Volumetric three-dimensional (3D) printing system

Abstract

A method can include: (a) providing a cartridge including a volume of a photocurable composition in an irradiation zone; (b) selectively irradiating the volume of photohardenable composition included in the cartridge with excitation light of one or more wavelengths to at least partially harden, polymerize and / or crosslink the resin composition to at least partially form one or more objects in the volume; (c) removing the cartridge from the irradiation zone after the selective irradiation step; and optionally repeating steps (a)-(c) with a series of one or more further cartridges, said one or more further cartridges comprising a next volume of the photocurable composition. An assembly for printing 3D objects may include a printer having at least one excitation light source configured to cure a photocurable resin and form one or more 3D objects in a cartridge.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This patent claims priority to U.S. Provisional Patent Application No. 63 / 343,562, filed on May 19, 2022, by Quadratic 3D, Inc., "Cartridge, System, and Method for Volumetric 3D Printing"; and U.S. Provisional Patent Application No. 63 / 400,448, filed on August 24, 2022, by Quadratic 3D, Inc., "Volumetric Three-Dimensional (3D) Printing System," each of which is incorporated herein by reference in its entirety for all purposes. Technical Field

[0003] Aspects of the present invention relate generally to three-dimensional (3D) printing, and particularly to methods and apparatus for hands-free volumetric printing of one or more 3D objects. Background Art

[0004] 3D printers are known to be used to form a variety of objects. Some 3D printers can direct one or more light sources into a container of light-hardenable material to form a 3D object within the container. Such 3D printers can form the 3D object on a building platform located within the container. Once the 3D object is printed, it must be separated from the building platform.

[0005] It would be ideal to provide a zero-contact or hands-free system for printing one or more 3D objects by projecting (projecting) one or more light sources into a container of photohardenable material and performing post-processing steps on the 3D objects, including washing, drying, curing, inspecting and / or packaging. Summary of the invention

[0006] The present invention includes a high throughput system and method for manufacturing multiple 3D objects.The principles of the present invention can be used to create 3D objects within a volume of resin in a carriage by exposing the resin to one or more excitation light sources.

[0007] According to a first aspect, a method may include: (a) providing a box comprising a volume of a photohardenable composition in an irradiation zone; (b) selectively irradiating the volume of photohardenable composition included in the box with one or more wavelengths of excitation light to at least partially harden, polymerize and / or cross-link the resin composition, thereby at least partially forming one or more objects in the volume; (c) removing the box from the irradiation zone after the selective irradiation step; and repeating steps (a)-(c) with a series of one or more additional boxes, wherein the one or more additional boxes comprise the next volume of the photohardenable composition.

[0008] According to another aspect, a 3D printing assembly includes a printer clamping assembly configured to move a box containing a photohardenable resin. The printer assembly includes at least one excitation light source configured to cure the photohardenable resin and form one or more 3D objects in the box. The box flipping assembly is configured to insert a basket in an inverted orientation (position) into the box and rotate the box to an inverted orientation so that one or more 3D objects are transferred to the basket and liquid resin flows out of the box. The basket clamping assembly is configured to remove the basket from the box and transfer the basket to a first washing station. A second washing station is located downstream of the first washing station. A drying station is located downstream of the second washing station. A pre-curing station is located downstream of the drying station. A transfer assembly is configured to transfer the one or more 3D objects from the basket to the curing tray. An inspection station is configured to inspect the one or more 3D objects in the curing tray. A sealing station is configured to fix a sealing film to the top surface of the curing tray. A transfer tray is configured to receive one or more curing trays.

[0009] Using an automated system to print 3D objects in a resin provided in a box can provide significant improvements in throughput and efficiency while reducing the cost for manufacturing multiple 3D objects. These and other features and advantages disclosed herein will be further understood from the following detailed disclosure of some embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 A schematic diagram of a process for printing one or more 3D objects.

[0011] Figure 2 For use Figure 1 A perspective view of the printed components during the process.

[0012] Figure 3 for Figure 2 A perspective view of a portion of a printing assembly showing an array of cartridges ready for printing.

[0013] Figure 4 for Figure 2 A perspective view of a portion of a printing assembly showing a cartridge loaded into a printer.

[0014] Figure 5 for Figure 2 A perspective view of a portion of a printing assembly showing printing of a first volume of a cartridge.

[0015] Figure 6 for Figure 2 A perspective view of a portion of a printing assembly showing further printing of the first volume of the cartridge.

[0016] Figure 7 for Figure 2 A perspective view of a portion of a printing assembly showing printing of the fourth volume of the cartridge.

[0017] Figure 8 for Figure 2 A perspective view of a portion of a printing assembly showing a cassette with a printed 3D object therein prior to transfer to a basket.

[0018] Fig. 9 for Figure 2 A perspective view of a portion of a printing assembly showing the cover removed from the cartridge.

[0019] Fig.10 for Figure 2 A perspective view of a portion of a printing assembly showing the basket prior to insertion into the cartridge.

[0020] Fig.11 for Figure 2 A perspective view of a portion of a printing assembly of FIG. 1 , showing the basket inverted and inserted into the cassette.

[0021] Fig.12 for Figure 2 A perspective view of a portion of the printing assembly of FIG. 1 , showing the basket and cartridge before the resin is drained from the cartridge.

[0022] Fig.13 for Figure 2 A perspective view of a portion of the printing assembly showing the inverted cartridge and basket so that resin is draining from the cartridge.

[0023] Fig.14 for Figure 2 A perspective view of a portion of a printing assembly of FIG. 1 is shown placing a basket into a basket carriage.

[0024] Fig.15 for Figure 2 A perspective view of a portion of a printing assembly showing a basket in a basket carrier and an empty cassette lifted from the basket.

[0025] Fig.16 for Figure 2 A perspective view of a portion of a printing assembly showing an empty cartridge being removed from a process stream.

[0026] Fig.17 for Figure 2 A perspective view of a portion of a printing assembly showing an empty cartridge placed in a cartridge collection tray.

[0027] Fig.18 for Figure 2 A perspective view of a portion of a printing assembly showing the basket clamping assembly moving the basket.

[0028] Fig.19 for Figure 2 A perspective view of a portion of a printing assembly showing a basket deposited into a first wash tub.

[0029] Fig. 20 for Figure 2 A perspective view of a portion of a printing assembly showing the basket deposited into a second wash tub.

[0030] Fig. 20A for Figure 2 A perspective view of a portion of the printing assembly showing the basket being deposited into the drying basin.

[0031] Fig.21 for Figure 2 A perspective view of a portion of a printed assembly showing the basket being deposited into a pre-curing basin.

[0032] Fig. 22 for Figure 2 A perspective view of a portion of the printing assembly showing the transfer assembly holding the curing tray and basket.

[0033] Fig.23 for Figure 2 A perspective view of a portion of the printing assembly showing the rotating basket to slide the 3D object into the curing tray.

[0034] Fig.24 for Figure 2 A perspective view of a portion of the printing assembly showing the bulkhead walls of the transfer assembly that guides the 3D objects from the basket to the curing tray.

[0035] Fig.25 for Figure 2 A perspective view of a portion of a printed assembly showing an inspection station including a camera for inspecting 3D objects.

[0036] Fig.26 for Figure 2 A perspective view of a portion of a printing assembly showing a sealing station applying a sealing film to a curing tray.

[0037] Fig. 27 for Figure 2 A perspective view of a portion of a printing assembly of , showing a needle injecting gas into the curing tray when the curing tray is sealed.

[0038] Fig.28 for Figure 2 A perspective view of a portion of a printing assembly showing a curing tray being transported in a transfer tray.

[0039] Fig.29 for Figure 2 A side perspective view of a cartridge of a printing assembly.

[0040] Fig.30 for Fig.29 Bottom perspective view of the box.

[0041] Fig.31 for Fig.29 A front view of the box, shown in its orientation when filled.

[0042] Fig.32 For Fig.31 A bottom perspective view of a portion of the box shown in FIG. 1 , shown partially cut away.

[0043] Fig.33 For Fig.31 A top perspective view of a portion of the box shown in FIG. 1 , shown partially cut away.

[0044] Fig.34 Examples of dimensional parameters for determining preferred box dimensions are depicted. Coordinate axes for the drawings are also shown.

[0045] Fig.35 An example of an example of dimensional parameters for determining a preferred box size is depicted. Coordinate axes for the drawing are also shown.

[0046] Fig.36 Describes the use Fig.34 and 35 Legend for .

[0047] Fig.37 Examples of dimensional parameters for determining preferred box dimensions are depicted. Coordinate axes for the drawings are also shown.

[0048] Fig.38 Depicted is an example of dimensional parameters for a box comprising multiple print zones, one of which is outlined and labeled "1 Bounding Box." Coordinate axes for the drawing are also shown.

[0049] Fig.39 Describes the use Figure 2 Legend for A and 2B.

[0050] Fig.40 An example of a box comprising five printing zones is depicted.

[0051] Fig.41 An example of a system including two optical systems positioned to direct excitation light transmission into a print zone is depicted. (Other optical systems associated with other print zones are not shown.)

