A method for producing a three-dimensional object on an additive fabrication device (100, 200, 300, 400) that includes placing a first composite material patch (204, 304, 404, 504) on a bottom of a vessel (206, 306, 406, 506) of the additive fabrication device. The method also includes moving a build plate (105, 205, 305, 405) of the additive fabrication device whereby at least one of the build platform or a layer of at least partially cured resin (203, 303, 403) on the build plate touches the first composite material patch. The method further includes irradiating resin (R) contained inside the vessel with an energy source to at least partially cure a layer of resin integrated with the first composite material patch.
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
2.
AUTOMATED PARTS RELEASE AND COLLECTION FOR ADDITIVE MANUFACTURING
A post-processing device (200, 700) configured to be coupled to a three-dimensional printer (100). The post-processing device includes a head assembly (204, 600, 600a, 702) that includes a release device (208, 708) and a collection device (206, 606, 606a, 702). A rail (202) extends in a first direction, and the head assembly is configured to travel along the rail. The device also includes a pedestal assembly (211, 710) coupled to a base (101) of the three-dimensional printer, and an opening device (714) for opening a cover (128) of the three-dimensional printer. At a parts collection location (504) on the rail, the release device of the head assembly is configured to engage with a build platform (105) of the three-dimensional printer to release printed parts on the build platform, and the collection device of the head assembly is below the build platform and is configured to collect the released printed parts.
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
A method includes curing a photopolymer resin (R) disposed between a first build surface (106) and a flexible film layer (204, 304, 404) to form a print layer (L) of a printed part (P). Here, the print layer of the printed part defines a second build surface (L) attached to the flexible film layer. The method also includes translating a peeling mechanism (202, 301, 302, 402) between the second build surface and the flexible film layer to detach the flexible film layer from the second build surface.
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
B29C 64/223 - Foils or films, e.g. for transferring layers of building material from one working station to another
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
4.
ORGANIC DYE POLARIZERS IN A PHOTOPOLYMER CURING DEVICE
A curing system (170) for an additive fabrication system includes a light source (210), a liquid crystal cell (220), and a first polarizer (230). The light source (170) is configured to emit light at a wavelength suitable for curing a material. The liquid crystal cell (220) is configured to receive the light from the light source (170). The first polarizer (230) comprises a polyvinyl alcohol (PVA) matrix and organic dyes impregnated into the PVA matrix.
B29C 64/129 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
G02F 1/1335 - Structural association of cells with optical devices, e.g. polarisers or reflectors
An improved additive fabrication device and a build platform are provided. The additive fabrication device is configured to form layers of material on a build surface. The additive fabrication device comprising: a build platform comprising: a rigid structure; an actuation structure attached to the rigid structure, wherein the actuation structure comprises one or more sheet handles and a flexible sheet, and wherein a first surface of the flexible sheet forms a build surface on which the additive fabrication device is configured to form layers of materials; and the one or more sheet handles are configured to be actuated to apply a force to the flexible sheet while at least a part of the actuation structure remains attached to the rigid structure, to deform at least a part of the flexible sheet away from the rigid structure.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
6.
TECHNIQUES FOR POWDER DELIVERY IN ADDITIVE FABRICATION AND RELATED SYSTEMS AND METHODS
Techniques are described for consistently moving powder from a hopper (510) into a trough for subsequent delivery into a build area of an additive fabrication system. A powder delivery apparatus (500) may comprise a hopper (510), a trough, and a doser (520). The doser (520) may be configured to rotate about an axis and may include a recess (522, 523) that, when the doser (520) is rotated about the axis, travels into and out of the hopper and into and out of the trough. As a result, when powder is present in the hopper (510), the recess (522, 523) may carry powder from the hopper (510) to the trough when the doser rotates. The trough and doser (520) may be configured so that when the trough contains the desired amount of powder for recoating, the doser does not transfer additional material from the hopper (510) into the trough. As a result, the amount of powder in the trough may be self-regulating.
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
B29C 64/255 - Enclosures for the building material, e.g. powder containers
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
7.
