the 3D modeled object and an area of the powder to which the modeling solution is applied and an area of the powder to which the modeling solution is not applied are alternate in the inside of the 3D modeled object.
    Type: Grant
    Filed: November 15, 2021
    Date of Patent: October 10, 2023
    Assignee: RICOH COMPANY, LTD.
    Inventor: Souichi Nakazawa
  • Patent number: 11771655
    Abstract: The present invention utilises 3D printing technology, specifically fused filament fabrication (FFF) 3D printing, to produce solid dosage forms, such as pharmaceutical tablets. The production process utilises novel printing filaments, typically on a spool, which contain the active ingredient. Such active-containing filaments have proved to be extremely robust and the principles outlined in the present disclosure provide access to a variety of viable formulations directly from a 3D printer. This, for the first time, affords a viable means for the in situ (e.g. within a pharmacy) 3D printing of personalised medicines tailored to a patient's needs. The invention also relates to purpose-built software for operating the printing apparatus, as well as local, national and global systems for monitoring the real time operation of a plurality of printing apparatuses to enable facile detection of malfunctions, thereby making regulatory approval viable and facilitating regulatory compliance.
    Type: Grant
    Filed: September 8, 2015
    Date of Patent: October 3, 2023
    Assignee: University of Central Lancashire
    Inventor: Mohamed Albed Alhnan
  • Patent number: 11773956
    Abstract: Techniques for joining nodes and subcomponents are presented herein. An additively manufactured first node or subcomponent has a groove. An additively manufactured second node or subcomponent has a tongue configured to extend into and mate with the groove to form a tongue-and-groove connection between the first and second node or subcomponent. In some aspects, the tongue-groove connection may extend substantially around a periphery of the node or subcomponent. In other aspects, a first subcomponent having a fluid pipe interface may be coupled via a tongue-groove connection to a second subcomponent having a fluid pipe interface, thereby enabling fluid to flow between subcomponents of the resulting integrated component.
    Type: Grant
    Filed: December 10, 2020
    Date of Patent: October 3, 2023
    Assignee: DIVERGENT TECHNOLOGIES, INC.
    Inventors: Antonio Bernerd Martinez, Eahab Nagi El Naga, David Brian TenHouten, John Russell Bucknell, Broc William TenHouten, Chukwubuikem Mercel Okoli, Thomas Samuel Bowden, Jr., Muhammad Faizan Zafar
  • Patent number: 11759996
    Abstract: An example system includes a three-dimensional (3D) printer to generate a 3D object and a surface feature formation arrangement to receive the 3D object. The 3D object has at least one surface with a layer of at least partly uncured material. The surface feature formation arrangement includes a controller and a heat source. The controller is to operate the heat source to selectively apply heat to the at least one surface of the 3D object. The heat from the heat source is to transform the at least partly uncured material to form a selected feature on the at least one surface.
    Type: Grant
    Filed: April 27, 2018
    Date of Patent: September 19, 2023
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Kristopher J. Erickson, Anthony McLennan, Lihua Zhao
  • Patent number: 11738528
    Abstract: A method for post-treating a three-dimensional object produced by selectively solidifying, layer by layer, of a building material in powder form and/or post-treating unsolidified building material in which the three-dimensional object is embedded. The three-dimensional object and/or the unsolidified building material may be treated with a liquid. The liquid may comprises a liquid carrier substance and at least one further substance that reduces surface tension of the carrier substance.
    Type: Grant
    Filed: December 8, 2017
    Date of Patent: August 29, 2023
    Assignee: EOS GmbH Electro Optical Systems
    Inventor: Florian Pfefferkorn
  • Patent number: 11731348
    Abstract: A system for manufacturing a three-dimensional article includes a controller. The controller is configured to: (a) receive an input file defining a solid body; (b) slice the solid body into horizontal slices; (c) analyze the sliced body to identify downward-facing slice regions, a downward-facing slice region intersects with a downward-facing surface of the solid body; (d) for the individual slices, define a contour region to span a Boolean union between a default lateral peripheral contour and the downward-facing slice region; and (e) for the individual slices, define a hatch region that spans a Boolean difference between the slice and the contour region.