[0052] The drawings mentioned above are not necessarily drawn to scale and should be understood to provide representations of specific embodiments disclosed herein and are only conceptual in nature and illustrative of the principles involved. Some features of the 3D printing components depicted in the drawings have been enlarged or deformed relative to other features to facilitate description and understanding. For similar or identical components and features shown in various alternative embodiments, the same reference numerals are used in the drawings. The 3D printing components disclosed herein will have configurations and components determined in part by the intended application and environment in which the components are used. DETAILED DESCRIPTION

[0053] The present invention can be implemented in various forms. For convenience, the terms "upper" and "lower" and "top" and "bottom" are used herein to distinguish between the upper and lower ends of the components described herein. The terms "interior" and "exterior" are used herein to distinguish between the interior and exterior portions of the components described herein. It will be understood that the use of "upper" and "lower", and "top" and "bottom", and "interior" and "exterior" is only for ease of description and understanding, and is not intended to limit the possible spatial orientations of the components described herein during assembly or use.

[0054] As used herein, the term "substantially" is intended to mean mostly the same or nearly the same within the constraints of reasonable commercial engineering goals, costs, manufacturing tolerances, and capabilities in the field of volumetric 3D printed component manufacturing and use. Similarly, the term "approximately" as used herein is intended to mean close to or about a particular value within the constraints of reasonable commercial engineering goals, costs, manufacturing tolerances, and capabilities in the field of volumetric 3D printed component manufacturing and use.

[0055] A method 10 for printing one or more 3D objects is schematically presented in Figure 1 In step A, a first array 12 of primary containers, such as boxes 14, and a second array 16 of secondary containers, such as baskets 18, may be provided. Each basket 18 may have an open end 20 and an opposite closed end 22.

[0056] Each basket 18 can be configured so that a liquid, such as a resin, can flow therethrough while still maintaining the ability to retain solid objects therein. In some embodiments, the basket 18 can be formed of a perforated material. In other embodiments, the basket 18 can be formed of a grid or mesh material. Other suitable forms for the basket 18 will become readily apparent to those skilled in the art, given the benefit of this disclosure.

[0057] Each box 12 may contain a volume of a photopolymerizable or photohardenable composition 24. The photohardenable composition may be a resin 24. The resin 24 may include liquids such as monomers and oligomers, additives, and photoinitiators, and may undergo at least partial hardening, polymerization, or crosslinking to at least partially form an object when exposed to one or more excitation light sources. The resin 24 may also include polymers, prepolymers, additives, and fillers. Other suitable elements to be added to the resin 24 will become readily apparent to those skilled in the art given the benefit of this disclosure.

[0058] Preferred photoinitiators include photoconvertible photoinitiators that can be activated by exposure to light having a first wavelength and light having a second wavelength to at least partially harden, polymerize or crosslink a photohardenable composition, wherein the first and second wavelengths are different. Photohardenable compositions that exhibit non-Newtonian rheological behavior may be preferred. Examples of such non-Newtonian rheological behavior include, but are not limited to, pseudoplastic fluids, yield pseudoplasticity, Bingham pseudoplasticity, or Bingham plastic behavior. Photohardenable compositions that exhibit pseudoplasticity or Bingham pseudoplasticity behavior may be more preferred. Photohardenable compositions that exhibit non-Newtonian behavior can promote the formation of an object in a certain volume of photohardenable composition when selectively exposed to one or more wavelengths of excitation light without the need for adding a support structure, wherein the object remains in a fixed position during the formation of the object or is minimally displaced in the volume of the unhardened photohardenable composition. Minimum displacement refers to the displacement of the object in the volume during the formation of the object, which is acceptable for accurately producing the desired component (or object) geometry. Most 3D printing techniques typically require support structures to stabilize the part during printing or to allow printing of thin or fragile overhanging portions of the part; after printing, post-processing is required to remove the support structures, which can damage or leave marks on the printed part. Avoiding the addition of support structures can advantageously simplify post-processing of the printed part and improve part surface quality. The non-Newtonian behavior of the photohardenable composition can advantageously simplify separation of the part from unpolymerized photohardenable composition when pressure is applied. Exemplary photoconvertible photoinitiators and photohardenable compositions including the same as may be included in the methods and printing components described herein are discussed in International Application No. PCT / US2022 / 037491, filed on July 18, 2022, by Quadratic 3D, Inc., “Photohardenable Compositions And Methods For Forming An Object In A Volume Of A Photohardenable Composition,” and U.S. Provisional Patent Application No. 63 / 341,594, filed on May 13, 2022, by Quadratic 3D, Inc., “Photoinitiators, Compositions, and Methods For Forming An Object,” each of which is incorporated herein by reference.

[0059] At step B, one of the cassettes 14 filled with resin 24 may be removed from the first array 12 and introduced into a printer containing an irradiation zone. It will be appreciated that each cassette 14 may include one or more printing zones 26 in which a 3D object may be created. Figure 1 , each cartridge 14 has three (3) print zones 26, such that three separate 3D objects may be sequentially formed within a volume of resin 24 in the cartridge 14. For purposes of illustration, vertical lines are shown herein within the cartridge 14 to delineate the separate print zones 26. However, it will be understood that there may be no actual physical barriers between the separate print zones 26 within the cartridge 14.

[0060] It will be appreciated that each cartridge 14 may include one or any other number of print zones 26. In further embodiments described herein, each cartridge 14 may include five (5) print zones 26. Other embodiments may naturally include more than five (5) print zones 26. The appropriate number of print zones 26 for a cartridge 14 will become readily apparent to those skilled in the art, given the benefit of this disclosure.

[0061] The box 14 can be an open container or a closed container. An open container is not airtight and can optionally include one or more openings while retaining its ability to contain a certain volume of resin 24. For example, the box 14 can have one or more openings above the portion of the box containing the volume, such as a fully or partially open top side of the container and / or one or more openings in the sidewalls or ends of the container. The container can be a closable container. Examples of closable containers include, but are not limited to, for example, containers with removable lids or hinged lids. The removable or hinged lid can be a fully or partially removable lid or a fully or partially hinged lid. In Figure 1 In the embodiment shown in FIG. 8 , the cassette 14 may include a removable cover 28 .

[0062] In step C, the volume of resin 24 in each box 14 can be irradiated with one or more wavelengths of excitation light to at least partially harden, polymerize and / or cross-link the resin 24, thereby at least partially forming one or more 3D objects 30 in the volume of resin 24.

[0063] In some embodiments, for example, embodiments including irradiation with two light sources, the primary light source can be a projector that patterns an image with light of one wavelength, and the secondary light source can project a light sheet, which can be a one-dimensional line or scanned beam, at a wavelength different from that of the patterned image. The patterned image and light sheet can be arranged so that they are projected to meet at different intersecting surfaces in space, and in some embodiments, can be projected orthogonally relative to each other.

[0064] Examples of projectors or projection devices for use with the methods and systems described herein may include, but are not limited to, laser projection systems, liquid crystal displays (also referred to herein as “LCDs”), spatial light modulators (also referred to herein as “SLMs”) (such as, but not limited to, digital micromirror devices (also referred to herein as “DMDs”) or digital light processing devices (also referred to herein as “DLPs”)), micro-LED arrays, vertical cavity laser arrays (also referred to herein as “VCLs”), vertical cavity surface emitting laser arrays (also referred to herein as “VCSELs”), liquid crystal on silicon (also referred to herein as “LCoS”) projectors, and scanning laser systems. (Light emitting diodes are also referred to herein as “LEDs”).

[0065] Examples of light sources that may be suitable for use in the present invention including excitation light in various aspects of the light source include, by way of example and not limitation, lasers, laser diodes, light emitting diodes, light emitting diodes (LEDs), micro-LED arrays, vertical cavity lasers (VCLs), and filter lamps. Such light sources are commercially available, and the selection of suitable light sources can be readily performed by a person of ordinary skill in the relevant art. LEDs of the type such as the Phlatlight LEDs available from Luminus for use with DMDs may be preferred.

[0066] Optionally, the excitation light may be temporally and / or spatially modulated. Optionally, the intensity of the excitation light may be modulated. Optionally, source drive modulation may be used to adjust the absolute power of the light beam.

[0067] The configuration of the projector device and the light source may optionally further include one or more optical components (eg, projection optics, illumination optics, lenses, lens systems, mirrors, prisms, etc.).

[0068] In embodiments where excitation light is projected from two light sources into box 14, resin 14 at least partially hardens, polymerizes or crosslinks at the intersection of the projections of excitation light from the two light sources. By moving the intersection through box 14, a 3D object can be created from resin 14.

[0069] In some embodiments, the intersection of the primary and secondary sources of excitation light may be movable relative to the box 14. In other embodiments, the intersection may be fixed and the box 14 may be movable to form one or more 3D objects 30 in the box 14.

[0070] At step D, the cartridge 14 may be removed from the printer, and the cover 28 may be removed from the cartridge 14. The cover 28 may then be collected for cleaning and then installed on another cartridge 14 after the cartridge 14 has been filled with resin 24.

