Device, system and method for multi-projector three-dimensional printing

Abstract

To provide a device, system and method for three-dimensional printing, for example, additive manufacturing that may include stereo-lithographic approaches (SLA) and / or digital light patterning (DLP) for three-dimensional printing.SOLUTION: There are provided a device, system, and / or method for three-dimensional printing, for example, additive manufacturing, wherein an array of an energy patterning (for example, light patterning) module is used in conjunction with an automated positional control system to coordinate implementation of the patterning module of the array. Implementation of the array can be controlled by a sensory feed-back.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] Cross-reference This patent application was filed on March 29, 2019, and claims the benefit of priority of U.S. Provisional Application No. 62 / 826,361, entitled "METHOD AND SYSTEM FOR METHODOLOGIES AND HARDWARE FOR MULTI-PROJECTOR THREE DIMENSIONAL PRINTING", the content of which is hereby incorporated by reference in its entirety.

Background Art

[0002] This disclosure relates to three-dimensional printing.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The disclosed embodiments may relate to devices, systems, and methods for additive manufacturing that may include three-dimensional printing, such as stereolithographic approaches (SLA) and / or digital light patterning (DLP) for three-dimensional printing.

Means for Solving the Problems

[0005] According to at least some of the disclosed embodiments, an array of energy patterning (e.g., light patterning) modules may be used in a 3D printing method.

[0006] According to at least some of the disclosed embodiments, each patterning module may include a multi-axis micropositioning system that interfaces with an energy patterning system that includes a projector.

[0007] According to at least some of the disclosed embodiments, the projection system and / or the micropositioner may be involved in a feedback control loop for automatically aligning the energy patterning system to generate a continuous display area.

[0008] According to at least some of the disclosed embodiments, each patterning module may include an embedded microcomputer that receives commands from a local or remote host and is involved in allocating them to the energy patterning system and / or the micropositioning system. The communication between the microcomputer and the host may be (i) wired or wireless, (ii) encrypted, and (iii) bidirectional.

[0009] According to at least some of the disclosed embodiments, the microcomputer may receive commands / data sent to the patterning module and control the energy output (both pattern and intensity) of the projection of the energy patterning system. The micropositioner may receive commands / data used to adjust the position together with the projector within the patterning module for the patterning module.

[0010] Exemplary embodiments are illustrated in the drawings, and this embodiment will be described in detail below with reference to the figures.

Brief Description of the Drawings

[0011]

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DETAILED DESCRIPTION OF THE INVENTION

[0012] Conventionally, the stereolithographic approach (SLA) for additive manufacturing has presented unique capabilities and technological opportunities that exceed competing technologies. This is because SLA can achieve high printing speeds while generating objects from a robust library of materials.

[0013] Central to the printing configuration for SLA is the "light engine," i.e., the projector, which is involved in patterning light / energy to drive the polymerization reaction of a photosensitive liquid resin in the additive manufacturing process. The spectrum of the projected light, the output density of the projected light, and the speed at which the light can be patterned all govern the functionality of an additive manufacturing device or printer that utilizes the light engine.

[0014] In the present disclosure, the term "energy" is used to refer to energy measured in various forms including, but not limited to, radiant energy, e.g., both visible and invisible light. Thus, it is to be understood that the application of "energy" is intended to include, but not be limited to, the application of heat, light (radiation), electrical energy, and magnetic energy.

[0015] There are two common pathways for light / energy patterning in additive manufacturing devices. The first pathway utilizes a laser beam that is moved through a two-dimensional (2D) plane with a series of galvanometric mirrors (e.g., a reflecting galvanometer, also called a "galvo", or a resonant scanner) to trace a 2D cross-sectional image of the net shape to be printed.

[0016] Alternatively, a digital light processing (DLP) chip can be used in a conventional projector configuration to pattern fine pixels across a 2D plane, where each pixel is updated at an internal clock frequency.

[0017] Ultimately, both light / energy patterning techniques have limitations with respect to their ability to scale to larger 2D print beds.

[0018] In the case of a scanning laser beam, as the distance over which the beam spreads increases, there is a corresponding loss in the angular resolution of the beam cross-section. This results in a corresponding loss in the resolution of the printed object. Additionally, as a result of using a fixed scan speed, the 2D display frequency becomes significantly slower as the size increases, which limits the vertical printing speed of any 3D printer configured with a scanning laser beam.