    Type: Grant
    Filed: June 29, 2020
    Date of Patent: August 22, 2023
    Assignee: LAYERWISE NV
    Inventors: Ray Nachiketa, Paggi Umberto
  • Patent number: 11718690
    Abstract: A formulation for a photopolymer composite material for a 3D printing system includes an acrylate oligomer, an inorganic hydrate, a reinforcing filler, and an ultraviolet (UV) initiator. In the formulation the acrylate oligomer may be found in the range between about 20.0-60.0 w % of the formulation. The inorganic hydrate may be found in the range between about 20.0-50.0 w % of the formulation. The reinforcing filler may be found in the range between about 5.0-60.0 w % of the formulation, and the UV initiator may be found in the range between about 0.001-0.5 w % of the formulation. A method of generating a formulation of a photopolymer composite material for use in a 3D printing system includes using an acrylate oligomer, an inorganic hydrate, a reinforcing filler, and an ultraviolet (UV) initiator.
    Type: Grant
    Filed: September 23, 2021
    Date of Patent: August 8, 2023
    Assignee: Mighty Buildings, Inc.
    Inventors: Vasily Korshikov, Anna Trushina, Dmitry Starodubtsev, Slava Solonitsyn, Igor Kovalev, Aleksei Dubov
  • Patent number: 11718031
    Abstract: The present inventive concept relates to a method for improving a lifespan of a liquid crystal display (LCD) of a masked stereolithography (MSLA) 3D printer, the method including the steps of: slicing a three-dimensional (3D) image into two-dimensional (2D) images; outputting the 2D images to the LCD; calculating irradiation area coordinates of UV LEDs in accordance with the 2D images; and irradiating UV light of the UV LEDs on an area matching with the 2D images in accordance with the calculated irradiation area coordinates of the UV LEDs.
    Type: Grant
    Filed: February 21, 2022
    Date of Patent: August 8, 2023
    Inventors: Hee Jae Lee, Joon Ha Kim
  • Patent number: 11712849
    Abstract: A method of operating a 3-D printer apparatus includes a tank structure with a bottom wall with a printing area defined above and spaced apart from the bottom wall. A gas permeable liquid within the tank overlays the bottom wall of the tank structure defining a first mobile layer below the printing area. An inhibition liquid within the tank overlays the gas permeable liquid defining a second mobile layer below the printing area. A polymerizable resin overlays the inhibition liquid and flows into the printing area. Positioning of an object carrier controlled such that a lower surface of the object carrier is initially located within the polymerizable resin and within the printing area. Operation of a resin curing device beneath the bottom wall provides light to the printing area polymerizing predetermined portions of the polymerizable resin forming an object attached to the lower surface of the object carrier.
    Type: Grant
    Filed: July 6, 2020
    Date of Patent: August 1, 2023
    Assignee: NISSAN NORTH AMERICA, INC.
    Inventors: Nanzhu Zhao, Jinwei Cao, Nilesh Dale, Sandeep Patil, Cenk Gumeci, Mohammed Hussain Abdul Jabbar
  • Patent number: 11701817
    Abstract: A method of making a workpiece in an additive manufacturing process includes determining a preferred angular orientation of the grid array about a build axis extending perpendicular to a layer to be built for a first layer of a workpiece. The preferred angular orientation is selected to align an edge of one or more pixels with an edge of the layer of the workpiece being built. The method further includes orienting a patterned image of radiant energy to the preferred angular orientation by rotating a projector before solidifying a portion of a resin that forms the first layer of the workpiece.
    Type: Grant
    Filed: October 16, 2020
    Date of Patent: July 18, 2023
    Assignee: General Electric Company
    Inventors: Travis Gene Sands, Stephen Michael Deak
  • Patent number: 11701822
    Abstract: A method of three-dimensional manufacturing including depositing a layer of powder in a powder bed, the layer comprising particles of at least a first component of a two-component reactive material, dispensing a first solution containing at least one of a solvent and a second component of the two-component reactive material the solvent selected to cause the two components to form one or more cross-linked regions of a three-dimensional object, iterating the depositing and dispensing to form subsequent layers of the three-dimensional object until the object is formed, and removing any unwanted particles from the object. A three-dimensional manufacturing system has a powder bed to hold layers of particles, and one or more print heads positioned to dispense liquid onto the powder bed to cause the particles for form one or more cross-linked regions in layers of a solid object.