[0071] At step E, the basket 18 may be inserted into the cassette 14 in an inverted manner such that the open end 20 of the basket 18 is placed over the corresponding 3D object 30 within the cassette 14 and the closed end 22 faces upward.

[0072] At step F, the cartridge 14 may be inverted so that the resin 24 flows out of the cartridge 14 into the collection basin 32. The resin 24 may then be retrieved from the collection basin 32 for reuse in forming additional 3D objects 30.

[0073] At step G, the cartridge 14, which is in an inverted orientation, is rotated to an upright orientation. The cartridge 14 may then be transferred to a refilling station where additional resin 24 may be inserted into the cartridge 14. Optionally, the cartridge 14 may be cleaned prior to refilling. The cartridge 14 with the resin 24 may then be subsequently placed within the first array 12 for use in forming additional 3D objects 30. It will be appreciated that, in the event that the cartridge 14 is not suitable for reuse, the cartridge 14 may be disposed of (discarded) at this step.

[0074] At step H, basket 18 with 3D objects 30 located therein may be moved to first washing station 34, where 3D objects 30 may undergo a first wash using a washing solution. At step J, basket 18 with 3D objects 30 located therein may be moved from first washing station 34 to second washing station 36, where 3D objects 30 may undergo a second wash using a washing solution.

[0075] At step K, the basket 18 with the 3D objects 30 located therein may be moved from the second washing station 36 to a drying station 38, where the 3D objects 30 within the basket 18 may be dried. In some embodiments, the 3D objects within the basket may also undergo initial ultraviolet (UV) curing at the drying station 38 or at a separate curing station downstream of the drying station 38.

[0076] At step L, the basket 18 may be transferred from the drying station 38 and inverted such that the closed end 22 of the basket 18 faces upward and the open end 20 faces downward, such that the 3D objects 30 fall or slide out of the basket 18 into the curing tray 40 .

[0077] In step M, with 3D object 30 in curing tray 40, additional processing steps may be performed, including, for example, polishing of 3D object 30. Additionally, during step M, oxygen may be purged from curing tray 40, and an inert gas such as argon or nitrogen may be introduced into curing tray 40 to provide an inert atmosphere for 3D object 30. A cover or seal 42 may then be secured to curing tray 40.

[0078] At step N, the 3D object 30 may be optically inspected and then undergo additional post-curing treatments, including but not limited to UV exposure and heating. The curing tray 40 may be located in a shipping tray 44. The shipping tray 44 may then be moved to a packing station (not shown), where the curing tray 40 may be labeled and packed for shipping.

[0079] It will be appreciated that steps AN can each be performed in a zero-contact, hands-free manner by a robotic automated handling assembly, thereby providing a high-throughput system with increased efficiency and reduced cost for the fabrication of multiple 3D objects.

[0080] By forming one or more 3D objects 30 within a volume of resin 24 in cartridge 14 without a build platform, there is no expense or labor required to separate the 3D objects from the build platform, and therefore, no chance of damage to 3D objects 30 when removing them from the build platform.

[0081] Because each 3D object 30 is formed within a different print zone 26 of the cassette 14 and then transferred to a separate basket 18, it is easy for the system to track each individual 3D object as it progresses through the automation components, thereby enhancing quality control throughout the entire process.

[0082] An exemplary volumetric 3D printing assembly 50 is shown in Figure 2 In. Will understand, Figure 1 Some of the reference numerals used in describing the overall printing process may be used in the following figures for similar or identical components and features shown in various alternative embodiments.

[0083] The printing assembly 50 can be configured as an automated assembly that operates in a zero-touch, hands-free manner, thereby providing a high-throughput system with increased efficiency and reduced cost for the manufacture of multiple 3D objects. The printing assembly 50 may include a housing or shell 52 to house the printing assembly 50. The shell 52 may include a UV blocking window 54 to shield elements of the printing process from UV light and for laser safety, for example, by attenuating the optical power of light that can leave the system. The shell 52 may include one or more ventilation or exhaust hoods 56 having exhaust ports 58 that work in conjunction with one or more exhaust fans (not shown) to allow gases and vapors from the printing process to be exhausted from the shell 52.

[0084] Printing assembly 50 may include one or more human machine interfaces (HMI) 59 that allow an operator to interact with a controller (not shown) for printing assembly 50. The controller may be any type of computer, such as, for example, a programmable logic computer (PLC), that allows an operator to control various components and processes associated with printing assembly 50.

[0085] The printing assembly 50 may include a 3D printer assembly 60 that uses an excitation light source to form a 3D object from a volume of resin, as described in more detail below. It will be understood that various assembly steps or processes such as printing of a 3D object are performed using the printing assembly 50 at various locations or stations within the printing assembly 50. Figure 1 The steps discussed are discussed in more detail below.

[0086] like Figure 3-4 , the first array 12 of cassettes 14 may be located on a conveyor assembly 62, which may include one or more conveyors 64 that move the cassettes 14 forward or downstream in the direction of arrow P through the printing process to a pick-up position 66 at the downstream end of the conveyor assembly 62. At this point, the cassettes 14 are filled with resin 24 and have lids 28 secured thereto, and are ready to be moved to the printer assembly 60 to print a 3D object. It is desirable that the resin 24 in the closed cassettes 14 be free of bubbles. It is also desirable that, if a lid is included, there be no gap between the top surface of the resin 24 and the inner surface of the lid 28, for example, so that the resin 24 is in contact with the inner surface of the lid 28.

[0087] The box 14 can be constructed of materials including, for example, but not limited to, glass, quartz, fluoropolymers (e.g., Teflon FEP, Teflon AF, Teflon PFA), cyclic olefin copolymers, polymethyl methacrylate (PMMA), polynorbornene, sapphire, or transparent ceramics. Other materials that are optically transparent and optically flat with appropriate hardness may also be suitable. Other suitable materials for the box 14 will become readily apparent to those skilled in the art given the benefit of this disclosure.

[0088] Each box 14 may include one or more transparent areas to allow one or more wavelengths of excitation light to enter the box 14. For example, one or more of the side walls of the box 14 and the cover 28 may be transparent to allow light to pass therethrough. Additionally, one or more of the walls or sides of the box 14 or the entire box 14 may be coated. For example, but not limited to, one or more sides may include an anti-reflective coating, a mechanical enhancement coating, a chemical resistant coating, etc. Optionally, one or more sides may include a coating on its inner surface to enhance the cleanability of the box 14 after the box 14 is emptied.

[0089] It will be appreciated that the cartridge 14 may be sized to accommodate the dimensions of a 3D object to be printed therein, as described in greater detail below.

[0090] When the cartridge 14 is placed in the pick-up position 66, the printer gripper assembly 68 may move the new, ready-for-printing cartridge 14 into the printer assembly 60. The printer gripper assembly 68 may include one or more cartridge grippers 70 that grip the cartridge 14 to move it into the printer assembly 60. As used herein, a gripper may be a claw, clamp, forceps, or any other mechanical gripping device suitable for gripping onto or clamping onto an object so that the object may be moved or otherwise manipulated.

[0091] In the illustrated embodiment, the first set 72 of two cartridge grippers 70 is operated to grasp opposite sides of the cartridge 14. The printer gripper assembly 68 can then move the cartridge 14 onto the print carriage 74, as shown. Figure 4 7, where the cartridge anchor assembly 75 can engage the cartridge 14 and temporarily secure it to the print carriage 74. The printer clamp assembly 68 may include a track or guide 76 along which components of the printer clamp assembly 68, including the clamp 70, can move upstream and downstream along the printing process.

[0092] Once the cartridge 14 has been placed on the print carriage 74, the first set 72 of grippers 70 may release the cartridge 14 and move upwardly away from the cartridge 14 (not shown). The print carriage 74 may then be operated to move the cartridge 14 laterally out of the printing process into the printer assembly 60 in the direction of arrow A, wherein a 3D object is partially or fully formed in the cartridge 14, as described in more detail below.

[0093] When the first group 72 of the box clamps 70 is clamping the box 14 ready for printing, the second group 78 of the box clamps 70 can simultaneously grab the just-printed box 14 located on the print carriage 74 and just transferred laterally out of the printer assembly 60, such as Figure 3 As seen in Figure 4 As seen in FIG. 1 , the first set 72 and the second set 78 of grippers 70 may travel downstream along the track 76 to move the just-printed cartridge 14 to the basket platform 80, which has moved upstream to an unloading position for the just-printed cartridge 14. At this point, the second set of grippers 70 may release the just-printed cartridge 14 and move upwardly away from the cartridge 14. The just-printed cartridge 14 may be secured to the basket platform 80 with suitable releasable fasteners (not shown).

[0094] The printing of the 3D object 30 in the box 14 will now be done by Figure 5-7 Once the first set 72 of clamps 70 have been moved upwardly away from the cartridge 14, the print carriage 74 may be moved along the print carriage track 81 into a printing position within the printer assembly 60. Figure 5 As seen in FIG. 1 , the box 14 is positioned to print in the first or innermost printing area 26 of the box 14.