[0019] In the case of DLP-based patterning technology, a projection lens may be used to cover a larger 2D area. However, conventionally, the pixel density of DLP chips available on the market is limited, so the technical effect of this configuration is similarly limited. More specifically, due to the limited pixel density, when projecting over a wider area, simply the projected pixels become larger and the 3D printed object becomes coarser.

[0020] A further limitation of the DLP approach is that when scaling to a larger area, the projection output density is limited. This is because when the number of photons fed per unit area decreases, the chemical reactions involved in the printing mechanism slow down, becoming a bottleneck in the printing process. Conventional techniques to address this problem include using multiple projectors to handle a larger area. Such techniques have been used with both DLP and laser scanning systems by lighting experts in the entertainment industry for decades. In this way, the projection area of each independent light engine can be switched to generate a large image. In fact, conventionally, (as disclosed, for example, in Patent Document 1), an array of light engines has been shown to successfully perform 3D printing.

[0021] However, in implementation, to combine the effects of each independent light engine, a method and device are required that enable tiling these projectors in an infinite means. Mirrors can be used to easily tile two to four projectors as an array, but beyond a certain point, the conventionally known use of mirrors becomes non - practical if not impossible for scaling.

[0022] Therefore, a new configuration is needed for tiling a larger number of light patterning modules. The presently disclosed embodiments provide a system implemented by hardware and software that enables automatic alignment and stitching of the high lateral accuracy of micro - patterning modules (i.e., pixel sizes smaller than 500 μm).

[0023] The disclosed embodiments enable the technical utility of tiling DLP-based micro-projectors for SLA printing applications (collectively referred to herein as "DLP SLA" printing applications), but the hardware and techniques described herein also have technical utility applicable to other forms of 3D printing, and in such technical utility, it should be understood that multiple energy patterning modules may be used.

[0024] For example, the novel techniques disclosed herein have particular utility applicable to selective laser (SL) SLA (often referred to as SL-SLA) or selective laser sintering (SLS), in which multiple laser modules may be tiled to address a larger area with enhanced resolution.

[0025] It should be understood that the hardware and corresponding software described herein are unique in both technical structure and function with respect to the hardware and software used in conventional entertainment applications where the 2D projection surface is often substantially an order of magnitude larger than the hardware footprint (such as a theater stage, movie screen, building facade, etc.).

[0026] Moreover, in the technical and industrial shaping contexts of 3D printing, the 2D projection surface is often smaller than the footprint of the projection / patterning hardware. Accordingly, the disclosed embodiments utilize miniaturized projection hardware and corresponding alignment systems for such hardware to fit the system into a footprint narrower than the desired projection area.

[0027] Such an implementation form enables the ability to scale more effectively with a larger 2D printing bed. As mentioned above, as the number of patterning modules in the optical system increases, the precise alignment of those modules becomes a greater problem. More specifically, the manual alignment system used in a projection system including a small number of projectors quickly becomes impractical. For example, in a two-projector system, adjustments to a single projector via a manual manipulator are less likely to interfere with nearby projectors. This is because the manipulator is not obstructed in any direction except one direction.

[0028] However, when there is an array of 10 to 100 micro-projection systems, precise alignment becomes a technical problem and an obstacle to effective implementation. The reason is that there is no practical way to manually adjust one of the micro-projection systems in the array without disturbing the surrounding micro-projection systems too much.

[0029] To solve this obstacle, the disclosed embodiments provide a system having a micro-projection patterning module that uses wireless communication to transmit data regarding both position control data and projection data. In one example, the technical effect of such transmission of both position data and projection data can be recognized, for example, in a large array, such as an array of 10 to 100 projectors, and wireless transmission from a centralized controller significantly reduces the number of wires / connection lines necessary to perform position adjustment and supply of projection data for patterning. Although not shown, such a centralized controller may be implemented using one or more computer processors and associated hardware for wireless communication with each of the plurality of projection modules.

[0030] According to the disclosed embodiments, each patterning module may comprise only a single fixed wire for supplying operating power. Thus, all other control, content, and operating information may be wirelessly conveyed from the centralized controller to the patterning module.

[0031] The high modularity of the system provided according to the disclosed embodiments improves flexibility, ease of use, and reduces maintenance time. If a projector (i.e., one of 100 projectors) in a single patterning module within a 10x10 projector array fails, the patterning module can be removed and replaced with a functional patterning module without interfering with the rest of the projection system.

[0032] Furthermore, this modularity enables the ability to arrange projectors in a variable aspect ratio or, in some cases, a discontinuous domain array according to the requirements of a given application. For example, instead of arranging 100 projectors in a 10x10 array, the array can be made into a 1x100 array, 2x50 array, 4x25 array, 5x20 array, etc.