    Type: Grant
    Filed: May 17, 2021
    Date of Patent: July 18, 2023
    Assignee: Palo Alto Research Center Incorporated
    Inventors: Michael Benedict, Junhua Wei, Gabriel Iftime
  • Patent number: 11697248
    Abstract: An additive manufacturing system (100) includes a build tool (110) configured to deposit a feedstock material and/or deliver consolidation energy promoting consolidation of the feedstock material within an accessible range defining a build space. The system also includes a controller (120) configured to determine a build trajectory through the build space, where the build trajectory includes build points at which the feedstock material and/or the consolidation energy is applied (202), determine respective consolidation times of the feedstock material for one or more of the plurality of the build points (204), determine a deposition rate at which the feedstock material is deposited and/or consolidation energy is delivered to the feedstock material based at least in part on the determined consolidation times of the feedstock material (204), and cause the build tool to build an object in accordance with the determined build trajectory and the determined deposition rate (208).
    Type: Grant
    Filed: September 30, 2019
    Date of Patent: July 11, 2023
    Assignee: FISHER CONTROLS INTERNATIONAL LLC
    Inventor: Ryan E. Spotts
  • Patent number: 11679558
    Abstract: An optical forming device includes a resin tank that is to retain a photocurable resin containing dichroic polymerization initiator and a light emitter to emit light for causing the photocurable resin to undergo curing. An alignment film for causing the dichroic polymerization initiator to align in a predetermined direction is provided on a bottom portion of the resin tank. The light emitter irradiates the photocurable resin with the light by passing the light through the bottom portion of the resin tank as linearly polarized light having a polarization direction in a direction perpendicular to a direction in which the dichroic polymerization initiator is aligned by the alignment film.
    Type: Grant
    Filed: December 4, 2020
    Date of Patent: June 20, 2023
    Assignee: TIANMA JAPAN, LTD
    Inventor: Chikaaki Mizokuchi
  • Patent number: 11673326
    Abstract: A three dimensional printing apparatus includes a carrier, a glass plate and a film. The glass plate is disposed on the carrier. The film covers the glass plate and is folded over an edge of the carrier. An interface between the glass plate and the film is in communication with the external space via a channel between the edge and the sidewall of the glass plate.
    Type: Grant
    Filed: November 20, 2019
    Date of Patent: June 13, 2023
    Assignee: Young Optics Inc.
    Inventor: Chien-Hsing Tsai
  • Patent number: 11673327
    Abstract: The present invention concerns an apparatus for 3D printing of bottom-up photo-curing type, comprising a light source (26) above which a tank (10) containing a photo-curing liquid material (24) is placed inside which it is immersed an extraction plate (25), which is equipped with moving means with alternating rectilinear motion, along a direction perpendicular to the bottom of said tank (10) from a position at a distance from the bottom of said tank (10) equal to the thickness of a layer obtainable by photo-curing of said photo-curing liquid material (24), the bottom (14) of said tank (10) being constituted by an elastic membrane (23) transparent to the radiation of said light source (26), said tank (10) being positioned in correspondence with a hole (13) of a support plate (12), said hole being provided with a rigid support (11), transparent to the radiation of said light source (26), wherein said rigid support (11) is provided with means for displacing with respect to said hole (13), from a position in whic
    Type: Grant
    Filed: March 27, 2019
    Date of Patent: June 13, 2023
    Assignee: Sisma S.p.A.
    Inventors: Gianni Zitelli, Federico Iacovella, Vittorio Gaudino, Massimo Petrilli
  • Patent number: 11667080
    Abstract: A system for obtaining a photopolymerized prepolymer for use as a component of a material suitable for manufacturing buildings or building components by 3D printing processes. The system contains a flexible closed loop conveyor stretched between a precursor loading station and a prepolymerization material receiver from which the product is unloaded to a construction 3D printing machine. The conveyor carries a plurality of flexible trays capable of looping around the pulleys of the closed loop conveyor. The trays are shallow troughs that have open tops and carry dosed portions of the precursor, which is photopolymerized on its way from the loading station to the unloading station by sequentially passing under light sources of two photopolymerization stations. When the trays pass through the unloading position, they are turned upside-down and allow the precured material to fall into a receiver.
    Type: Grant
    Filed: April 29, 2019
    Date of Patent: June 6, 2023
    Assignee: Mighty Buildings, Inc.