[0095] As described above, the resin 24 in the box 14 can be irradiated with one or more wavelengths of excitation light to at least partially harden, polymerize and / or cross-link the resin 24, thereby at least partially forming one or more 3D objects 30 (not shown) in the volume of resin 24.

[0096] In the illustrated embodiment, the primary light source 82 may illuminate a projector device (not shown) that patterns an image 84 at a first wavelength by forming a temporal sequence of cross-sectional patterns corresponding to the cross-sections of the object to be printed. The image is preferably orthogonal to its projection axis into the box. The secondary light source 86 may illuminate a light sheet generator (not shown) for generating and directing a light sheet 88 at a second wavelength, which is a different wavelength from the first wavelength that patterns the image 84. Examples of light sheet generators include, by way of example, a cylindrical lens, a Powell lens, a galvanometer, a polygonal scanning mirror, a MEMS scanner, a diffractive optical element, and an axicon lens. The light sheet is preferably directed into the box in a direction orthogonal to the projection axis of the image.

[0097] The light sheet 88 is depicted here as having a substantial vertical thickness for illustrative purposes only. In the illustrated embodiment, the patterned image 84 and light sheet 88 are arranged so that they are projected to intersect at different areas within the box 14.

[0098] When the image 84 and the light sheet 88 are projected into the box 14, the resin 14 is at least partially hardened, polymerized or cross-linked at the intersection area of ​​the image and light sheet projections from the two light sources. By moving the intersection area through the box 14, a 3D object 30 can be created from the resin 14. Figure 5-7 In the embodiment shown in , the intersection of the wave image 84 and the light sheet 88 is fixed in space, and the box 14 moves to form one or more 3D objects 30 in the box 14.

[0099] The print carriage 74 may include a housing 90 and a movable first portion 92 configured to move vertically relative to the housing 90. The first portion 92 may include an angled lower surface 94. A movable second portion 96 of the housing 90 may be configured to move horizontally relative to the housing 90 and may include an angled upper surface 98. The piston 100 may be secured at one end thereof to the second portion 96 and at an opposite second end thereof to a reciprocating drive assembly (not shown) that is operated to move the piston back and forth along the print carriage track 81.

[0100] As the piston 100 moves back and forth along the print carriage track 81, the upper surface 98 of the second portion 96 drivingly engages the lower surface 94 of the first portion 92, thereby causing the first portion 92 to move upward and downward. The upward and downward movement of the first portion 92 and the lateral movement of the print carriage 74 along the print carriage track 81 allow the print area 26 of the cartridge 14 to move relative to the intersection of the wave pattern 84 and the light sheet 88.

[0101] Movement of the print carriage 74 along the print carriage track 81 provides positioning or translation of the cartridge 14, and therefore, provides positioning or translation of the print volume 26 in the y-direction. Vertical movement of the first portion 92 provides positioning or translation of the cartridge 14, and therefore, provides positioning or translation of the print volume 26 in the z-direction. The print carriage 74 can also move in a direction orthogonal to the print carriage track 81 to provide positioning or translation of the cartridge 14, and therefore, provides positioning or translation of the print volume 26 in the x-direction.

[0102] Thus, the cartridge 14 is moved relative to the intersection of the image 84 and the light sheet 88 as needed to form the desired 3D object in the first print region 26 of the cartridge 14. After printing of the 3D object within the first print region 26, additional 3D objects may be formed in the remaining print regions 26 of the cartridge 14. Figure 5 and 6 As shown in FIG. 2 , display printing is performed in the first or innermost print area 26 . Figure 7 Printing in the fourth printing area 26 is shown. Figure 5-7 In the illustrated embodiment, the cartridge 14 includes five (5) print zones 26 in which the 3D objects are printed. As described above, the cartridge 14 may include any desired number of print zones. Once the 3D object has been printed in each print zone 26, the print carriage 74 may be moved laterally back out of the printer assembly 60.

[0103] It will be appreciated that in other embodiments, the area of ​​intersection of image 84 and light sheet 88 may be moved by moving primary light source 82 and secondary light source 86 relative to cartridge 14 .

[0104] Other exemplary printers that can be used in the printing assembly 50 are discussed in: International Application No. PCT / US2022 / 039766, filed on August 9, 2022, by Quadratic 3D, Inc., “Methods And Systems ForForming An Object In A Volume Of A Photohardenable Composition,” and U.S. Provisional Application No. 63 / 287,510, filed on December 8, 2021, by Quadratic3D, Inc., “Volumetric Three-Dimensional Printing Methods Including a Combined Light Sheet And System,” each of which is incorporated herein by reference. Optionally, the printer may further include one to three additional light sheet generation systems (e.g., including a light sheet generator and a light source having the same wavelength as the first light sheet) for generating one to three additional light sheets and directing them into the box 14 orthogonal to the first light sheet so as to intersect with the first light sheet and be imaged at the same different locations in the box 14. The wavelength of any additional light sheet may be the same as or different from the wavelength of the first light sheet.

[0105] In the systems and methods disclosed herein, the selection of the wavelength(s) of the excitation light for the excitation light projection is preferably made taking into account the photohardenable composition and hardening mechanism used. For example, for a photohardenable composition that can be hardened via a hardening mechanism involving excitation light of a single wavelength, one or more excitation light projections having the same wavelength can be used. Optionally in this case, excitation light projections comprising light of different wavelengths can also be included, for example, to suppress undesired hardening of the photohardenable composition.

[0106] In the case of a photohardenable composition that can be hardened via a hardening mechanism involving more than one wavelength of excitation light, the wavelength of the excitation light projection will be selected to project excitation light having an appropriate wavelength for the hardening mechanism. Optionally, additional wavelengths of light may also be used to inhibit undesired hardening of the photohardenable composition.

[0107] The systems and methods disclosed herein can be used with other 3D printing technologies that include initiating a photochemical reaction in a photoreactive system to form an object via absorption of light energy provided by one or more excitation light projections. Examples include tomography printing, two-photon printing, upconversion printing, and dual-wavelength printing.

[0108] As mentioned above about Figure 3-4As described, after the just printed cartridge 14 has been moved out of the printer assembly 60, it is then moved to the basket platform 80 while the cartridge 14 ready for printing is moved from the array 12 to the print carriage 74. The cartridge 14 can then be movably secured to the basket platform 80 by the cartridge anchor assembly 75.

[0109] The basket platform 80 can then be moved along the printing process by the servo slide 102, which is used to properly position the cassette 14. Figure 8 As seen in FIG. 8 , the basket holder 104 is located just downstream of the cassette 14 , and an empty basket may be located in the first position 106 of the basket holder 84 .

[0110] The cover 28 is then removed from the box 14, as shown. Fig. 9 1. The cover clamping assembly 108 may include a pair of cylindrical clamps 110, each of which grasps and rotates a corresponding fastener 112, which secures the cover 28 to the box 14. In the illustrated embodiment, the fastener 112 is a quarter turn fastener, which is released by the cylindrical clamp 110. The cover clamping assembly 108 may include one or more cover clamps 114 that grasp the cover 28. Once the cylindrical clamp 110 releases the fastener 112, the cover clamping assembly 108 can remove the cover 28 from the box 14 and then move it laterally to the cover collection tray 116, at which time the cover 28 is lowered into the collection tray 116 and the cover clamp 114 releases the cover 28. The cover collection tray 116 may include a pair of opposing cover rails 118, and a plurality of covers 28 can be moved downstream in the cover collection tray 116 by a pneumatic slide 119 along the cover rails 118 for subsequent collection, cleaning and reuse.

[0111] Fig.10 The movement of an empty basket 18 from a first position 106 in a basket bracket 104 to a freshly printed cassette 14 on the basket platform 80 is shown and is illustrated with reference to FIG. Figure 3-9 In contrast, here the process is viewed from the opposite side. As seen here, the box flip assembly 120 may include a pair of basket grippers 122 that grasp the basket 18, which is positioned in an upright position in the basket bracket 104 with the open end 20 facing upward. A pair of cutouts 124 formed in the basket bracket 104 may allow the basket grippers 122 to grasp the basket 18 near its bottom edge.

[0112] The cassette invertor assembly 120 then lifts the basket 18 off the basket bracket 104, rotates the basket 18 to an inverted orientation with the open end 120 facing downward, moves the basket 18 to a position above the cassette 14, and lowers the basket 18 into the cassette 14, as shown. Fig.11It will be appreciated that the box flip assembly 120 may be controlled by a servo motor that allows fine control of the movement of the box flip assembly 120 to help prevent damage to the 3D objects within the box 14 and basket 18.

[0113] Once the basket 18 is fully inserted into the box 14, a pair of box grippers 126 ( Fig.10 and 13 The box 14 is released from the basket platform 80, and the box flip assembly 120 lifts the box 14 and the basket 18 upward off the basket platform 80, as shown in FIG. Fig.12 The basket platform 18 then moves upstream away from the box turning assembly 120.