[0033] As described above, according to at least some of the disclosed embodiments, an array of energy patterning (e.g., light patterning) modules may be used in a 3D printing method. In SLA 3D printing, the resolution in the x-y plane is often limited by the optical projection system that feeds light / energy to the build interface. The ability to tile multiple projection systems into a large high-resolution array is often limited by the ability to laterally align multiple micro-projection systems.

[0034] To achieve this, the disclosed embodiments utilize a projection module package volume that includes (i) an optical projection component, (ii) a data receiver, and (iii) an electronically controlled micropositioner. The optical projection component, the data receiver, and the micropositioner must all fit within the footprint of the projected image. For example, for illustration purposes, if a 1080p resolution DLP projection module is given a "coarse" resolution of 100 μm, the cross-section of this projector / manipulator module may be limited to 4.25" x 7.5" horizontally. If a higher resolution system is required, such as a common standard of 50 nm, this area may shrink to ~2.2" x 3.8". The disclosed embodiments aim to provide a customized module that achieves such required resolution when given such minor constraints.

[0035] Figures 1 - 4 show examples of a patterning module provided in accordance with the disclosed embodiments. The figures show various views of the patterning module 100 and its components. As shown in Figures 1 - 4, the patterning module 100 may include a microprojector 110 that is configured and operative to pattern energy (UV light via DLP). However, it should be understood that the microprojector 110 may be implemented by one or more lasers in conjunction with galvo mirrors or off-the-shelf or custom-made patterning / energy systems.

[0036] According to at least one disclosed embodiment, the patterning module 100 disclosed herein may include a microprojector that is an off-the-shelf model (i.e., a model that is conventionally available in an un-customized state), in which case the model is modified to project ultraviolet (UV) light (required for the photoinitiator used in the SLA printing process). The patterning module 100 may include a microcomputer 120, which is wirelessly coupled to a host computer and receives commands (including, for example, position data and projection data) from the host computer to control the placement and energy output of the projector 110 and enable patterning of the 3D printing process. Thus, according to at least some disclosed embodiments, the microcomputer 120 may receive commands / data sent to the patterning module 100 by the host computer to control the energy output (both pattern and intensity) of the projection of the projector 110.

[0037] The microcomputer 120 may include any suitable microcomputing device, such as a processor / microprocessor, CPU, RAM electronic circuit defined as a microcomputing device equipped for external communication (e.g., by means of a wired Ethernet® connection, a Wi-Fi® module, NFC, Bluetooth®, NIR, optical, and / or other suitable wired or wireless communication devices). An exemplary microcomputing device may be smaller than the size range of a standard laptop or desktop computing device. Exemplary suitable microcomputing devices may include a Raspberry Pi, an Arduino board, an Intel ‘Stick’ or ‘NUC’ computer, or any computing device having a volume equal to or less than that of the enumerated devices.

[0038] The microcomputer 120 and / or the host computer may include appropriate memory and / or communication circuitry for performing the disclosed operations. Examples of suitable processors may include, in particular, one or more microprocessors, integrated circuits, system-on-chip (SoC). Examples of suitable memory may include, in particular, one or more primary and / or non-primary storage (e.g., secondary storage, tertiary storage, etc.), permanent, semi-permanent, and / or temporary storage, and / or without limitation, hard drives (e.g., magnetic, solid state), optical discs (CD-ROM, DVD-ROM), RAM (e.g., DRAM, SRAM, DRDRAM), ROM (e.g., PROM, EPROM, EEPROM, Flash EEPROM), and memory storage devices including volatile and / or non-volatile memory. The communication circuitry may include components for facilitating processor operations, for example, suitable components may include transmitters, receivers, modulators, demodulators, filters, modems, analog-to-digital converters, operational amplifiers, and / or integrated circuits.

[0039] The patterning module 100 may include a micropositioning system 130 driven by a plurality of stepping motors 140, for example, a combination of three stepping motors. The stepping motors can be replaced by other actuating devices such as pneumatic systems, DC motors, rail systems. Each projector 110 may be attached to a modified X-Y-Z positioning stage. The axes of these stages may be modified to be operated by the coordinated control and operation of a plurality of stepping motors (one for each axis). The micropositioner 130 may receive commands / data via the microcomputer 120, and such commands / data are used to adjust the position together with the projectors within the patterning module 100 for the patterning module.

[0040] The micro-projector 110, the Wi-Fi (registered trademark)-equipped microcomputer 120, and the micro-positioning component 130 are collectively sized, arranged, and function such that the cross-sectional area of the overall patterning module including these components is narrower than the projection field of a single micro-projector.