    Inventors: Denis Indyk, Alexander Trushin, Anna Trushina, Aleksei Dubov, Dmitry Starodubtsev, Slava Solonitsyn
  • Patent number: 11661468
    Abstract: Provided herein are systems and processes to control multiple temperatures in additive manufacturing. Such temperature control adjusts polymer properties and facilitates processing of materials to form 3D objects. The systems and processes disclosed herein also facilitate the processing of typically difficult-to-process materials and deliver such materials to a photocuring zone configured to photopolymerize materials into 3 dimensional objects with a layer-by-layer process. Such processes can include the steps of heating a resin to a flowable temperature, applying the resin to a carrier, cooling the film to increase viscosity or to solidify the resin, and applying the film containing the resin onto an area being printed, then photocuring the film. Also provided herein are resins and related polymer materials having properties that are tunable with exposure to more than one temperature zone. The formed polymers can include multiple regions of polymer material, each independently having distinct properties.
    Type: Grant
    Filed: August 26, 2021
    Date of Patent: May 30, 2023
    Assignee: Align Technology, Inc.
    Inventors: Michael Christopher Cole, Peter Dorfinger
  • Patent number: 11654214
    Abstract: Ink formulations comprising bioactive particles, methods of printing the inks into three-dimensional (3D) structures, and methods of making the inks are provided. Also provided are objects, such as tissue growth scaffolds and artificial bone, made from the inks, methods of forming the objects using 3D printing techniques, and method for growing tissue on the tissue growth scaffolds. The inks comprise a plurality of bioactive ceramic particles, a biocompatible polymer binder, optionally at least one bioactive factor, and a solvent.
    Type: Grant
    Filed: April 26, 2018
    Date of Patent: May 23, 2023
    Assignee: NORTHWESTERN UNIVERSITY
    Inventors: Ramille N. Shah, Adam E. Jakus
  • Patent number: 11643504
    Abstract: A dual-cure method for forming a solid polymeric structure is provided. An end-capped, imide-terminated prepolymer is combined with at least one photopolymerisable olefinic monomer, at least one photoinitiator, and a diamine, to form a curable resin composition, which, in a first step, is irradiated under conditions effective to polymerize the at least one olefinic monomer, thus forming a scaffold composed of the prepolymer and the polyolefin with the diamine trapped therein. The irradiated composition is then thermally treated at a temperature effective to cause a transimidization reaction to occur between the prepolymer and the diamine, thereby releasing the end caps of the prepolymer and providing the solid polymeric structure. A curable resin composition comprising an end-capped, imide-terminated prepolymer, at least one photopolymerisable olefinic monomer, at least one photoinitiator, and a diamine, is also provided, as are related methods of use.
    Type: Grant
    Filed: March 24, 2022
    Date of Patent: May 9, 2023
    Assignee: ZHEJIANG XUNSHI TECHNOLOGY CO., LTD.
    Inventors: Hailun Borjigin, Lingzhu Zhang
  • Patent number: 11633909
    Abstract: Systems, apparatus, and methods are described for additive manufacturing or three dimensional (3D) printing of objects using a set of physical masks. An additive manufacturing device can include one or more light sources, a vessel containing a volume of print material and a transparent base through which light can enter the vessel to cure a portion of the volume of print material, and a set of masks defining a series of patterns associated with layers of a 3D object that are each positionable between the light source and the transparent base to control a pattern of the light that is received through the transparent base and therefore the pattern of the cured portion of print material.
    Type: Grant
    Filed: July 26, 2019
    Date of Patent: April 25, 2023
    Assignee: CALT DYNAMICS LIMITED
    Inventors: Ross Lawless, Irene Villafane, Warren Katz
  • Patent number: 11633910
    Abstract: A solidification substrate assembly for making a three-dimensional object from a solidifiable material includes a solidification substrate assembly. In certain examples, the solidifiable material solidifies in contact with the solidification substrate, and the tilting of the substrate and/or or the use of a peeling member facilitates separation of the substrate from the solidified material. In other examples, the solidification substrate assembly includes a film that is adjacent to a rigid or semi-rigid layer. The solidifiable material solidifies in contact with the film, and a peeling member peels the film away from the solidified material. Intelligent solidification substrate assemblies are also described in which a force sensor determines when to expose the solidifiable material to solidification energy and/or whether to use a peeling member to separate the solidification substrate from a solidified objection section.