[0114] like Fig.13 , the box flip assembly 120 then rotates the box 14 and the basket 18 using the pneumatic rotating cylinder 127 so that the box 14 is in an inverted orientation and the basket 18 is in an upright orientation, so that the resin 24 that has not yet hardened into a 3D object flows and / or drips out of the uncovered box 14 and through the basket 18, thereby leaving the 3D object within the basket 18. The resin 24 flows downwardly out of the box 14 into the drip tray 128. The resin 24 collected in the drip tray 128 can be collected and reused to refill the empty box 14 before being covered and returned to the array 12.

[0115] like Fig.12 As seen in FIG. 1 , the box inversion assembly 120 may include a vibrator 130, which may be pneumatic, that may apply a vibrating or shaking force to the box inversion assembly 120, which may help loosen or dislodge the resin 24 within the box 14 so that it more easily flows out of the box 14 into the drip tray 128. The box 14 may be suspended in this inverted orientation for a predetermined period of time to ensure that all of the resin 24 has flowed out of the box 14.

[0116] like Fig.14 106 , the basket platform 80 is then moved below the cassette flip assembly 120 and the basket 18 is lowered into the second position 132 within the basket holder 104. The second position 132 has a depth that is less than the depth of the first position 106. The gripper 122 then releases the basket 18 and the cassette flip assembly 120 is slightly raised, at which point the gripper 122 grabs the basket 18 at a higher point, thereby exposing more of the basket 18 below the gripper 122. The cassette flip assembly 120 is then raised, the basket platform 80 is slightly moved so that the basket 18 is above the first position 106, and the basket 18 is lowered into the first position 106 of the basket holder 104. As described above, the first position 106 of the basket holder 104 is deeper than the second position 132, providing more support to the sidewalls of the basket 18 as it passes through the remainder of the process, thereby helping to keep the basket 18 in a stable orientation and helping to prevent tilting of the basket 18.

[0117] The box flip assembly 120 then raises the empty box 14 in its inverted orientation, leaving the basket 18 with the 3D object located therein in the first position 106 of the basket holder 104, as shown in FIG. Fig.15 The box 14 is then rotated back to its upright position and moved laterally out of the printing process to the box collection tray 134, as shown. Figure 16-17 16. The cartridge collection tray 134 may be located above the lid collection tray 116 and may include a pair of opposing cartridge guides 133 along which a plurality of cartridges 14 may be moved downstream within the cartridge collection tray 134 by pneumatic slides 135 for subsequent collection, cleaning, and reuse. It will be appreciated that the cartridges 14 and lids 28 may be collected by an automated handling system or by an operator and subsequently cleaned and refilled and returned to the array 12, or otherwise processed.

[0118] like Figure 18-21 , the basket clamping assembly 136 may include one or more basket clamps 138 that can lift the basket 18 (including the 3D object located therein) out of the basket bracket 104 to complete the step. The first washing station 34 may include a first washing tub 140 and a cover 142 that can be moved laterally to expose the first washing tub 140. The basket clamping assembly 136 can then move the basket 18 into any open and unoccupied position within the first washing tub 140, such as Fig.19 . Then, the 3D objects in the basket 18 may undergo a first wash in the first wash tub 140. A washing solution such as a solvent may be used to rinse and wash the 3D objects in the first wash tub 140. The washing solution used in the first wash tub 140 may be any suitable organic or aqueous washing liquid, including solutions, suspensions, emulsions, microemulsions, and the like. Examples of suitable washing liquids include, but are not limited to, water, alcohols (e.g., methanol, ethanol, isopropanol, etc.), glycol ethers, esters (i.e., dimethyl adipate), benzene, toluene, and the like. Washing liquids comprising a mixture of two or more liquids (e.g., water and alcohols (e.g., isopropanol)) may also be suitable. Such washing solutions may optionally contain additional ingredients such as surfactants, and the like. In some embodiments, the first wash tub 140 may include an ejector and / or a nozzle (not shown) to direct a high-pressure washing solution onto the 3D object, and may include a heating element or an ultrasonic source to improve the speed or integrity of the washing process. In some embodiments, first wash tub 140 may include mechanical agitation or stirring elements (not shown) to assist in removing resin 24 from the 3D object.

[0119] The basket clamping assembly 136 can then move the basket 18 out of the first wash tub 140 to the second wash station 36, which can include a second wash tub 144 and a cover 146 that can be moved laterally to expose the second wash tub 144. The basket clamping assembly 136 can move the basket 18 into any open and unoccupied position within the second wash tub 144, such as Fig. 20 . Then the 3D objects in the basket 18 may undergo a second wash in the second wash basin 144. A washing solution such as a solvent may be used to rinse and wash the 3D objects in the second wash basin 144. The washing solution used in the second wash basin 144 may be any suitable organic or aqueous washing liquid, including solutions, suspensions, emulsions, microemulsions, and the like. Examples of suitable washing liquids include, but are not limited to, water, alcohols (e.g., methanol, ethanol, isopropanol, etc.), glycol ethers, esters (i.e., dimethyl adipate), benzene, toluene, and the like. Washing liquids comprising a mixture of two or more liquids (e.g., water and alcohols (e.g., isopropanol)) may also be suitable. Such a washing solution may optionally contain additional ingredients such as surfactants, etc., which may be the same or different from the washing solution used in the first wash basin 140. In some embodiments, the second wash basin 144 may include an ejector and / or a nozzle (not shown) to direct a high-pressure washing solution onto the 3D object, and may include a heating element or an ultrasonic source to improve the speed or integrity of the washing process. In some embodiments, second wash tub 144 may include mechanical agitation or stirring elements (not shown) to assist in removing resin 24 from the 3D object.

[0120] The basket may undergo repeated cleaning cycles while it is located in the first wash tub 140 and the second wash tub 144. After any desired number of wash cycles, the basket 18 may be transferred from the first wash tub 140 to the second wash tub 144.

[0121] After the baskets 18 have been cleaned in the second wash tub 144, the basket clamping assembly 136 may then move the baskets 18 out of the second wash tub 140 to a drying station 38, which may include a drying tub 148 and a cover 150 that may be moved laterally to expose the drying tub 148, such as Fig. 20A The basket clamping assembly 136 can move the basket 18 into any open and unoccupied position within the drying basin 148. The 3D objects within the basket 18 can then undergo a drying process within the drying basin 148.

[0122] After the basket 18 has been dried in the drying tub 148, the basket clamping assembly 136 may then move the basket 18 out of the drying tub 148 to a pre-curing station 152, which may include a pre-curing tub 154 and a cover 156 that may be moved laterally to expose the pre-curing tub 154, such as Fig.21The basket clamping assembly 136 can move the basket 18 out of any open and unoccupied position within the pre-curing basin 154. The 3D object within the basket 18 can then undergo an initial curing process within the pre-curing basin 154.

[0123] After pre-curing has been completed in the pre-curing basin 154, the basket clamping assembly 136 may move the basket 18 with the cleaned, dried and pre-cured 3D objects therein downstream from the opposite side of the process to the basket housing 158 of the transfer assembly 160, as shown in FIG. Fig. 22 The transfer assembly 160 operates to transfer the 3D object from the basket 18 to a curing tray for further processing, as described in more detail below.

[0124] The basket housing 158 may have two recesses 162 formed therein, and the basket gripping assembly 136 may move the basket into an empty recess of the two recesses 162. After the 3D objects have been transferred out of the basket 18, the empty basket is returned to one of the empty recesses 162. When the basket 18 is empty, the basket gripping assembly 136 may grab the empty basket 18 and return it upstream to the first position 106 in the basket carrier 104, as shown in FIG. Figure 8 Optionally, the empty basket 18 may be cleaned before being returned to the basket rack 104.

[0125] like Fig. 22 1, a magazine 164 in which a plurality of curing trays 166 may be located may be positioned transversely relative to the transfer assembly 60. Each curing tray 166 may have a plurality of compartments 168, each of which will receive a separate 3D object from the basket 18. In the illustrated embodiment, each curing tray 166 includes five (5) compartments. It will be appreciated that the curing tray 166 may have one or any other number of compartments, and that the number of compartments may be greater than the number of 3D objects located within the basket 18.

[0126] The first transfer carriage 170 is configured to move laterally along a transfer rail assembly 172 from below the magazine 164 into the process flow under a transfer arm 174 of the transfer assembly 160. The transfer arm 174 may be controlled by a servo motor that allows fine control of the movement of the transfer arm 174 to help ensure that the 3D objects are not damaged during their transfer out of the basket 18 to the curing tray 166.

[0127] An inspection camera 175 may be included to inspect the cassette throughout the printing process. In one embodiment, it may be placed adjacent to the magazine 164. As the curing tray 166 moves laterally in the transfer carriage 170 past the inspection camera 175, a picture of a label, such as a bar code, located in each compartment 168 of the curing tray 166 may be taken. This helps the system track individual 3D objects placed in specific compartments 168 of the curing tray 166.

[0128] To begin the transfer process, the curing tray 166 is dropped into the first transfer bracket 170, and the transfer bracket is moved laterally to a position below the transfer arm 174 (not shown here). The transfer arm 174 is then lowered, and one or more tray grippers 176 grab and lift the empty curing tray 166 off the first transfer bracket 170. Fig. 22 As shown in FIG. 1 , the transfer arm 174 holds the curing tray 166 after the curing tray 166 has been removed from the first transfer bracket 170 .

