3d Systems, Inc.

Evan Kuester

Ben Wynne

Andrew Enslow

Patrick Dunne

Colin Leonard Blain

Joseph Chang

Joseph Fulerton

Christopher Schneider

A method is provided for manufacturing a complex hollow article from a flexible polymer material. The method includes using an additive manufacturing system to form a precursory structure that is formed from a build material and phase change material, melting and removing the phase change material, injecting uncured liquid flexible polymer material into a cavity defined by the build material, curing and solidifying the flexible polymer material, and cracking and removing the build material from the flexible polymer material to provide the hollow article.

Method for forming complex hollow models from low modulus material

An apparatus for manufacturing a three-dimensional article by additive manufacturing includes a processor and an information storage device storing software instructions. In response to execution by the processor, the software instructions cause the apparatus to: receive initial data defining the three-dimensional article having an outer surface, define a shell having the outer surface of the three-dimensional article and an opposing inner surface that defines an inner cavity, define a transition zone between the inner surface of the shell and a boundary that is inside the inner cavity and generally follows the inner surface of the shell, define a lattice of arrayed unit cells that fill the inside of the boundary, the lattice is defined by connected lattice segments, and define transition segments that couple the lattice to the inner surface of the shell.

Defining a transition zone between a shell and lattice cell array in a three-dimensional printing system

A three-dimensional printing system includes a print engine and a controller. The controller in turn includes a processor coupled to a non-transient memory. The non-transient memory stores software instructions that when executed by the processor cause the controller to operate the print engine to fabricate a body. The body includes a three-dimensional arrangement of 3D articles that are pairwise coupled together. An individual pair of the arrangement of 3D articles includes a first article and a second article. A curved body couples a first surface of the first article to the second article. The curved body intersects the first surface to define a closed intersection curve that bounds a break surface. Along the closed intersection curve a surface of the curved body subtends an acute angle with the first surface.

High volume manufacturing method for precision articles based on three-dimensional printing

A three dimensional printing system includes a print engine, a fluid processing station, a fixture, a transport mechanism, and a controller. The fluid processing station includes a fluid injector port coupled to a fluid source. The fixture has a lower portion with a lower face and a first fluid conduit coupled to the lower face. The controller is configured to: (a) Operate the print engine to form a three dimensional article of manufacture onto the lower face and thereby defining an internal cavity and an inlet port that couples the internal cavity to the first fluid conduit of the fixture. (c) Transfer the fixture to the fluid processing station. (d) Couple the fluid injector port of the fluid processing station to the first fluid conduit of the fixture. (e) Operate the fluid source to inject fluid out of the fluid injector port and into the internal cavity.

Three dimensional printing on a fixture and rinsing channels through fixture conduits

An apparatus for manufacturing a three-dimensional article by additive manufacturing includes a processor and an information storage device. The information storage device includes a non-transient or non-volatile device storing software instructions. In response to execution by the processor, the software instructions cause the apparatus to: receive initial data defining the three-dimensional article having an outer surface, define a shell having the outer surface of the three-dimensional article and an opposing inner surface that defines an inner cavity, define a boundary in the inner cavity that further defines an outer lattice volume between the inner surface of the shell and the boundary and an inner volume inside the boundary, and define a lattice that fills the outer lattice volume.

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Del Mar, CA, United States of America

Evan Kuester