Formlabs, Inc.

Benjamin FrantzDale

Dmitri Megretski

Maxim Lobovsky

Andrew M Goldman

Steven Thomas

Justin Keenan

Konstantinos Oikonomopoulos

Shane Wighton

Ian Ferguson

Christian Reed

Adam Damiano

Nicholas M Sohn

Henry Whitney

Michael Fogleman

Alexander Nolet

Maximilian Zieringer

Robert Joachim

Jack Moldave

Marcin Slaczka

Andrey Mishchenko

James Loomis

Alec Rudd

Jacob Sanchez

Scott Norton

Kyle P McNulty

Jacob A Misra

Edward Tekeian

Techniques are described to gather information from an end user relating to fabrication process failures in a standardized manner. This information may be provided to an additive fabrication device manufacturer and analyzed by the manufacturer. Analysis may include identifying patterns in the data to identity problems relating to an additive fabrication device, software used to operate the device and/or user operations. Identification of such patterns may aid in selecting and/or generating support solutions to be provided the end user, or to improve the additive fabrication device and/or software.

Systems and methods for collecting and analyzing additive fabrication process results of an additive fabrication device

A method includes curing a photopolymer resin disposed between a first build surface and a flexible film layer to form a print layer of a printed part. Here, the print layer of the printed part defines a second build surface attached to the flexible film layer. The method also includes translating a peeling mechanism between the second build surface and the flexible film layer to detach the flexible film layer from the second build surface.

Blade assist part peel for additive manufacturing

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.

Techniques for designing and fabricating support structures in additive fabrication and related systems and methods

According to some aspects, techniques that address one or more drawbacks of laser-based optical systems in additive fabrication devices are described. In some aspects, an additive fabrication device may include one or more variable focus lenses that may be operated (e.g., actuated) during fabrication to adjust the focus, and thereby the spot size, of a laser beam. In some aspects, an additive fabrication device may comprise a laser array, such as a plurality of vertical-cavity surface-emitting lasers (VCSELs), that may be operated to direct light into a build region, rather than using a single laser beam, such as a single diode laser. In some aspects, an additive fabrication device may comprise a container that includes a flexible display film, such as a flexible LCD screen, which may be operated to direct light into the container to thereby cure a liquid photopolymer therein.

Techniques for generation and direction of light in additive fabrication and related systems and methods

According to some aspects, techniques are provided to mitigate challenges with additive fabrication devices that utilize a film. These techniques include: improvements to an additive fabrication device build platform to more evenly apply forces onto the film; techniques for inhibiting adhesion between a pair of films and for removing dirt or dust therein; techniques for detecting and/or mitigating the effects of scratches or dust on films; and techniques for detecting film punctures, detecting an imminent film puncture, and/or reducing the impact on the device when punctures occur.

Techniques for improved additive fabrication on a film surface and related systems and methods

Techniques for producing a flat film surface in additive fabrication are provided. According to some aspects, a movable stage may be arranged beneath a container having a base that includes a flexible film. The movable stage may include a segmented member in which a number of segments are aligned along a common axis. The segmented member may maintain contact with the flexible film as the movable stage moves beneath the container, with the segmented member producing a flat surface of the flexible film, at least within a region above the movable stage. According to some embodiments, multiple segmented members may be provided within the movable stage, such as in parallel with one another.

Techniques for producing a flat film surface in additive fabrication and related systems and methods

According to some aspects, calibration techniques are provided that allow an optics module of an additive fabrication device to be installed and operated in a stereolithography device 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.

Swappable optics module for additive fabrication devices

Techniques for directing light from a movable stage in an additive fabrication device are provided. According to some aspects, the movable stage may include a parabolic mirror onto which light may be directed at various different incident angles to produce light along different positions along an axis. In some cases, this axis may be perpendicular to a direction of motion of the movable stage.

Techniques for directing light from a movable stage in additive fabrication and related systems and methods

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. The area may subsequently be cured according to the generated energy density map 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 and thin positive features may be amplified.

Techniques for optimizing photopolymer cure energy in additive fabrication

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.

Techniques for surface preparation during additive fabrication and related systems and methods

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.

Optical sensing techniques for calibration of an additive fabrication device and related systems and methods

Multi-film containers for use in additive fabrication devices are provided. 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.

Multi-film containers for additive fabrication and related systems and methods

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.

Multi-material separation layers for additive fabrication

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.

Techniques for reducing differential cure artifacts for additive fabrication and related systems and methods

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.

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Harvard, MA, United States of America

Benjamin FrantzDale