TECHNIQUES FOR PRODUCING THERMAL SUPPORT STRUCTURES IN ADDITIVE FABRICATION AND RELATED SYSTEMS AND METHODS
Techniques for designing and fabricating thermal support regions via additive fabrication are described. Defects produced as a result of temperature differentials within an additive fabrication device that forms parts by sintering particles of material may be mitigated or avoided by directing energy to regions around a part that is sufficient to heat the material and cause it to partially sinter, but not enough to fully sinter the material. The mechanical properties of such a thermal support region may resist the effects caused by temperature gradients. In addition, or alternatively, the heating of the thermal support region material may reduce heat lost by nearby sintered material. In either or both cases, the thermal support region acts as a kind of 'volumetric armor' that surrounds some or all of the part and protects the part from defects.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
Techniques for preventing contamination of an electronic component via gas flow are described. According to some aspects, an electronic component module is configured to provide gas flow past and away from an electronic component such that thermal and material exchange is limited between the electronic component module and a coupled system. In some embodiments, the coupled system may be a portion of an additive fabrication device. As a result, a reduced number of contaminants may adhere to the electronic component, extending its lifespan and reducing maintenance.
Techniques for producing removable partial dentures (RPDs) through additive fabrication are described. According to some aspects, techniques are described by which a denture base may be additively fabricated in several separate portions and combined with a frame to form a completed denture base without the use of a refractory model. The denture base portions may be combined with a frame that was also produced through additive fabrication, or with a frame produced through traditional techniques. By creating an RPD through additive manufacturing it may be possible to eliminate many of the manual fabrication steps requiring highly- skilled and technical labor. This may reduce the total skilled labor time required in the production of RPDs, and/or may allow for repeatable and consistent results.
According to some aspects, degradation of material in a sintering additive fabrication process may be mitigated or avoided by fabricating parts within a chamber that includes one or more thermal breaks. The thermal break may be implemented using a variety of structures, but generally allows material in the chamber close to the surface to be maintained at different temperatures than the material further from the surface. For instance, as a result of the thermal break, parts located within the material of the chamber that were formed earlier during fabrication may be kept cooler to avoid damage to the parts yet the upper surface (sometimes called the "build surface") of unconsolidated material may be heated enough so as to require minimal additional energy exposure to trigger consolidation.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
According to some aspects, an additive fabrication apparatus is provided configured to form layers of material on a build platform (203), each layer of material being formed so as to contact a supporting liquid (205) or a film (507) disposed within a container (201), in addition to the build platform, a liquid photopolymer (206), and/or a previously formed layer (220) of a material. The additive fabrication apparatus may comprise a container (201) and a leveling element (207), wherein the leveling element (207) is configured to move across a liquid-liquid interface (204) to promote or create a flat interface between the two liquids. According to some aspects, the additive fabrication comprises a film (507) disposed between two liquids, wherein the film (507) maintains or provides a flat surface at the interface of the two liquids.
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
12.
TECHNIQUES FOR DESIGNING AND FABRICATING SUPPORT STRUCTURES IN ADDITIVE FABRICATION AND RELATED SYSTEMS AND METHODS
According to some aspects, techniques are described for generating support structures that may be easily removed after fabrication yet provide sufficient structural support during fabrication. In some cases, the techniques may include tuning an extent to which pillars of a support structure are interconnected to one another in regions proximate to the part. In some cases, the techniques may include fabricating very small contact structures, referred to herein as "hair" supports, in regions of a support structure where it connects with the part. In some cases, the techniques may include generating support structures that comprise obliquely- angled tips, which allow forces during fabrication to be applied in a preferred direction even when the support structure does not make a connection to the part in the preferred direction.
G06F 30/17 - Mechanical parametric or variational design
B29C 64/386 - Data acquisition or data processing for additive manufacturing
B29C 64/40 - Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
G06F 113/10 - Additive manufacturing, e.g. 3D printing
G06F 119/18 - Manufacturability analysis or optimisation for manufacturability
B33Y 50/00 - Data acquisition or data processing for additive manufacturing
13.