[0041] According to the disclosed embodiment, each patterning module 100 may include a multi-axis micro-positioning system 130 that interacts with an energy patterning system including the projector 110. More specifically, there is provided optical-mechanical hardware that couples the micro-projector 110 included in the patterning module 100 to an electric multi-axis micro-manipulator. When tiling these patterning modules 100 and their component micro-projectors 110 together, these patterning modules 100 and their component micro-projectors 110 can be aligned so as to generate a high-resolution optical projection system over any large print bed.

[0042] Similarly, each patterning module 100 may include a mounted microcomputer 120 that receives commands from a remote host (e.g., a centralized computer implementation controller for a multi-projector system) and is involved in allocating them to an energy patterning system and a micropositioning system 130. Communication between the microcomputer 120 and the host may include one or more of (i) wired and / or wireless communication, (ii) encrypted and / or secure communication, and (iii) unidirectional and / or bidirectional communication. In this way, the disclosed embodiments provide a system with a micropattern projection module 100 that uses wireless communication to transmit data regarding both position control data and projection data. The technical effect of such transmission of both position data and projection data can be recognized, for example, in large arrays, e.g., 10 to 100 projectors, and wireless transmission significantly reduces the number of wires / connection lines necessary to perform position adjustment and supply of projection data for patterning. In some embodiments, wired and wireless communication may be implemented together, e.g., one or more modules 100 communicate with the host computer by a wired connection, and one or more other modules 100 communicate with the host computer by a wireless connection.

[0043] The mounted microcomputer 120 is Wi-Fi (registered trademark) compliant, receives position commands, and converts these commands into motor driver instructions that control the operation of a plurality of stepping motors 140 to activate and relocate the projection module 100. Further, the mounted microcomputer 120 may be used to receive projection data from a common remote host, and the projection data may be routed to the microprojector 110 to control the display output.

[0044] Communication between the centralized host computer and the patterning module may be encrypted, for example, by encrypting a Scalable Vector Graphics (SVG) string via an algorithm such as AES (symmetric 128-bit encryption) and sending it to each patterning module address, whereby appropriate instructions are sent to each patterning module within the array without (or with reduced likelihood of) tampering. In some embodiments, the graphical vector string may include any suitable form of vector string definition, format, material, etc. For example, the projection data may be represented by any suitable string format, i.e., a series of vectors represented as a non-rasterized image. Similarly, encryption of control and / or feedback data may be performed using an encryption key unique to the overall multi-projector implementation additive manufacturing device itself (this may be performed, for example, using the MAC address to a location library), such that the x-y image plane data may be scrambled. Additionally, encryption may be based on a buffering frequency / speed that scrambles the z-image stack data. Scrambling may include randomizing the data (along the relevant axis) to non-linearize the information.

[0045] The projection data can be formed to enable auto-alignment (e.g., projection of position markers for feedback control) or to enable projection of a subset of a larger 2D image that is displayed across the array for 3D printing purposes. Thus, according to at least one embodiment, the patterning module 100 can project a test pattern at the build interface and utilize the build interface for high-resolution alignment (i.e., alignment by the resolution of a single pixel according to the resolution of the image sensor) by using a feedback control loop.

[0046] FIG. 5 shows an example of a single projector array 505 including a single patterning module 100 attached to an optical board 150. FIG. 6 shows an example of an array 605 of modules 100 arranged in a 3x3 configuration of a total of nine projectors mounted on an optical board 150.

[0047] According to at least some of the disclosed embodiments, the projection system and / or the micropositioner may be involved in a feedback control loop for auto-alignment of an energy patterning system for generating a continuous display area. FIGS. 7 and 8 show an example of an alignment operation for fields of view 360, 360' from two separate microprojectors 310, 310' that are part of separate patterning modules 300, 300' arranged relative to each other on a mounting plate, i.e., an optical board. The combined fields of view 360, 360' of the microprojectors 310, 310' represent an applicable display area.