[0129] Then one or more basket grippers 178 of the transfer arm 174 grab the basket 18 with the 3D object therein, lift the basket 18 from the basket housing 158, and rotate the basket 18 and the curing tray 166. Fig. 22 As shown in FIG. 1 , the basket 18 has been lifted out of the basket housing 158 and has been rotated 90° from its position within the basket housing 158 .

[0130] like Fig.23 As seen in FIG. 1 , the transfer arm 174 continues to rotate the basket 18 and the curing tray 166 so that the 3D objects in the basket 18 slide downward into the corresponding compartments 168 in the curing tray 166. In some embodiments, as shown in FIG. Fig.24 , the transfer arm 174 may include a plurality of baffle walls 180 for guiding the 3D objects as they slide out of the basket 18 into the compartments 168 of the curing tray 166. It will be appreciated that the baffle walls 180 are positioned within the interior of the transfer arm 174 and are not visible from the exterior of the transfer arm 174, but are shown here for purposes of clarity and understanding.

[0131] As described above, the transfer arm 174 can be controlled by a servo motor. In the event that the 3D object does not freely travel from the basket 18 into the curing tray 166, the transfer assembly arm 174 can be pushed and / or rocked to help move the 3D object out of the basket 18 into the curing tray 166.

[0132] Once the 3D object has been moved into the curing tray 166, the transfer arm 174 is rotated until the curing tray 166 is in an upright position (eg, Fig. 22 ), and then the curing tray 166 is placed on the second transfer bracket 182 (as shown in Fig.26The second transfer carriage 182 then moves downstream to an inspection assembly 184, which may include a camera 186, such as Fig.25 The camera 186 can cycle side-to-side and can be used to count and / or inspect the 3D objects as they pass through the inspection assembly 184. It will be appreciated that the second transfer bracket 182 and the curing tray 166 located therein are Fig.25 Not visible in.

[0133] After the inspection of the 3D object is completed, the second transfer carriage 182 is moved to the sealing station 188 (eg, Figure 26-27 ), wherein the curing tray 166 having the 3D object therein is sealed. The components of the sealing arm 190 are operated to horizontally stretch the sealing film 192 over the open curing tray 166 in a direction perpendicular to the process flow direction. The sealing film 192 is then lowered to the top of the curing tray 166, while one or more needles 194 are placed between the sealing film 192 and the curing tray 166. Fig. 27 The needle 194 is shown in a retracted position upstream of the sealing arm 190 after the curing tray 166 has been sealed and moved downstream from the sealing station 188 .

[0134] The needle 166 is used to inject argon or any other inert gas into the compartment 168 of the curing tray 166, which displaces oxygen out of the curing tray 166. When the sealing film 192 is lowered onto the top edge of the curing tray 166, the heat sealing plate 196 is lowered onto the sealing film 192 and presses the sealing film 192 against the top surface of the curing tray 166, thereby heat sealing the top of the curing tray 166 with the 3D object therein. It will be understood that after the inert gas has been injected into the compartment 168 of the curing tray 166, the needle 194 is retracted. When the needle 194 is retracted, any gap where the needle 194 is located is sealed by the sealing film 192, thereby completely sealing the curing tray 166.

[0135] After the curing tray 166 has been sealed, it may be moved downstream to a labeling station (not shown) where one or more labels may be secured to the curing tray 166. The labels may be bar codes or any other suitable labels. It will be appreciated that a single label may be placed on each curing tray 166. In other embodiments, multiple labels may be placed on the curing tray 166, with each label corresponding to a specific compartment 168 within the curing tray 166. Suitable labels and locations for such labels will become readily apparent to one of skill in the art given the benefit of this disclosure.

[0136] After the label is completed, the curing transfer arm 197 can move along the transfer track 198 of the transfer assembly 200, such as Fig.28 The transfer arm may include a tray gripper 199 that lifts the curing tray 166 from the second transfer bracket 182 and deposits the curing tray in a transfer tray 202, where a plurality of curing trays may be located. In the illustrated embodiment, five (5) curing trays 166 may be located in each transfer tray 202, so that twenty-five (25) 3D objects may be located in each transfer tray 202.

[0137] The transfer tray 202 can then be moved downstream for curing and other post-curing processing. The empty transfer tray 202 can then be placed in a position downstream of the labeling station to receive additional curing trays 166.

[0138] The transfer tray 202 can then be transferred to a curing station (not shown). In some embodiments, the curing station can be in line with the flow of the printing process, and in such embodiments, the curing station can be a channel through which the transfer tray 202 passes. In other embodiments, a transfer assembly or operator can remove the completed transfer tray 202 and move it to an oven for curing.

[0139] An exemplary cartridge 14 for use in the printing system 50 is shown in FIG. Figure 29-32 . The box 14 may include a housing, which in some embodiments may be a metal such as aluminum and stainless steel. The box 14 may include a lid 28, a pair of opposing side walls 210, a pair of opposing end walls 212, and a bottom 214. As discussed above, the quarter-turn fastener 12 secures the lid 28 to the box 14.

[0140] As described above, the cartridge 14 may include one or more transparent regions to allow one or more wavelengths of excitation light to enter the cartridge 14. For example, the lid 28, sidewall 210, end wall 212, and bottom 214 may each include a fused quartz window.

[0141] Alignment cleats 216 may be placed at opposite ends of the base 214 and cooperate with the cartridge anchor assembly 75 to temporarily secure the cartridge 14 to the print carriage 74, such as Figure 8 Seen in.

[0142] To fill the box 14, it is placed with one end wall 212 facing downward, such as Fig.31A pump (not shown) then injects resin 24 into the cartridge 14 through a spring-loaded valve 218 formed in the downwardly facing end wall 212. As the resin 24 fills the cartridge 14, any air contained within the cartridge 14 above the level of the resin 24 may escape through an air trap 220 formed in the opposite end wall 212. Various embodiments of volumetric 3D printing assemblies and printing processes have been described herein, including various components and features. In other embodiments, the volumetric 3D printing assemblies may be provided with any combination of such components and features. It will also be understood that in other embodiments, the various devices, components, and features of the volumetric 3D printing assemblies described herein may be constructed using similar structural and functional elements having different configurations (including different decorative appearances).

[0143] Another embodiment of the box 14 is shown in Figure 34-41 middle.

[0144] In some embodiments, the systems and / or methods described herein may include a box for printing one or more three-dimensional objects, the box being configured to contain a volume of a photopolymerizable composition, the box comprising side walls (preferably four) attached to a bottom wall to define a volumetric space for containing the volume, the box being configured to include one or more printing zones, wherein the printing zones are sized to facilitate irradiation by one or more, preferably at least two, excitation light projections to at least partially form a three-dimensional printed object in the printing zone within the volume of photopolymerizable composition.

[0145] The box may be open. An open box may further include a removable cover to close the box. The box may be closed, including a top wall relative to a bottom wall, in which case at least one of the walls may include at least one port in at least one of the walls to facilitate the introduction and / or removal of unpolymerized photopolymerizable composition, and / or removal of one or more three-dimensional objects from the box.

[0146] In some other embodiments, the systems and / or methods described herein may include a box for printing one or more three-dimensional objects, the box being configured to contain a volume of a photopolymerizable composition, the box including opposing end walls and including at least one port in at least one of the end walls of the box to facilitate the introduction and / or removal of unpolymerized photopolymerizable composition, and / or removal of one or more three-dimensional objects from the box, the box being configured to include one or more printing zones, wherein the printing zones are sized to facilitate irradiation by one or more, preferably at least two, excitation light projections to at least partially form a three-dimensional printed object in the printing zone within the volume of photopolymerizable composition.

[0147] It may be desirable for the entire cartridge described herein to be optically clear.

[0148] Alternatively, the cartridges described herein may include one or more optically transparent regions associated with the print zone to facilitate directing projection of excitation light through the one or more optically transparent regions into the print zone.

[0149] For example, when the print zone is addressed by two optical systems, two optically transparent areas or sides may be included in the box. When three optical systems address the print zone, three optically transparent areas or sides may be included in the box. Additional optically transparent areas or sides may optionally be included.

[0150] Preferably, the optically transparent region(s) of the cartridge are also optically flat.

[0151] The cartridge may include a first port to introduce a photopolymerizable composition into the cartridge and a second port to remove unpolymerized photopolymerizable composition and / or one or more three-dimensional objects from the cartridge.

[0152] For the purpose of removing the contents of the cartridge after printing, it may also be desirable to include two ports, for example. For example, including two ports at opposing end walls of the cartridge may facilitate applying pressure (e.g., by pumping air), or pumping fluid into the cartridge through one port to transport the contents toward and through the outlet port, thereby removing / expelling the contents from the cartridge through the second port.

[0153] The printing zone in the cartridges described herein preferably has dimensions determined taking into account the dimensions of the object to be printed, the numerical aperture characteristics of the projected light projection, and the refractive index of the photopolymerizable composition (or a suitable alternative).

