3d Systems, Inc.

Guthrie Cooper

John D Clay

Christopher Knaack

A three-dimensional printing system for solidifying a photocurable resin in a layer-by-layer manner at a build plane includes a scan module, a transparent plate, a sensor, and a controller. The scan module is configured to scan the light beam along two axes to address the build plane. The transparent plate is positioned in the optical path between the scan module and the build plane. The transparent plate has at least one reflective feature in the optical path. The sensor is mounted above the glass plate and is positioned to receive light reflected from the reflective feature. The controller is configured to operate the scan module to scan the light beam across the build plane, receive a signal from the sensor when the light beam impinges upon the reflective feature, and analyze the signal to verify a proper alignment of the light beam to the build plane.

Method of manufacturing a three-dimensional article

A three-dimensional printing system is configured to selectively solidify a build material at a build plane in a layer-by-layer manner. The three-dimensional printing system includes a laser module, a scan module, and a controller. The laser module is for emitting a light beam along a main optical path from the laser module to the build plane. The scan module includes a motorized mirror and a sensor. The motorized mirror includes a substrate having an optical coating that reflects at least 90% of incoming beam power such that the mirror transmits no more than 10% of the incoming beam power. The sensor is positioned to receive transmitted light from the mirror. The controller is configured to operate the laser module to emit the light beam along the main optical path, analyze a signal from the sensor, and based upon the analysis, to estimate a calibration error for the laser module.

Three-dimensional printing system with laser calibration system

A three-dimensional printing system for manufacturing a three-dimensional article includes a build platform, a light engine, a sensor, and a controller. The build platform is for supporting the three-dimensional article. The light engine is for addressing the build plane for selectively solidifying the material layer onto an active surface. The sensor is mounted on the light engine and is configured to generate a signal based upon vibrations from an external source. The controller is configured to form layers of the three dimensional article. Concurrent with forming the layers, the controller is configured to receive a signal from the sensor, analyze the signal to compare received vibrations to a predetermined vibration threshold, and, if the received vibrations exceed the predetermined threshold, take further action.

Three-dimensional printer responsive to external vibrations

Three-dimensional printing system with integrated scan module calibration

A method and system for calibrating a three dimensional printing system includes a specialized sensor. The three dimensional printing system forms a three dimensional article of manufacture through a layer-by-layer process. Layers are formed by the operation of a light engine selectively curing photocure resin onto a face of the three dimensional article of manufacture. The sensor includes a photodetector overlaid by an optical element. The optical element simulates a 'dense portion' of an optical path between the light engine and the face of the three dimensional article of manufacture being formed. The 'dense portion' of the optical path includes a layer of photocure resin that is disposed between the light engine and the face of the three dimensional article of manufacture.

Sensor that simulates resin optical properties

A three dimensional printing system includes a plurality of light engines, an alignment article, a camera, and a controller. The plurality of light engines define a corresponding plurality of build fields which overlap and define a build plane. The alignment article carries an alignment calibration image and is configured to be mounted in the three dimensional printing system with the alignment calibration image proximate to the build plane and in facing relation with the plurality of light engines. The alignment calibration image defines a dark field with an array of reflective alignment targets. The camera is mounted to be in facing relation to the alignment calibration image. The controller is configured to operate at least the light engines and the camera to individually align the light engines to the alignment calibration image.

Method of aligning pixelated light engines

Systems and methods for calibrating a solid-imaging system () are disclosed. A calibration plate () having a non-scattering surface () with a plurality () of light-scattering fiducial marks () in a periodic array is disposed in the solid-imaging system. The actinic laser beam () is scanned over the fiducial marks, and the scattered light (S) is detected by a detector () residing above the calibration plate. A computer control system () is configured to control the steering of the light beam and to process the detector signals (SD) so as to measure actual center positions (x, y) of the fiducial marks and perform an interpolation that establishes a calibrated relationship between the angular positions of the mirrors and (x,y) locations at the build plane (). The calibrated relationship is then used to steer the laser beam in forming a three-dimensional object ().

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Mill Spring, NC, United States of America

Guthrie Cooper