[0048] As can be seen by referring to FIG. 7, even when the micro-projectors 310, 310' are attached, alignment is not perfect. The adjacent edges of the fields of view 360, 360' (the longitudinal bottom edge of 360 and the longitudinal top edge of 360') are spaced apart from each other. The corresponding lateral edges (left and right edges) of the fields of view 360, 360' are misaligned. In some embodiments, adjacent fields of view 360, 360' adjacent to each other may be subject to misalignment in other ways, for example, inclinations such that the corresponding longitudinal edges and / or lateral edges are not parallel to each other. In contrast, as shown in FIG. 8, the arrangement of the micro-projectors 310, 310' on the mounting plate shown in FIG. 7 remains in the same position as shown in FIG. 7 (i.e., alignment is not perfect), but the micro-projector 310 and its resulting field of view 360 are repositioned in one or more of the x-y-z directions by a micro-positioning system (such as the micro-positioning system 130 using the stepping motor 140 under the control of the mounted components shown in FIGS. 1 to 4) so as to create continuous fields of view 360, 360' that are aligned and have continuity at the adjacent edges of the fields of view 360, 360'. The example of FIG. 8 shows a continuous display by the corresponding longitudinal edges at a strictly predetermined position so as to eliminate the gap between the fields of view 360, 360' such that the fields of view 360, 360' contact and / or engage with each other, and alignment between the corresponding lateral edges. However, in some applications, the continuous display may not require such alignment of the lateral edges. For example, the applicable footprint of the object to be built may be covered by adjacent fields of view that are offset from each other. Similarly, in some applications, adjacent edges may be considered continuous such that the lateral edges contact and / or engage with each other, and the longitudinal edges may have a relative arrangement regardless of whether they are aligned or offset according to a particular application. In some embodiments, the continuous display may not require precise contact of the adjacent edges, but may include reducing the gap between the adjacent edges to a threshold interval, for example, a value smaller than one pixel width.However, the threshold interval is an interval specific to the application example, and for example, it may be an interval within any appropriate range of pixel widths from 0.1 pixel to 10 pixels (for convenience, approximately 0.001 inch (0.0254 mm) to approximately 0.10 inch (2.54 mm)).

[0049] Within the present disclosure, the field of view 360 of each individual module 100 is arranged to be larger than the footprint of module 100. As can be seen by briefly referring to FIG. 7, the field of view 360 is larger than the footprint 363 of module 100 in the x - y plane. Similarly, the field of view 360’ is larger than the corresponding footprint of module 100 in the x - y plane. As can be seen by briefly referring to FIG. 9, the field of view of each individual module 100 in the array is larger than the footprint of the corresponding module. In the illustrated embodiment, the collective field of view of the array constituting the display area is larger than the collective footprint of the modules 100 of the array.

[0050] FIGS. 9 and 10 illustrate an example of a 3D printing system 400, in which an array 405 of a plurality of patterning modules 410A, 410B, 410C, 410A’, 410B’, 410C’, and 410A”, 410B”, 410C” is aligned (e.g., a 3x3 array of modules). As shown in FIGS. 9 and 10, the observation sensor 420 is configured to detect the deviation of the position indicator markers 430 associated with the field of view of each of the projectors included in the patterning module array 405.

[0051] Based on the relative arrangement with the position indicator marker 430 in the vicinity of these position indicator markers 430, the observation sensor 420 of the 3D printing system 400 can detect that the central projection module 410B' is misaligned and needs to be repositioned, as indicated by the arrow in FIG. 9. In that case, the position of the central projection module 410B' may be translated to act on the alignment arrangement or complete the alignment arrangement. FIG. 10 shows the alignment obtained after performing x-y plane movement using the micropositioner and stepping motor exemplified herein.

[0052] The observation sensor 420 may also include sensors configured to recognize that the distance between position indicator markers (i.e., the left and right sides of the projection field of view) on a single projector is too large or too small, as well as related calculation and control software. This may be regarded as indicating whether the patterning module (in this case, having a fixed focal length) is underfocus or overfocus. Based on that indication and that recognition, the calculation and control software may perform corresponding adjustments in the z-axis for that projector. The observation sensor 420 may include images (e.g., photos, videos, thermal, infrared, UV, etc.), positions (e.g., radar, lidar, time of flight, etc.), and / or other suitable sensor devices.

[0053] Although several exemplary embodiments have been described, it is clear to those skilled in the art that numerous alternative, modified, substituted, and variant embodiments will become apparent in view of the above description. Accordingly, the various embodiments as described above are exemplary and not restrictive. Various changes may be made without departing from the spirit and scope of the present invention.

[0054] For example, as described above, according to the disclosed embodiments, modularity enables the placement in various aspect ratios or in some cases an array of discontinuous regions as required for a given application, for example, enabling the ability to have 100 projectors in a 10x10 array. Alternatively, if a large-diameter tubular structure is required, as shown in FIGS. 11 and 12, there is a potentially optimal placement of projectors that covers the footprint of an annulus with a discontinuous portion in the center, and thus there may be no need for a patterning module at that location.

