Intrepid Automation

Hewlett-packard Development Company, L.p.

Ivan Dejesus Chousal

Ben Wynne

Robert L Mueller

Christopher Sean Tanner

Jamie Lynn Etcheson

James Pingel

Shirley Lee

Madison Stadtmueller

Samiel H Chau

Robert Lee Mueller

Samuel Hon Chau

The present disclosure provides techniques for calibration systems and methods for additive manufacturing systems with multiple image projection. In some embodiments, a method of calibrating two or more image projectors of a photoreactive 3D printing system (PRPS) includes: projecting a sub-image from each of the two or more image projectors; measuring light from an image projector using a light sensor of a calibration system; receiving a signal from the light sensor; processing information from the light sensor; and changing a parameter of a sub-image based on the processed information. In some cases, a PRPS includes a calibration fixture comprising the light sensor. In some cases, a PRPS can be calibrated using a modular calibration fixture comprising the light sensor, wherein the modular calibration fixture can be coupled to the PRPS, leveled and height adjusted, and then a calibration routine can be performed.

Calibration systems and methods for additive manufacturing systems with multiple image projection

An additive manufacturing system, and associated methods, comprise an image projection system comprising a plurality of image projectors that project a composite image onto a build area within a resin pool. The composite image comprises a plurality of sub-images arranged in an array. The properties of a sub-image and the alignment of the position of the sub image within the composite image can be adjusted using a set of filters comprising an irradiance mask that normalizes irradiance, and a gamma adjustment mask that adjusts sub-image energy based on a reactivity of the resin.

Multiple image projection system and method for additive manufacturing

In some embodiments, the techniques described herein relate to photoreactive 3D printing systems and methods. The 3D printing system can include: a moveable print platform; a resin tub with a membrane; resin contained within the resin tub; an illumination system; a force sensor, and a print recipe including information for layers in a 3D printed part to be built on the print platform. The photoreactive 3D printing system can be configured to: project an image through the membrane into the volume of resin using the illumination system; move the print platform in a z-direction; measure a force on the print platform using the force sensor, and update a print platform movement in the print recipe during a printing run based on the force on the print platform.

Closed loop print process adjustment based on real time feedback

Methods of creating additive manufactured parts include selectively dispensing a second composition onto a top surface of a first composition in a vat. The second composition is dispensed in a shape area according to a layer of a part to be created by additive manufacturing. Polymerization components for formation of the layer are kept separate from each other until the dispensing, with at least one of the polymerization components being in the second composition. The top surface is illuminated to expose the first composition and the second composition to light having a polymerization wavelength, thereby causing polymerization of the layer of the part only in the shape area where the second composition was dispensed.

Vat-based additive manufacturing with dispensed material

An additive manufacturing system, and associated methods, comprise an image projection system comprising a plurality of image projectors that project a composite image onto a build area within a resin pool. The composite image comprises a plurality of sub-images arranged in an array. The properties of each sub-image and the alignment of the position of each sub image within the composite image can be adjusted using a set of filters comprising: 1) an irradiance mask that normalizes irradiance, 2) a gamma adjustment mask that adjusts sub-image energy based on a reactivity of the resin, and 3) a warp correction filter that provides geometric correction.

In some embodiments, a photoreactive 3D printing system includes: a moveable print platform; a resin tub comprising a membrane; a tension apparatus; a volume of resin contained within the resin tub; an illumination system; a print platform force sensor; and a print recipe comprising information for layers in a 3D printed part to be built on the print platform. In some embodiments, the photoreactive 3D printing system is configured to: project an image through the membrane at a polymer interface using the illumination system; moving the print platform in a z-direction; apply a tensioning force using the tension apparatus to induce a membrane tension on the membrane; measure an amount of print platform force using the print platform force sensor; and update the print platform movement in the print recipe during a printing run based on the amount of print platform force measured by the print platform force sensor.

