X Development LLC

Intrinsic Innovation LLC

Jonathan Proto

Brandon Kruysman

Jeff Linnell

Kendra Byrne

Jeffrey Linnell

Marek Piotr Michalowski

Anthony Sean Jules

Eli Reekmans

Steven Moody

Michael Beardsworth

Matthew A Bitterman

Johan Jessen

Described herein are three-dimensional (3D) printer systems and methods, which may provide for 'continuous pull' 3D printing. An illustrative 3D printer includes: a resin container, a base plate, a light source arranged below the resin container and operable to cure resin in the resin container; and a control system operable to: (a) receive model data specifying a 3D structure; (b) determine 2D images corresponding to layers of the 3D object; and (c) generate control signals to operate the light source and the base plate to sequentially form the layers of the 3D object onto the base plate, wherein the base plate moves a formed portion of the 3D object upward after formation of each layer, and wherein at least a surface of a formed portion of the 3D object remains in contact with the resin in the resin container throughout the formation of the layers of the 3D object.

Continuous pull three-dimensional printing

A robotic system includes end-effector(s) that combine a plurality of objects in a production process. The system includes sensor(s) that obtain measurement(s) relating to a combination of a first object and one or more other objects during the production process. The system includes a control system communicatively coupled to the sensor(s). The control system stores specifications relating to the combination of the plurality of objects. The control system receives the measurement(s) from the sensor(s), determines a difference based on the measurement(s) and the specifications, determines adjustment(s) to the production process based on the determined difference, and sends, for the end-effector(s), instruction(s) based on the specifications and the one or more adjustment(s). The end-effector(s) combine a second object with the first object and the one or more objects based on the specifications and the one or more adjustment(s).

Error accrual and mitigation during robotic process

A robotic system includes one or more end-effectors that combine, according to a production process, at least one object and structure(s) at a production site. Sensor(s) generate, from the production site, sensor data relating to the production process. A control system stores specifications for the production process based on a model of the production site and/or the at least one object. The control system: receives, from the sensor(s), the sensor data; determines, from the sensor data, properties of at least one of: the production site or the at least one object; determines difference(s) between the properties and the model; determine(s) adjustment(s) to the production process based on the difference(s); and sends, for the end-effector(s), instruction(s) for combining the at least one object and the structure(s) based on the specifications and the one or more adjustments to the production process.

Customized robotic installation based on measurements collected on site

The present application discloses implementations relate to automated generation of interlocking joint features. An example method involves obtaining a virtual model of an object. The virtual model specifies dimensions of a first element, dimensions of a second element, and a spatial relation between the first element and the second element that defines a joint angle. The example method also involves obtaining a relationship that correlates element dimensions and joint angles with cut dimensions. The example method further involves determining cut dimensions for the first element the second element based on the relationship, the dimensions of the first element, the dimensions of the second element, and the joint angle. Modifying the first element and the second element according to the cut dimensions produces interlockable features on the first element and the second element. Additionally, the method involves providing an output signal indicative of the cut dimensions.

Parametric generation of interlocking joints

An example fabrication system includes a light source, a resin container, and a base plate on which resin is cured using the light source so as to build up an object one layer at a time. The disclosed base plate includes a build surface and an anchor channel that extends into the base plate from the build surface. The anchor channel is a recess in the base plate configured to have a narrow width that is closer to an opening to the build surface than a broad width. The base plate can also have a light source that emits light into the anchor channel to cure resin within the anchor channel. Resin anchors cured within the anchor channel to conform to the anchor channel resist being extracted, and an object formed on the build surface remains anchored during fabrication via adhesion to the resin anchors.

Fabrication baseplate with anchor channels

Example implementations may relate to interactive object fabrication. In particular, a control system may receive model data defining a 3D shape of a physical object that is fabricable out of a substrate at a work site. The system may then direct a projection system to emit onto the substrate a projection illustrative of the 3D shape defined by the model data. Also, the system may transmit, to a robotic system, fabrication instructions that direct the robotic system to fabricate the physical object in accordance with the model data. subsequently, during fabrication of the physical object, the system may (i) receive progress data indicative of a portion of the physical object that has been fabricated from the substrate, and (ii) direct the projection system to update the projection of the 3D shape to remove a portion of the projection corresponding to the portion of the physical object that has been fabricated.

Interactive object fabrication

A 3D printing process may form a 3D object by alternatingly forming layers from a liquid resin and a solid. For instance, when printing a 3D object, the 3D printer may at least partially cure a layer of liquid resin, and before the curing of the resin is complete, dip the semi-cured resin into a vat containing graphene powder so as to create a super strong 3D object. As another example, each semi-cured resin layer could be pressed into a vat of fiberglass such that the fiberglass is coupled to the semi-cured resin. The resin may then be allowed to finish curing before the next layer of resin is formed. In other embodiments, this process could be used to embed sensors in 3D printed objects.

Wet/dry 3D printing

An example system includes: (i) a resin container defining a cavity; (ii) a plurality of rods extending from an inner base surface of the resin container and into the cavity; (iii) a plurality of light sources arranged to emit radiation into the plurality of rods, such that when the cavity contains liquid resin, radiation passing through a given one of the rods cures liquid resin that surrounds the given rod; and (iv) a control system configured to: (a) receive data specifying a three-dimensional structure; (b) determine a shape for a layer of a plurality of layers that collectively form the three-dimensional structure; and (c) determine one or more of the light sources that correspond to the shape of the layer; and (d) form the layer by operating the one or more determined light sources that correspond to the shape of the layer.

Voxel 3D printer

Example implementations may relate to shifting a curing location during a three-dimensional (3D) printing procedure. A system may control components of a 3D printer to form a first layer of the 3D structure from resin in a first area of a resin container. The components may include: (i) a base plate and (ii) light source(s) operable to emit radiation that cures resin. After formation of the first layer, the system may move the resin container with respect to the base plate such that a second layer of the 3D structure can be formed in a second area of the resin container. The second area and the first area may be at least partially non-overlapping. The system may then control the components of the 3D printer to form the second layer of the 3D structure from resin in the second area of the resin container.

Shifting a curing location during 3D printing

An example three-dimensional printer system includes (a) a resin container, (b) a base plate, (c) a light source arranged below the resin container, where the light source is operable to emit electromagnetic radiation that causes resin in the resin container to cure, (d) a robotic device having the base plate attached thereto, wherein the robotic device positions the base plate above the resin container and is operable to move the base plate with at least two degrees of freedom, such that a build volume of the three-dimensional printer system extends beyond the edges of the resin container, and (e) a control system that is operable to (i) receive data specifying a three-dimensional structure and (ii) generate control signals that coordinate movement of the base plate by the robotic device and operation of the light source to form the three-dimensional structure from layers of resin.

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San Francisco, CA, United States of America

Jonathan Proto