[0055] FIG. 11 shows a top view of an optical module with the field of view aligned (represented by the black dotted line). The desired object has the outer shape of an annulus represented by the shaded curve. This enables printing of this object using fewer optical module units, for example, 10 optical module units instead of 12 in a continuous array. Such savings become significant as such structures grow in size. Thus, in implementation, such embodiments have particular technical utility in scenarios where a gasket with an outer diameter of 3 feet (91.44 cm) needs to be printed. In that scenario, it should be understood that when implementing such an embodiment, the annulus does not require an optical module within the inner diameter to be printed.

[0056] FIG. 12 shows a top view of an optical module with the field of view aligned (also represented by the black dotted line in this case). In FIG. 12, the 2D projection of the desired object, also represented by the shaded curve in this case, does not require the entire array of 16 optical modules (i.e., 4x4). Again, in implementation, such embodiments have particular technical utility in scenarios where a large non-circular gasket needs to be printed. In that scenario, when implementing such an embodiment, it is possible to use 75% of the projection modules that would otherwise be required, and in doing so, it should be understood that this implementation form significantly reduces the manufacturing cost of the 3D printer for this particular application.

[0057] It should be understood that the proposed methods and related devices can be implemented in various forms of hardware, software, firmware, dedicated processors, or combinations thereof. Accordingly, both the devices disclosed herein as part of the projection module and the remote centralized controller host can be implemented. Thus, the dedicated processor may comprise an application specific integrated circuit (ASIC), a reduced instruction set computer (RISC), and / or a field programmable gate array (FPGA). Accordingly, the multi-projector implementation additive manufacturing device and related functions currently disclosed may be implemented as a combination of hardware and software. This software may be installed as an application program on a program storage device. In this case, generally, a machine based on a computer platform having hardware such as, for example, one or more central units (CPUs), random access memory (RAM), and one or more input / output (I / O) interfaces is used. Further, an operating system is generally installed on the computer platform. Each of the different processes and functions described herein may form part of an application program or a part executed via the operating system.

[0058] Accordingly, according to the disclosed embodiments, the patterning module may be provided in an additive manufacturing device to be used as part of an array of patterning modules under common control by a device controller remote from the patterning module array, and the patterning module includes a micro-projector configured to project energy for performing energy patterning based on data received from a remote controller for the device, and the placement of the micro-projector is controlled relative to micro-projectors included in other patterning modules within the patterning module array based on the received data.

[0059] According to the disclosed embodiments, the patterning module may include a microcomputer coupled to a microprojector to receive data from a remote controller for a device for emitting energy, in some cases, via the microprojector, and to control the microprojector to emit energy based on the received instructions.

[0060] According to those disclosed embodiments, the patterning module may, in some cases, include a multi-axis micropositioning system coupled to the microcomputer and configured to control the placement of the microprojector within the patterning module array relative to other microprojectors included in other patterning modules within the patterning module array, the micropositioning system including a plurality of actuators operable based on data provided by the micropositioning system, such data being based, in some cases, on data received by the micropositioning system from a remote device via the microcomputer.

[0061] Similarly, according to some disclosed embodiments, in a layered manufacturing device, a patterning module is provided for use as part of an array of patterning modules under common control by a remote device controller remote to the array of patterning modules, the patterning module including a microprojector configured to project energy for performing energy patterning, and a multi-axis micropositioning system for controlling the placement of the microprojector relative to other microprojectors included in other patterning modules within the patterning module array, the micropositioning system including a plurality of actuators operable based on data provided by the remote device controller.

[0062] According to those disclosed embodiments, the patterning module may optionally include a multi-axis micropositioning system that relays data received by a microcomputer coupled to the microprojector and / or a remote device controller to either the microprojector or a multi-axis micropositioning system.

[0063] Furthermore, according to each of those disclosed embodiments, the data between the microcomputer and the remote device controller is encrypted. For example, in this case, optionally, encryption of the SVG string sent to an address associated with the patterning module, which is performed by applying symmetric encryption, encryption performed by applying one or more encryption keys or tokens specific to the additive manufacturing device, and / or encryption that scrambles the x-y image plane data and the encrypted data based on the buffering frequency / speed, thereby scrambling the z-image stack data may be used.

[0064] Furthermore, according to each of those disclosed embodiments, the multi-axis micropositioning system may automatically align the fields of view of the microprojectors in the patterning module array to generate a continuous display area by automatically controlling the placement of the microprojector of the microprojector relative to other patterning modules included in the patterning module array.