    Type: Grant
    Filed: October 20, 2020
    Date of Patent: April 25, 2023
    Assignee: Global Filtration Systems
    Inventors: Ali El-Siblani, Alexandr Shkolnik
  • Patent number: 11630439
    Abstract: Toolpath generation for additive manufacturing systems involves operations on polygonal contours derived from a model for additively manufacturing a structure. One aspect involves modifying or creating a model to allow parts to be printed without starting and stopping the printing equipment by generating continuous toolpaths or toolpaths having a reduced number of isolated paths. Another aspect involves modifying a slicing engine to generate a continuous toolpath or toolpath having a reduced number of isolated paths based on a representation of an object to be additively manufactured. Another aspect involves selectively placing the gaps at alternating positions among the sliced layers to create a zippering effect.
    Type: Grant
    Filed: April 7, 2020
    Date of Patent: April 18, 2023
    Assignee: UT-Battelle, LLC
    Inventors: Michael C. Borish, Alex C. Roschli, Brian K. Post, Phillip C. Chesser, Seokpum Kim
  • Patent number: 11629203
    Abstract: A photopolymerizable composition comprises at least a polymerizable resin, a photosensitizer, an annihilator, and a photoinitiator. The photosensitizer is formulated to absorb an excitation light signal received in a first range of wavelengths. The annihilator is formulated to emit a light signal in a second range of wavelengths different from the first. During the absorption of light by the photosensitizer in the first range of wavelengths, the annihilator emits a light signal in the second range, a photon energy of the emitted light signal being greater than a photon energy of the light signal received by the photosensitizer. The annihilator is also formulated to implement an energy transfer mechanism to excite the photoinitiator for polymerization of the resin. The excited photoinitiator is formulated to generate at least one polymerizable initiator to cause the polymerization reaction. Related methods, such as three-dimensional printing methods, and materials are also disclosed.
    Type: Grant
    Filed: July 31, 2018
    Date of Patent: April 18, 2023
    Assignees: ECOLE NORMALE SUPERIEURE DE LYON, UNIVERSITE CLAUDE BERNARD LYON 1, CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE
    Inventors: Patrice Baldeck, Akos Banyasz
  • Patent number: 11629227
    Abstract: A dual-cure method for forming a solid polymeric structure is provided. An end-capped, imide-terminated prepolymer is combined with at least one photopolymerisable olefinic monomer, at least one photoinitiator, and a diamine, to form a curable resin composition, which, in a first step, is irradiated under conditions effective to polymerize the at least one olefinic monomer, thus forming a scaffold composed of the prepolymer and the polyolefin with the diamine trapped therein. The irradiated composition is then thermally treated at a temperature effective to cause a transimidization reaction to occur between the prepolymer and the diamine, thereby releasing the end caps of the prepolymer and providing the solid polymeric structure. A curable resin composition comprising an end-capped, imide-terminated prepolymer, at least one photopolymerisable olefinic monomer, at least one photoinitiator, and a diamine, is also provided, as are related methods of use.
    Type: Grant
    Filed: July 28, 2022
    Date of Patent: April 18, 2023
    Assignee: ZHEJIANG XUNSHI TECHNOLOGY CO., LTD.
    Inventors: Hailun Borjigin, Lingzhu Zhang
  • Patent number: 11623396
    Abstract: The present disclosure relates to a tensioning system for use in a stereolithography manufacturing application. The system may have a build plate for supporting a three dimensional part being formed using a photo responsive resin, a base plate and a release element extending over the base plate. The release element is configured to receive a quantity of photo responsive resin for forming a new material layer of the three dimensional part. A pair of tensioning components are secured to opposite ends of the release element, and apply a controlled tension force to the release element during peeling of the release element to reduce a separation force required to separate the release element from the new material layer after the new material layer is cured.