Methods of producing an additive manufactured part with a smooth surface finish and customized properties include creating a compensated design that serves as a print recipe for an additive manufacturing process for a part, where the creating comprises modifying a desired design with a geometric offset correction to compensate for a first portion of an uncured surface finish material to be retained on the part. A spinning device is provided that has a platform. The part is formed with the additive manufacturing process and secured to the platform, where the part is at least partially wetted with the uncured surface finish material. The platform is rotated, where a second portion of the uncured surface finish material is removed due to forces imparted by the rotating. The uncured surface finish material is chosen to customize a property of the part.

Additive manufactured parts with smooth surface finishes and customizable properties

In some embodiments, a photoreactive 3D printing system and methods comprise providing a system with a resin tub comprising a membrane, wherein the membrane rests on a physical tension element such that increasing downward force on the resin tub induces increasing tension on the membrane. The system also comprises a plurality of sensors comprising a resin bulk temperature sensor, and a print recipe comprising information for each layer in a 3D printed part to be built on the print platform. In some embodiments, a resin bulk temperature is measured, and the information in the print recipe, including information related to the downward force on the resin tub, is updated during a printing run based on the resin bulk temperature measurement. In some embodiments, the print recipe can be updated during a printing run based on input from at least two sensors of the plurality of sensors.

An additive manufacturing system, and associated methods, comprise an image projection system comprising a plurality of image projectors that project a composite image onto a build area within a resin pool. The composite image comprises a plurality of sub-images arranged in an array. The properties of each sub-image and the alignment of the position of each sub image within the composite image can be adjusted using a stack of filters comprising: 1) an irradiance mask that normalizes irradiance, 2) a gamma adjustment mask that adjusts sub-image energy based on a reactivity of the resin, 3) a warp correction filter that provides geometric correction, and 4) an edge blending bar at one or more sub-image edges.

Multiple image projection method for additive manufacturing

Methods of creating additive manufactured parts include providing a first composition in a vat, where the first composition is a liquid with a first viscosity. A build platform is placed adjacent to and submerged under a top surface of the first composition. A second composition is dispensed on the top surface, the second composition having a second viscosity and being dispensed in a shape area according to a part to be created. The top surface is illuminated to expose the first composition and second composition to light having a polymerization wavelength, thereby causing polymerization of at least one of the first composition or second composition. In some embodiments, the first composition is a base resin that is absent of a photoinitiator, and the second composition is a photoinitiator solution. The photoinitiator solution may have a second viscosity that is less than the first viscosity of the base resin.

Systems and methods for managing an additive manufacturing production line include an additive manufacturing machine having a first sensor and an auxiliary equipment having a second sensor. A server includes security protocols, a workflow module, an industrial Internet of things (IIoT) module and a machine learning module. The workflow module, IIoT module, machine learning module, additive manufacturing machine and auxiliary equipment are in communication with each other using the security protocols. The machine learning module processes feedback from the first sensor and the second sensor to control operation of the additive manufacturing machine through the workflow module and the IIoT module.

Management platform for additive manufacturing production line

Multiple image projection system for additive manufacturing

A photoreactive additive manufacturing system comprises a resin tub, a membrane, and a resin pool confined by the resin tub and the membrane. In some embodiments, the membrane comprises a polymeric blend comprising a first polymer and a second polymer, and the first polymer is a fluoropolymer. In some embodiments, the membrane comprises a polymer and an additive to control the free volume of the polymer.

Membrane materials for photoreactive additive manufacturing

Apparatuses and methods for detecting failures in a photoreactive 3D printing system include a light-emitting device configured to emit light into and along a plane of a membrane or of a substrate below the membrane. The membrane is a bottom surface of a resin tub. The light has a wavelength that is different from a photopolymerization wavelength of resin in the resin tub. The membrane or substrate is transparent to the wavelength of the light and to the photopolymerization wavelength. An imaging device is oriented to capture an image of the light emitted from the membrane or the substrate. A detection system is in communication with the imaging device, the detection system being configured to detect a spatial or temporal disruption in the image.

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Chula Vista, CA, United States of America

Ivan Dejesus Chousal