[0065] Furthermore, according to each of those disclosed embodiments, the sensing element collects data used to determine the relative positions of the patterning modules and enables alignment of the field of view of the microprojector with the microprojectors of at least one other patterning module in the array.

[0066] Furthermore, according to each of those disclosed embodiments, the control of the multi-axis micropositioning system may, in some cases, be performed using a feedback loop that includes a microprojector and / or a micropositioner.

[0067] Furthermore, according to each of those disclosed embodiments, the data received by the microcomputer from the remote controller may include position commands for the multi-axis micropositioner and / or a data set to be projected by the microprojector.

[0068] As can be seen by referring to FIGS. 13 to 18 next, a stereolithography device and / or system similar to the stereolithography device and / or system already described above are shown, and the disclosure of the devices, systems, and methods described above is equally applicable to the devices, systems, and methods described below. In FIG. 13, a patterning module 1100 is shown that includes a microprojector, a microcomputer, and an actuator (x, y, and z) with a stepping motor for realizing precise movement of the position of the microprojector. As can be seen by referring to FIGS. 14 and 15, the stepping motor is configured to translate the frame support of the module along guide rails oriented along the corresponding x, y, and z axes to position the microprojector. Limit switches may be provided to guide the operation control of the stepping motor by the microcomputer according to the remote host computer. As can be seen by referring to FIG. 16 next, each module 1000 illustratively includes one or more control boards 1112 for operating the actuator. The control board 1112 may operate under the guidance of the microcomputer.

[0069] Referring to FIGS. 18 and 19, a layered manufacturing system including a base mount 1140 is shown. The base mount 1140 is illustratively embodied as a mounting plate for receiving the connection of the patterning module 1100. The base mount 1140 is illustratively formed as a structural member that constitutes a support for the load-bearing operation of the actuator while accommodating the selective arrangement of the module 1100 to be mounted. As shown in FIG. 18, the patterning module 100 is shown with one (longitudinal) end attached to the base mount 1140. One end of the module 1100 is illustratively the opposite side of the end having the micro-projector. The base mount 1140 illustratively includes a guide 1142 that is illustratively embodied as an alignment pin inserted to assist proper attachment within the alignment holes in the attached patterning module 1100. In some embodiments, an array of one or more alignment pins may be formed on the module 1100, and corresponding one or more alignment holes may be formed on the base mount 1140. The base mount 1140 illustratively includes a connector 1144. The connector 1144 is illustratively embodied to enable wired electrical communication between the host computer and the microcomputer of the patterning module 1100. In an exemplary embodiment, the connector 1144 enables electrical connections for power and data communication. In some embodiments, the connector 1144 may be configured to supply wired power, and data may be communicated wirelessly between the module 1100. The patterning module 1100 is connected to the corresponding connector 1144 via the mating connector 1146 of the patterning module 1100. A power circuit may be mounted on the base mount 1140.

[0070] Referring next to FIG. 19, four patterning modules 1100 attached to the base mount 1140 are shown. Each patterning module 1100 is disposed via its mating connector 1146 to communicate with a corresponding connector 1144. Thus, a modular array can be formed by selectively positionable modules 1100 that can be easily connected and disconnected to be attached at various positions to configure a display area suitable for a build project.

[0071] Within the present disclosure, a patterning module for a stereolithography system as part of an array of patterning modules under common control by a remote controller remote from the array of patterning modules may include a microprojector configured to project energy for performing energy patterning for stereolithography, and a multi-axis micropositioning system for controlling the placement of the microprojector relative to the microprojectors of other patterning modules within the array of patterning modules. The micropositioning system may include a plurality of actuators operable based on patterning data provided by a remote controller.

[0072] In some embodiments, the multi-axis micropositioning system may perform the placement of the microprojector relative to the microprojectors of other patterning modules of the array and align the fields of view of the microprojectors of the array to generate a continuous display area. The multi-axis micropositioning system may perform the placement of the microprojector according to automated control commands from a remote controller to automatically align the field of view of the microprojector with at least one field of view of other patterning modules of the array.

[0073] In some embodiments, the remote controller may be configured to communicate with at least one sensor for collecting data, determine the relative positions of one or more of the other patterning modules, and align the field of view of the microprojector with the microprojectors of at least one of the other patterning modules of the array. Automated control commands for the multi-axis micropositioning system may be generated by the remote controller using feedback control information taking into account at least one of the microprojector and the micropositioning system. In some embodiments, any suitable mode of control, including derivative control, feedforward control, and / or combinations thereof, may be applied.