    Type: Grant
    Filed: September 22, 2020
    Date of Patent: April 11, 2023
    Assignees: Lawrence Livermore National Security, LLC, Board of Regents, The University of Texas System
    Inventors: Eric B. Duoss, James Oakdale, Nicholas Anthony Rodriguez, Hongtao Song, Richard Crawford, Carolyn Seepersad, Morgan Chen
  • Patent number: 11613081
    Abstract: A material management apparatus for an additive manufacturing system comprises a build material supply system to supply build material to a building area for building an object by additive manufacturing. The build material supply system includes a first build material supply unit to supply build material from a first side of a building area and a second build material supply unit to supply build material from a second side of the building area, the second side opposing the first side. The material management apparatus also includes a controller to control the build material supply system to vary an amount of build material to be supplied via the first build material supply unit based on a detected difference between a first amount of material available for supply via the first build material supply unit and a second amount of material available for supply via the second build material supply unit.
    Type: Grant
    Filed: September 29, 2016
    Date of Patent: March 28, 2023
    Assignee: Hewlett-Packard Development Company, L.P.
    Inventors: Gabriel De La Cal, Pablo Dominguez Pastor, Pau Martin Vidal, Anna Torrent, Albert Mora Murciano
  • Patent number: 11607847
    Abstract: The invention relates to a stereolithography apparatus comprising: a container for a fluid material curable by radiation, a substrate plate, an actuator means for generating a relative movement between the container and the substrate plate, and an irradiation device for selectively irradiating the material arranged in the container. According to the invention, the actuator means and the irradiation device are mounted on a frame assembly, and the container and the substrate plate are combined to form an assembly and the assembly consisting of the container and the substrate plate is jointly inserted into the frame assembly, detachably secured therein by means of an attachment means and to be jointly removed from the frame assembly.
    Type: Grant
    Filed: July 31, 2015
    Date of Patent: March 21, 2023
    Assignee: BEGO BREMER GOLDSCHL√ĄGEREI WILH. HERBST GMBH & CO. KG
    Inventors: Heinz Lambrecht, Sergej Tregubow
  • Patent number: 11602891
    Abstract: Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be used to deposit a material layer onto a build surface of an additive manufacturing system. In some instances, the recoater assembly may include a powder entrainment system that trails behind a recoater blade of the recoater assembly relative to a direction of motion of the recoater blade across a build surface of the additive manufacturing system. The powder entrainment system may generate a flow of fluid across a portion of the build surface behind the recoater blade that at least temporarily entrains powder above a threshold height from the build surface to mitigate, or prevent, the formation of defects on the build surface with heights greater than the threshold height.
    Type: Grant
    Filed: August 30, 2021
    Date of Patent: March 14, 2023
    Assignee: VulcanForms Inc.
    Inventor: Matthew Sweetland
  • Patent number: 11597137
    Abstract: Provided is a method of producing a cured product pattern, including: a first step (arranging step) of arranging a layer formed of a curable composition (?1?) that is the components of the curable composition (?1) except the component (D) serving as a solvent on a substrate; and a second step (applying step) of applying droplets of a curable composition (?2) discretely onto the layer formed of the curable composition (?1), the curable composition (?1) having a number concentration of particles each having a particle diameter of 0.07 ?m or more of less than 2,021 particles/mL, and the curable composition (?1?) having a surface tension larger than that of the curable composition (?2).
    Type: Grant
    Filed: October 3, 2018
    Date of Patent: March 7, 2023
    Assignee: CANON KABUSHIKI KAISHA
    Inventors: Jun Kato, Takeshi Honma, Toshiki Ito, Hidetoshi Tsuzuki
  • Patent number: 11590707
    Abstract: A multi-station stereolithographic group, includes: support and movement apparatus for a modelling plate with respect to a fixed base facing the modelling plate, the fixed base including at least two work stations positioned in respective areas able to be reached by the modelling plate moved by the support and movement apparatus. Such a fixed base includes at least three work stations: at least one first station for forming an object, at least one second station for washing a formed object, at least one third station for stabilising a formed object.
    Type: Grant
    Filed: November 12, 2018
    Date of Patent: February 28, 2023
    Assignee: DWS S.R.L.
    Inventors: Ettore Maurizio Costabeber, Renzo Busato
  • Patent number: 11584078
    Abstract: Apparatuses, systems and methods of providing heat to enable an FDM additive manufacturing nozzle having refined print control and enhanced printing speed. The heating element may include at least one sheath sized to fittedly engage around an outer circumference of the FDM printer nozzle; at least one wire coil at least partially contacting an inner diameter of the sheath; and at least one energy receiver associated with the at least one wire coil.