[0154] Fig.34 A diagram showing an example of the dimensions of a projected optical image is depicted: projected image height A; projected image width B; and maximum addressable Z dimension C for printing. In the depicted example, values ​​A=20 nm, B=70 nm, and C=80 nm are assumed. These values ​​are exemplary only and other values ​​may be found to be suitable.

[0155] Fig.35 Depicts display superimposed on Fig.34 An example of the dimensions of the projected image entrance area on the projected optical image dimensions shown in Figure 1 and a diagram of the calculation used to determine the dimensions of the projected image entrance area. Two half-angle intervals δ are used to determine the maximum projection dimensions projected by the optical system for one print zone. The projected image entrance height is represented by A'; the projected image entrance width is represented by B'; the farthest (from the incident surface) projection plane depth is represented by C'; NA is the numerical aperture of the projection under consideration; and ε is the distance selected to separate the print zone from the front and rear walls of the container. These values ​​are calculated using the following formula:

[0156] C' = C + ε

[0157]

[0158] A' = A + 2δ

[0159] B' = B + 2δ

[0160] in:

[0161] n = refractive index of the medium, such as the photohardenable composition

[0162] NA = Numerical aperture of the projector

[0163] ε = axial wall spacing

[0164] δ = half angle interval

[0165] exist Figure 1 In B:

[0166] In calculation Figure 1 The following projection image incident area assumptions are used in A', B', and C' in B:

[0167] n=1(air)

[0168] NA = 0.05 (f / 11)

[0169] ε = 2 mm

[0170] Here, for NA and ε, Fig.35 The values ​​provided in are exemplary only and other values ​​may also be suitable. It should be noted that the same analysis can be performed for multiple optical projections into the print volume, each with different dimensions and numerical apertures, and the largest corresponding value of δ is selected.

[0171] Fig.36 For description Fig.34 and 35 Legend for the variables included in the .

[0172] Fig.37 Depicts display superimposed on Fig.35 1 and 10. An example of the dimensions of a print area or zone 26 (referred to in the figure as a "bounding box") with projected image incident area dimensions shown in FIG. 1 and a diagram of the calculations used to determine the dimensions of the print area (referred to in the figure as a "bounding box"). The bounding box height is represented by A"; the bounding box width is represented by B"; the bounding box depth is represented by C"; and z is the distance selected to separate the print area from (one or more) adjacent print areas. These values ​​are calculated using the following formula:

[0173] A” = A' + 2ζ

[0174] B” = B' + 2ζ

[0175] C” = C' + ε

[0176] in:

[0177] NA = Numerical aperture of the projector

[0178] ε = axial wall spacing

[0179] C' = box interior depth

[0180] δ = half angle interval

[0181] A' = Projected image entrance height

[0182] B' = Projected image entrance width

[0183] ζ = Projected image interval

[0184] A” = bounding box height

[0185] B" = bounding box width

[0186] C" = bounding box depth

[0187] L = box interior length

[0188] W = box inner width

[0189] H = box interior height

[0190] V = box volume

[0191] n = refractive index of the medium, such as the photohardenable composition

[0192] exist Fig.37 middle:

[0193] In calculating Figure 2 The following bounding box assumptions are used in A'', B'', and C'' of B:

[0194] A' = 28 mm

[0195] B' = 78 mm

[0196] C' = 82 mm

[0197] ε = 2 mm

[0198] ζ = 1 mm.

[0199] Fig.38An example of a box 14 is depicted that is designed to include multiple print areas or zones 26 (referred to as "bounding boxes" in the figure). As depicted, the box 14 includes five (5) print zones 26. Fig.34 , 35 , 36 and 37, the dimensions of the depicted box 14 (including five print zones 26) are: the box interior length is represented by L; the box interior width is represented by W; and the box interior height is represented by H. The box interior length takes into account the number of print zones selected to be included in the box. The calculated interior volume of the box is the product of L x W x H.

[0200] Fig.39 For description Fig.37 and 38 Legend for the variables included in the .

[0201] Fig.40 An example of a box 14 including five print zones 26 is depicted and the top wall, opposite end walls are identified. The bottom wall opposite the top wall and the side wall opposite the labeled side wall are not shown. It is desirable to irradiate the optical projection through one or more of the top wall, the bottom wall, and any side wall into the print zone.

[0202] Preferably, when more than one print zone is included in the cassette to accommodate the formation of multiple objects in the same cassette, the print zones are sized to prevent objects printed in adjacent print zones from contacting each other during printing.

[0203] Optionally, when multiple printing zones are included in the box, partitions may be included between the printing zones to provide further protection, preventing unwanted aggregation in adjacent printing zones. When included, it is desirable that any such partitions are removable to facilitate emptying the box after printing.

[0204] Optionally, a movable partition may be included to facilitate the variable volume of the print zone(s). Optionally, the movable partition may be translated during addition (filling) of the box with the photohardenable composition and / or emptying of the photohardenable composition and one or more three-dimensional objects from the box. Optionally, fluid and / or air pressure may be used to facilitate movement of the partition.

[0205] The box preferably has a uniform cross-section over its length dimension.

[0206] The box may have a circular or oval cross-section.

[0207] The box may have a polygonal cross-section.

[0208] The box preferably has a rectangular or square cross-section.

[0209] Optionally the box has a rectangular or other elongated shape. Other shapes may also be available.

[0210] The print zone is preferably configured to facilitate directing one or more, preferably at least two, excitation light projections into the print zone.

[0211] To facilitate directing the excitation projection into the print zone, the print zone may include one or more optically transparent regions.

[0212] Preferably, the box includes one or more optically transparent areas placed for projecting (one or more) excitation light or guiding the channel for projecting excitation light into the printing area in the box. As mentioned above, optionally, the entire box can be optically transparent, and all sides of the printing area can be optically transparent. For an open box, if a removable cover is included, it is also desirable that the cover is optically transparent.

[0213] It may be desirable for the box to include flat, straight sides that meet at a 90° angle.

[0214] Preferably, the cell has a rectangular prism shape. In such a case, the rectangular prism shaped cell preferably has a uniform cross section in its longest dimension.

[0215] The box (without regard to ports included in the walls or its sides, if included) can be a single-piece unit, or can be constructed from two or more pieces. For example, a box including more than one piece can include side or wall parts that are fused together at their edges to form a three-dimensional box unit. Alternatively, the side or wall parts can be held together by a frame to form a three-dimensional rectangle. Other construction options may also be suitable.

[0216] When a port is included, it is preferably included in a wall other than the wall through which the excitation light is to be directed into the volume.

[0217] Optionally, one or more of the walls or sides of the box or the entire box may be coated. For example, but not limited to, one or more sides may include an anti-reflective coating, a mechanical enhancement coating, a chemical resistance coating, etc. Optionally, one or more sides may include a coating on its inner surface to enhance the cleanability of the box after the box is emptied.

[0218] The cartridge may preferably be reusable.

[0219] Examples of photoconvertible photoinitiators used in the photopolymerizable composition may absorb at about 300 nm to about 550 nm, including but not limited to about 300 nm to about 450 nm. (The light sheet is preferably generated by light in this wavelength range.) Depending on the absorption spectrum for the particular photoconvertible photoinitiator, the conversion to the second form can be induced by exposure to any source emitting in this range, such as a laser, a light emitting diode, a mercury lamp. A filter may be used to limit the output wavelength. Non-limiting examples of filtered light include filtered emission from a mercury arc lamp, etc. The second form of the photoconvertible photoinitiator will preferably absorb in the range of about 450 to 1000 nm, and most typically 450 to 850 nm. (The image projection preferably includes light in this wavelength range.)

[0220] Examples of power densities for the first and second wavelengths include between about 0.01 and about 100,000 W / cm 2 power density in the range of .

[0221] Examples of exposure energies for the second wavelength of light include about 0.001 to about 1,000 mJ / cm 2 Examples of exposure energies for the first wavelength of light include exposure energies from about 0.01 to about 100,000 mJ / cm 2 exposure energy in the range of .

[0222] Before printing, a digital file of the object to be printed is obtained. If the digital file is not in a format that can be used to print the object, then the digital file is converted into a format that can be used to print the object. An example of a typical format that can be used for printing is an STL file. Typically, the STL file is then sliced ​​into two-dimensional layers using three-dimensional slicing software and converted into G-code or a set of machine commands, which facilitates the construction of the object. See B. Redwood et al. "The 3D Printing Handbook - Technologies, designs applications", 3D HUBS BV 2018.

[0223] When used as a property of a portion of a box or build chamber, "optically transparent" means having high optical transmission for the wavelength of light used, and "optically flat" means being undistorted (e.g., the optical wavefront of the portion entering the box or build chamber remains essentially unaffected).

[0224] Those skilled in the art will recognize through the knowledge obtained from the present disclosure that various changes can be made to the disclosed apparatus and method to obtain these and other advantages without departing from the scope of the present disclosure. Therefore, it should be understood that the features described herein are susceptible to modification, alteration, change or substitution. For example, it is clearly intended that all combinations of those elements and / or steps that perform substantially the same functions in substantially the same manner to achieve the same results are within the scope of the embodiments described herein. The substitution of elements from one described embodiment to another embodiment is also fully expected and considered. The specific embodiments shown and described herein are for illustrative purposes only and are not limited to the contents set forth in the appended claims. Other embodiments will be clear to those skilled in the art. It should be understood that the foregoing description is provided only for clarity and is exemplary only. The spirit and scope of the present disclosure are not limited to the above examples, but are covered by the appended claims.