METHOD AND SYSTEM FOR CALIBRATION OF OPTICS MODULES FOR ADDITIVE FABRICATION DEVICES
According to some aspects, calibration techniques are provided that allow an optics module (1010) of an additive fabrication device to be installed and operated in a stereolithography device (900) by a user. In particular, the calibration techniques enable the optics module to be calibrated in a way that only depends on the characteristics of the optics module, and not upon any other components of the stereolithography device. As a result, the techniques enable a user of a stereolithography device to remove one optics module and replace it with another, without it being necessary to repair or replace the whole device. In some cases, the calibration techniques may include directing light onto one or more fiducial targets within the stereolithography device and measuring light scattered from said targets.
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B23K 26/02 - Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
14.
TECHNIQUES FOR OPTIMIZING PHOTOPOLYMER CURE ENERGY IN ADDITIVE FABRICATION
According to some aspects, techniques are provided to more accurately produce fine features in additive fabrication. According to some embodiments, the techniques comprise a process that amplifies exposure to edges and thin positive features whilst not substantially affecting negative features. In particular, an area to be cured may be adapted using signal processing techniques to produce an energy density map (350). The area may subsequently be cured according to the generated energy density map (350) by, for example, adjusting the scan speed, light power and/or number of passes of the light beam according to the map. As a result, the net exposure to edges (353) and thin positive (351) features may be amplified.
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
B29C 64/386 - Data acquisition or data processing for additive manufacturing
According to some aspects, a mixer (202) for detection and/or removal of material in an undesired location of an additive fabrication device (100, 200, 300) is provided. For instance, in an inverse stereolithography device, liquid photopolymer may adhere and cure or partially cure to a surface of the additive fabrication device in a location that may interfere with the additive fabrication process and/or cause the additive fabrication process to be unsuccessful. The mixer may be coupled to a movable structure (206) within the additive fabrication device so that the mixer (202), when coupled to the movable structure (206), may be moved along at least one axis within the additive fabrication device. The mixer may be configured to detect and/or remove undesired material from a surface within the additive fabrication device.
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
According to some aspects, techniques are provided for identifying contamination in additive fabrication devices by measuring light interacting with the contamination using one or more light sensors (110). Contamination located between a light source (106) and a target of a light source can affect the uniformity and intensity of the light source when incident upon the target. For instance, in an inverse stereolithography device, contamination located between a light source (106) and a liquid photopolymer resin that is to be cured can affect the quality of the fabricated object when the light is scattered or blocked by the contamination. Identifying the presence of contamination between the light source and the liquid photopolymer resin and alerting the user prior to initiating a fabrication process may increase the quality of the resulting fabricated object and improve the user experience by saving time and photocurable liquid.
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
G01N 21/94 - Investigating contamination, e.g. dust
Improved stereolithography techniques are provided. Such improved techniques may include multi-film containers, techniques for producing a flat film surface, techniques for force sensing, techniques for directing light from a movable stage, and/or film tensioning techniques. According to some aspects, a container may include multiple films that are at least partially detached from one another. In some embodiments, the multiple films may include films formed from different materials. As one example, an upper film may be formed so as to be relatively impermeable to substances within a source material of an additive fabrication device, whereas a lower film may be formed so as to provide desirable mechanical properties. In some cases, the multiple films may be commonly tensioned while being unattached to one another.
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
18.
MULTI-MATERIAL SEPARATION LAYERS FOR ADDITIVE FABRICATION
According to some aspects, a laminated multi-material separation layer is provided for use in an additive fabrication device wherein layers of solid material are formed in contact with the separation layer by curing a liquid photopolymer. In some embodiments, the laminated multi-material layer may include an elastic first layer that aids in separation of cured photopolymer from the container in addition to a barrier layer on an upper surface that protects the first layer from exposure to substances in the liquid photopolymer that may not be compatible with the material of the first layer.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
The present disclosure relates generally to curable resins, in particular latent cure resins, and related methods for use in an additive fabrication (e.g., 3-dimensional printing) device.
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
B29C 64/129 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
20.
HEATING TECHNIQUES IN ADDITIVE FABRICATION AND RELATED SYSTEMS AND METHODS
Substantially equal amounts of thermal energy may be provided over a build area of an additive fabrication device using as few as one heat source by selectively attenuating thermal energy emitted by the heat source. The thermal energy may be selectively attenuated by a structure that blocks portions of the thermal energy from being directly incident upon the build area such that the heat is normalized over the build area. The heat distribution over the build area may, in some embodiments, approximate the heat distribution produced by a flat field heating element, yet may be produced at comparatively lower cost and with less complex engineering.