    Type: Grant
    Filed: October 3, 2017
    Date of Patent: February 21, 2023
    Assignee: JABIL INC.
    Inventors: William MacNeish, Erik Gjovik
  • Patent number: 11578221
    Abstract: Described herein are methods and compositions for forming three-dimensional objects via material jetting processes, the methods including the repeated steps of selectively depositing a liquid thermoset material onto a surface from a nozzle of at least one jetting head in a first specified direction and exposing at least a portion of the liquid thermoset material to a source of actinic radiation in order to form a three-dimensional object from the cured thermoset material, wherein the jetting head is configured to eject droplets of the liquid thermoset material from the nozzle at prescribed elevated operating temperatures, and wherein the liquid thermoset material is chosen so as to possessing prescribed viscosity and rheological characteristics.
    Type: Grant
    Filed: December 14, 2018
    Date of Patent: February 14, 2023
    Assignee: Covestro (Netherlands) B.V.
    Inventors: Paulus Antonius Maria Steeman, Adrianus Cornelis Bastiaan Bogaerds, Marco Marcus Matheus Driessen, Rudolfus Antonius Theodorus Maria Van Benthem, Robbert Van Sluijs, Franciscus Johannes Marie Derks
  • Patent number: 11571850
    Abstract: The present invention relates to a building platform (100) for building up a workpiece (200) in layers or continuously by stereolithography, comprising: a rear illumination device (101-1) for illuminating a layer (103-n) from a rear side; a photosensor (105) for detecting a light intensity of a light from a front illumination device (101-2) through the layer (103-n) and/or a material and/or a deflecting mirror; and a control device (107) for activating the rear illumination device (101-1) when the detected light intensity of the front illumination device (101-2) is above a predetermined threshold.
    Type: Grant
    Filed: April 19, 2021
    Date of Patent: February 7, 2023
    Assignee: Ivoclar Vivadent AG
    Inventor: Hendrik John
  • Patent number: 11571856
    Abstract: A device for producing three-dimensional objects by successively solidifying layers of a construction material that can be solidified using radiation on the positions corresponding to the respective cross-section of the object, with a housing comprising a process chamber, a construction container situated therein, an irradiation device for irradiating layers of the construction material on the positions corresponding to the respective cross-section of the object, an application device for applying the layers of the construction material onto a carrying device within the construction container or a previously formed layer, a metering device for delivering the construction material, wherein the application device comprises a coating element which distributes the construction material delivered by the metering device as a thin layer in an application area along a linear application movement, wherein at the end of a coating process for a layer when returning the coating element 11 to a coating starting position.
    Type: Grant
    Filed: March 31, 2016
    Date of Patent: February 7, 2023
    Assignee: CONCEPT LASER GMBH
    Inventors: Frank Herzog, Florian Bechmann, Fabian Zeulner, Markus Lippert, Jens Stammberger, Christian Diller
  • Patent number: 11565475
    Abstract: A method operates a three-dimensional (3D) metal object manufacturing system to compensate for errors that occur during object formation. In the method, thermal image data and dimensional image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object. Thermal conditions are identified from these data and compared to predetermined ranges corresponding to the identified thermal conditions to identify one or more errors. For identified errors outside a corresponding predetermined difference range, the method performs an error compensation technique. The error compensation includes modification of a surface data model, modification of machine-ready instructions, or operation of a subtractive device.
    Type: Grant
    Filed: April 10, 2020
    Date of Patent: January 31, 2023
    Assignee: Xerox Corporation
    Inventors: David A. Mantell, Christopher T. Chungbin, Chu-Heng Liu, Scott J. Vader, Zachary S. Vader, Viktor Sukhotskiy, Denis Cormier, Kareem Tawil
  • Patent number: 11549012
    Abstract: Modeling material formulations and formulation systems usable in additive manufacturing of a three-dimensional object, featuring, when hardened, a Shore A hardness lower than 10 and/or a Shore 00 hardness lower than 40, are provided. Additive manufacturing processes utilizing these formulations and formulation systems, and three-dimensional objects obtainable thereby, are also provided.
    Type: Grant
    Filed: July 27, 2018
    Date of Patent: January 10, 2023
    Assignee: Stratasys Ltd.
    Inventors: Mazi Amiel-Levy, Shiran Lupo, Tal Ely, Daniel Dikovsky