Claims

1. Methods, including: (a) providing a box comprising a volume of a photohardenable composition in an irradiation zone; (b) selectively irradiating the volume of photohardenable composition included in the cartridge with one or more wavelengths of excitation light to at least partially harden, polymerize and / or crosslink the resin composition to at least partially form one or more objects in the volume; (c) removing the cartridge from the irradiation zone after the selective irradiation step; as well as Optionally, steps (a)-(c) are repeated with a series of one or more additional cartridges comprising the next volume of the photohardenable composition. 2 . The method of claim 1 , further comprising emptying the cartridge in the irradiation zone before removing the cartridge.

3. Methods, including: (a) introducing a cartridge comprising a volume of a photohardenable composition into an irradiation zone; (b) selectively irradiating the volume of photohardenable composition included in the cartridge with one or more wavelengths of excitation light to at least partially harden, polymerize, or crosslink the resin composition to at least partially form one or more objects in the volume; (c) removing the cartridge from the irradiation zone after the selective irradiation step; (d) emptying the box; as well as (e) collecting the emptied cartridge for cleaning or disposal, wherein, after removing the cartridge from the irradiation zone, a next separate cartridge comprising a volume of the photohardenable composition is introduced into the irradiation zone to perform steps (b)-(e).

4. The method of claim 3, further comprising separating one or more at least partially formed objects from other contents emptied from the box.

5. The method of claim 4, further comprising subjecting one or more of the separated partially formed objects to one or more further processing steps.

6. A method according to claim 5, wherein the one or more further processing steps comprise washing one or more of the separated objects.

7. A method according to claim 6, wherein the one or more further processing steps comprise drying one or more of the washed objects.

8. The method of claim 5, wherein the one or more further processing steps include post-curing one or more of the separated objects.

9. The method of claim 8, further comprising packaging one or more of the post-cured objects.

10. The method of claim 9, further comprising inspecting the post-cured object prior to packaging.

11. The method of claim 7, wherein the one or more further processing steps include post-curing one or more of the dried objects.

12. The method of claim 11, wherein the one or more objects are placed under an inert atmosphere for post-curing.

13. The method of claim 3, further comprising packaging one or more of the separated objects.

14. The method of claim 13, further comprising inspecting the post-cured object prior to packaging.

15. The method of claim 1 or 2, further comprising monitoring formation of one or more at least partially formed objects during the irradiating step.

16. The method of claim 1 or 2, wherein the method further comprises encoding an at least partially formed object during the method with an identification code.

17. 3D printed components, including: a printer clamping assembly configured to move a cartridge containing a photohardenable resin; a printer assembly including at least one excitation light source configured to cure the photohardenable resin and form one or more 3D objects in the cartridge; a box flip assembly configured to insert the basket in an inverted orientation into the box and rotate the box to an inverted orientation such that the one or more 3D objects are transferred into the basket and liquid resin flows out of the box; a basket clamping assembly configured to remove the basket from the caddy and transfer the basket to a first washing station; a second washing station, the second washing station being located downstream of the first washing station; a drying station, the drying station being located downstream of the second washing station; a pre-curing station, the pre-curing station being located downstream of the drying station; a transfer assembly configured to transfer the one or more 3D objects from the basket to a curing tray; an inspection station configured to inspect the one or more 3D objects in the curing tray; a sealing station configured to secure a sealing film to a top surface of the curing tray; as well as A transfer tray is configured to receive one or more curing trays.

18. The 3D printing assembly of claim 17, wherein the printer clamping assembly comprises a first set of box clamps and a track, the first set of box clamps being configured to grasp the box, the first set of box clamps being movable along the track to transfer the box to a printing box.

19. The 3D printing assembly of claim 17, wherein the printer clamp assembly includes a second set of cartridge clamps configured to grasp the cartridge after the cartridge has been removed from the printer assembly.

20. The 3D printing assembly of claim 17, wherein the printer assembly comprises a first excitation light source and a second excitation light source, and wherein the first excitation light source is configured to illuminate a projector that patterns an image with light of a first wavelength by forming a temporal sequence of cross-sectional patterns corresponding to cross-sections of the one or more 3D objects to be printed.

21. The 3D printing assembly of claim 20, wherein the second excitation light source is configured to illuminate a light sheet generator for generating and directing a light sheet at a second wavelength, the second wavelength being a different wavelength than the first wavelength.

22. The 3D printing assembly of claim 17, wherein the box flip assembly comprises a pair of basket grippers configured to grab an empty basket located in a basket holder and place the empty basket in an inverted orientation into the box, and a pair of box grippers configured to grip the box after the basket has been located in the box.

23. The 3D printing assembly of claim 22, wherein the box flipping assembly is configured to rotate the basket and box so that the one or more 3D objects move from the box into the basket and resin that has not yet hardened into a 3D object flows out of the box into a drip tray.

24. The 3D printing assembly of claim 22, wherein the basket bracket has a first position having a first depth and a second position having a second depth less than the first depth.

25. The 3D printing assembly of claim 17, wherein the basket clamping assembly comprises a basket clamp configured to grasp the basket.

26. The 3D printing assembly of claim 25, wherein the basket clamping assembly is configured to move a basket grasped by the basket clamp to the first washing station.

27. The 3D printing assembly of claim 26, wherein the first washing station comprises a removable cover.

28. The 3D printing assembly of claim 26, wherein the basket clamping assembly is configured to move a basket grasped by the basket clamp from the first washing station to the second washing station.

29. The 3D printing assembly of claim 28, wherein the second washing station comprises a removable cover.

30. The 3D printing assembly of claim 28, wherein the basket clamping assembly is configured to move a basket grasped by the basket clamp from the second washing station to the drying station.

31. The 3D printing assembly of claim 30, wherein the second washing station comprises a removable cover.

32. The 3D printing assembly of claim 30, wherein the basket clamping assembly is configured to move a basket grasped by the basket clamp from the drying station to the pre-curing station.

33. The 3D printing assembly of claim 30, wherein the pre-curing station comprises a removable cover.

34. The 3D printing assembly of claim 17, wherein the transfer assembly comprises a transfer arm, the transfer arm comprising a tray gripper, the tray gripper configured to grip a curing tray positioned in the first transfer bracket.

35. The 3D printing assembly of claim 34, wherein the transfer arm comprises a basket gripper configured to grasp a basket containing the one or more 3D objects.

36. The 3D printing assembly of claim 35, wherein the transfer arm is configured to rotate the basket containing the one or more 3D objects and the curing tray such that the one or more 3D objects slide from the basket into the curing tray.

37. The 3D printing assembly of claim 36, wherein the transfer arm comprises a partition wall configured to direct the one or more 3D objects from the basket into the curing tray.

38. The 3D printing assembly of claim 17, wherein the inspection station comprises a camera.

39. The 3D printing assembly of claim 17, wherein the sealing station comprises one or more needles configured to inject an inert gas into the curing tray.

40. The 3D printing assembly of claim 17, wherein the sealing station comprises a heat sealing plate configured to seal a sealing film to the curing tray.

41. The 3D printing assembly of claim 17, wherein the cartridge comprises two or more print zones, and wherein the print zones are spaced apart from one another such that excitation light projection can be directed into one print zone and at least partially form a three-dimensional object without triggering photopolymerization of the photohardenable composition in an adjacent print zone.

42. The method of claim 1 or 3, wherein the photohardenable composition included in the box is irradiated with excitation light of two or more wavelengths.

43. 3D printed components, including: a printer assembly including at least one excitation light source configured to cure the photohardenable resin and form one or more 3D objects in the cartridge; and A printer clamping assembly is configured to move a cartridge containing a photohardenable resin into or out of the printer assembly.

44. A system for removing one or more 3D objects from a box, comprising: a box flip assembly configured to insert a basket in an inverted orientation into a box containing one or more 3D objects and rotate the box to an inverted orientation such that the one or more 3D objects are transferred into the basket and liquid resin flows out of the box; and A basket clamping assembly is configured to remove the basket from the caddy and transfer the basket to a washing station.

45. The system according to new claim 44, further comprising an additional washing station placed downstream of the washing station.

46. ​​The system according to new claim 45, further comprising a drying station placed downstream of the additional washing station.

47. The system according to new claim 46, further comprising a pre-curing station placed downstream of the drying station.

48. The system of any of the new claims 47, further comprising a transfer assembly configured to transfer the one or more 3D objects from the basket to a curing tray.

49. The system of new claim 48, further comprising an inspection station configured to inspect the one or more 3D objects in the curing tray.

50. The system of new claim 49, further comprising a sealing station configured to secure a sealing film to a top surface of the curing tray.

51. The system of new claim 50, further comprising a transfer tray configured to receive one or more curing trays.

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