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
Techniques of optically sensing fiducial targets, such as calibration patterns, within an additive fabrication device are provided. In some embodiments, fiducial targets may be disposed on a structure configured to contact source material of the additive fabrication device, the source material being a material from which the device is configured to fabricate solid objects. Indirect sensing means may be employed such that light emitted from a light source of the additive fabrication device scatters from the surface of a fiducial target. At least some of this scattered light can be measured by a sensor and used to determine a position of the fiducial target. In some embodiments, the fiducial target may be configured to move relative to the light source and/or sensor to provide additional information on the target's position via the light scattered from its surface.
E21B 47/10 - Locating fluid leaks, intrusions or movements
G01D 5/353 - Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using optical means, i.e. using infrared, visible or ultraviolet light with attenuation or whole or partial obturation of beams of light the beams of light being detected by photocells influencing the transmission properties of an optical fibre
22.
TECHNIQUES FOR BUILD PLATFORM PART RELEASE IN ADDITIVE FABRICATION AND RELATED SYSTEMS AND METHODS
According to some aspects, an additive fabrication device and a build platform suitable for use within an additive fabrication device are provided. The build platform may include a build surface on which material may be formed by the additive fabrication device when the build platform is installed within the additive fabrication device. According to some embodiments, the build platform may include a flexible build layer and at least one removal mechanism configured to be actuated to apply a force to the flexible build layer. Such actuation may cause the flexible build layer to deform, thereby enabling separation of material adhered to the build surface from the build platform. According to some embodiments, the build platform may comprise a restorative mechanism that acts to return the flexible build layer to a flat state so that subsequent additive fabrication may form material on a flat build surface.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
23.
TECHNIQUES FOR DEBRIS REMOVAL IN STEREOLITHOGRAPHY AND RELATED SYSTEMS AND METHODS
According to some aspects, a method is provided of removing debris from a liquid photopolymer in an additive fabrication device. According to some embodiments, a mesh of solid material may be formed in an additive fabrication device from a liquid photopolymer, and particles of debris present in the liquid photopolymer may adhere to the mesh. The debris may thereby be removed from the liquid photopolymer by removing the mesh from the additive fabrication device. The mesh may then be discarded.
Techniques for improved efficiency of sintering in additive fabrication are described. According to some aspects, mechanisms for depositing and leveling source material are combined with a mechanism for heating the material. In some embodiments, one or more heating elements may be arranged to lead and/or follow a material deposition mechanism such that heat may be applied to the build region in concert with deposition of material. As a result of this technique, the heating and depositing steps may be performed closer together in time and/or heat may be applied more directly to the material than in conventional systems. As a result, greater control over material temperature may be achieved, thereby avoiding excess temperature exposure and subsequent undesirable changes to the material.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
25.
TECHNIQUES FOR APPLICATION OF LIGHT IN ADDITIVE FABRICATION AND RELATED SYSTEMS AND METHODS
Techniques for illuminating a photocurable material within a build area of an additive fabrication device are described. According to some aspects, a light source is provided that can be moved alongside a build area, allowing light to be directed to any desired position within the build area by moving the light source. This configuration may also allow the distance from the light source to the build area to be substantially the same for each position across the build area by moving the light source whilst maintaining a fixed distance from the light source to the build volume. The described approach may allow for fabrication of larger parts in an additive fabrication device by expanding or eliminating the practical upper limit on the area of the build volume that can be imposed by use of a laser light source in such a device.
B29C 64/129 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
B29C 64/277 - Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
G03F 7/00 - Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printed surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
26.
TECHNIQUES FOR PRODUCING THERMAL SUPPORT STRUCTURES IN ADDITIVE FABRICATION AND RELATED SYSTEMS AND METHODS
Techniques for designing and fabricating thermal supports via additive fabrication are described. In some additive fabrication techniques, sufficiently high temperature differentials may contribute to any of a diverse array of part defects and failure modes. Additional volumes, referred to as thermal supports, may be fabricated along with a desired object such that the thermal supports adjusted, in a desired manner, temperatures that would otherwise be experience within the fabrication material during fabrication. For instance, the presence of a thermal support structure may serve to reduce changes in temperature experienced by the material between one or more adjacent layers during fabrication. According to some embodiments, thermal supports may be generated to be fabricated with a part so as to not be in contact with the part. Such a thermal support may reduce a temperature differential without affecting the finish of the fabricated object.
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
According to some aspects, a method is provided of casting an object from a mold, the method comprising obtaining a mold comprising a hollow shell of rigid material, the material comprising a thermoset polymer having a plurality of pores formed therein, providing a metal and/or ceramic slurry into an interior of the mold, exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment. According to some aspects, a method of forming a porous mold is provided. According to some aspects, a photocurable liquid composition is provided, comprising a liquid photopolymer resin, particles of a solid material, in an amount between 30% and 60% by volume of the composition, and a water-soluble liquid.
B29C 33/38 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor characterised by the material or the manufacturing process
B29C 33/44 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
B29C 33/52 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles soluble or fusible
B29C 33/54 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles made of powdered or granular material
Techniques for illuminating an interior of an enclosure in an additive fabrication device are described. According to some aspects, an additive fabrication device includes a build region into which source material may be disposed and at least one source of electromagnetic radiation configured to direct radiation onto the source material in the build region to thereby form a layer of solid material from the source material. A first heater may be included that is configured to heat at least a portion of the source material in the build region. In some embodiments, an enclosure surrounds the build region and comprises a refractive aperture. In some embodiments, at least one light source is arranged to direct light into the enclosure through the refractive aperture.
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
Techniques for producing removable build modules for additive fabrication devices are described. According to some aspects, a removable build module may comprise an enclosure having an open top, a fabrication platform arranged in an interior of the enclosure, and at least one actuator incorporated into the enclosure and configured to move the fabrication platform towards and away from the open top of the enclosure.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
The present application relates generally to photopolymer blends and related methods for use in an additive fabrication (e.g., 3-dimensional printing) device. According to some aspects, compositions are provided for the modification of a base photopolymer resin. The compositions may comprise colorant agent and/or cure-modifying composition. The compositions may be selected to cause, when combined with the base photopolymer resin to form a photo-curable composition, at least one property (e.g., color, depth of the cure) of the photo-curable composition to fall within a pre-determined range. Related kits and methods are also generally described.
C08J 3/24 - Crosslinking, e.g. vulcanising, of macromolecules
C08J 3/28 - Treatment by wave energy or particle radiation
C09D 11/101 - Inks specially adapted for printing processes involving curing by wave energy or particle radiation, e.g. with UV-curing following the printing
31.
MULTI-MATERIAL SEPARATION LAYERS FOR ADDITIVE FABRICATION
According to some aspects, a container is provided for use in an additive fabrication device configured to fabricate parts by curing a liquid photopolymer to form layers of cured photopolymer. The container may comprise a laminated multi-material layer having an elastic first layer that aids in separation of cured photopolymer from the container in addition to a barrier layer on an upper surface that protects the first layer from exposure to substances in the liquid photopolymer that may not be compatible with the material of the first layer.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 33/00 - SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING - Details thereof or accessories therefor
B29C 33/56 - Coatings; Releasing, lubricating or separating agents
B29C 33/60 - Releasing, lubricating or separating agents
According to some aspects, a method is provided of forming a metallic object via additive fabrication, the method comprising obtaining a geometric description of a first object with an exterior surface, generating a geometric description of a second object, the second object bounded by the exterior surface of the first object and having one or more voids, fabricating said second object via additive fabrication based on said geometric description of the second object, and depositing a metallic material onto said second object, wherein the metallic material is deposited into said voids of second object.
B22D 7/02 - Casting compound ingots of two or more different metals in the molten state, i.e. integrally cast
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B22F 3/20 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor by extruding
B22F 3/23 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor involving a self-propagating high-temperature synthesis or reaction sintering step
B29C 67/20 - Shaping techniques not covered by groups , or for porous or cellular articles, e.g. of foam plastics, coarse-pored
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
33.
TECHNIQUES FOR REDUCING DIFFERENTIAL CURE ARTIFACTS FOR ADDITIVE FABRICATION AND RELATED SYSTEMS AND METHODS
According to some aspects, techniques for reducing time-dependent fabrication artifacts in additive fabrication are provided. By selectively activating and deactivating an element of an additive fabrication device that forms solid material, adjacent regions of material may be formed sequentially, thereby reducing time-dependent fabrication artifacts at the cost of increasing the time taken to fabricate an object. In some embodiments, selective activation and deactivation of an element of an additive fabrication device that forms solid material may be performed to a subset of an object being fabricated based on an assessment of which portions of an object will be visible upon fabrication.
According to some aspects, techniques for determining a position of a build platform in an additive fabrication device are provided. According to some embodiments, forces resisting separation of the build platform from an opposing surface are measured and a position of the build platform with respect to the opposing surface is determined. In some embodiments, such forces may include fluid forces present during separation of a build platform from an interior surface of a liquid photopolymer container.
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
B29C 67/00 - Shaping techniques not covered by groups , or
B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
35.
SYSTEMS AND METHODS OF FLEXIBLE SUBSTRATES FOR ADDITIVE FABRICATION
According to some aspects, a method of additive fabrication is provided wherein a plurality of layers of material are formed on a build platform, the method comprising forming a layer of material in contact with a substrate and further in contact with either a previously formed layer of material or the build platform, the substrate being an actinically transparent, flexible, composite material, and subsequent to the forming of the layer of the material, actively separating the layer of material from the substrate.
B29C 67/00 - Shaping techniques not covered by groups , or
B32B 5/28 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
36.
TECHNIQUES FOR SURFACE PREPARATION DURING ADDITIVE FABRICATION AND RELATED SYSTEMS AND METHODS
According to some aspects, an additive fabrication device is provided configured to form layers of material on a build platform, each layer of material being formed so as to contact a container in addition to the build platform and/or a previously formed layer of material. The additive fabrication device may comprise a container and a wiper, wherein the wiper comprises a wiper arm and a wiper blade coupled to said wiper arm using a pivoting coupling.
According to some aspects, a method of additive fabrication is provided wherein a plurality of layers of material are formed on a surface of a build platform, each layer of material being formed so as to contact a container in addition to the surface of the build platform and/or a previously formed layer of material. The method comprises forming a layer of material in contact with the container and in contact with a previously formed layer of material, and subsequent to the forming of the layer of the material, separating the layer of material from the container by simultaneously applying a first force to the layer of the material in a direction perpendicular to the surface of the build platform, and a second force to the layer of the material in a direction parallel to the surface of the build platform.
According to some embodiments, a method of optimizing an additive fabrication process for an object is provided, the method comprising obtaining a representation of an intermediate form of the object, the intermediate form being an expected shape of the object when partially fabricated by the additive fabrication process, simulating one or more forces expected to be applied to the intermediate form of the object during the additive fabrication process, evaluating one or more results of the simulating step against one or more criteria, and adapting the additive fabrication process based at least in part on a result of the evaluating.
According to some aspects, a method of additive fabrication wherein a plurality of layers of material are formed on a build platform is provided. The method may comprise forming a layer of material in contact with a container, and subsequent to the forming of the layer of material, rotating the container relative to the build platform and moving the build platform relative to the container, thereby creating an effective fulcrum about an axis, wherein the rotating of the container and moving of the build platform causes the layer of material to separate from the container. According to some embodiments, the container may be configured to rotate about a fixed axis. According to some embodiments, moving the build platform may comprise moving the build platform toward the container.
According to some aspects, a storage unit for storing a photopolymer resin is provided. The storage unit may comprise a photopolymer resin (310), a bottom face comprising at least one region of actinically transparent material (307), the actinically transparent material being actinically transparent with respect to the photopolymer resin, at least one wall (300) extending upwards from said bottom face comprising at least one region of actinically opaque material, the actinically opaque material being actinically opaque with respect to the photopolymer resin, and a lid (304) comprising the actinically opaque material and removably connectable to the at least one wall.
patents