[0074] In some embodiments, the patterning module may further include a microcomputer. The microcomputer may be configured to communicate with at least one of the microprojector and the multi-axis micropositioning system. The microcomputer may be configured to receive from the remote controller control commands including patterning data for controlling the operation of at least one of the microprojector and the multi-axis micropositioning system.

[0075] In some embodiments, the patterning data received from the remote controller by the microcomputer may include position commands for the multi-axis micropositioner. The patterning data may include a projection data set to be projected by the microprojector for additive manufacturing. The patterning data may include synchronization data for synchronizing the timing of the modules of the array. For example, the synchronization data may include a clock signal, and / or may be formed digitally, and / or may be formed by an analog signal.

[0076] In some embodiments, the communication between the microcomputer and the remote controller may be encrypted. Encryption of the communication between the microcomputer and the remote controller may include encryption of the vector string sent to the address associated with the patterning module. Encryption may include the application of symmetric encryption. In some embodiments, encryption may include the application of an encryption key and / or token specific to the additive manufacturing system. Encryption may include scrambling at least one of the x-y image plane data and the z image stack based on at least one of the data buffering frequency and the data transmission speed.

[0077] Within the present disclosure, an additive manufacturing device may include a device controller and an array of patterning modules under the common control of the device controller, the device controller being remotely located with respect to the patterning module array. By being remote, the device controller enables a preferred physical placement of the modules, which are located in the vicinity but are different from the modules, while allowing for centralized control. In some embodiments, each of the patterning modules within the array may include a micro-projector configured to project energy for performing energy patterning for additive manufacturing. One or more of the patterning modules may include a multi-axis micro-positioning system for controlling the placement of the micro-projector of the patterning module relative to the micro-projectors of the other patterning modules of the patterning module array. The one or more micro-positioning systems may include a plurality of actuators operable based on patterning data provided by the device controller.

[0078] In some embodiments, each patterning module may further include a microcomputer that communicates with at least one of the corresponding microprojector and the multi-axis micropositioning system. Each microcomputer may be configured to receive from a remote controller a control command including patterning data for controlling the operation of at least one of the corresponding microprojector and the multi-axis micropositioning system.

[0079] In some embodiments, the multi-axis micropositioning system performs the placement of one or more of the microprojectors relative to at least one of the other patterning modules of the array and aligns the fields of view of the microprojectors of the array to generate a continuous display area. The multi-axis micropositioning system may perform the placement of one or more microprojectors according to an automated control command from a remote controller to automatically align the fields of view of the microprojectors of the array.

[0080] In some embodiments, the additive manufacturing device may further include at least one sensor for collecting data. The at least one sensor may be configured to communicate with a device controller to determine the relative positions of one or more of the patterning modules and align one or more fields of view of the microprojectors of the array.

[0081] In some embodiments, the automated control commands for the multi-axis micropositioning system may be generated by a remote controller. The remote controller may generate the automated control commands using feedback control information considering at least one of the microprojector and the micropositioning system. In some embodiments, any suitable control method including derivative control, feedforward control, and / or combinations thereof may be implemented.

[0082] In some embodiments, the patterning data received from the remote controller by at least one microcomputer may include position commands for the multi-axis micropositioner. The patterning data may include a projection data set to be projected by the microprojector. The patterning data may include synchronization data for synchronizing projections between different modules of the array.

[0083] In some embodiments, the communication between one or more of the microcomputers and the remote device controller may be encrypted. The encryption may include encryption of the vector string sent to the address associated with the patterning module. The encryption may include the application of symmetric encryption. The encryption may include the application of an encryption key and / or token specific to the additive manufacturing system. The encryption may include scrambling at least one of the x-y image plane data and the z image stack based on at least one of the data buffering frequency and the data transmission speed.

[0084] In some embodiments, the additive manufacturing device may further include a base mount configured to receive the attachment of one or more patterning modules of the array. The base mount may include several connection ports for supplying power and / or enabling communication. Each connection port may communicate with one of the patterning modules mounted on the base mount and be configured to enable communication with the remote controller and supply power and / or enable communication.

[0085] In the present disclosure, a method of performing additive manufacturing may include controlling, by a device controller, the emission of projected energy by an array of a plurality of patterning modules. The device controller may be remote from the patterning module array. Each of the patterning modules in the array may include a microprojector configured to project energy for performing energy patterning. The method may include using a multi-axis micropositioning system to control the placement of the microprojector relative to other microprojectors included in other patterning modules in the patterning module array, the micropositioning system including a plurality of actuators operated based on instructions provided by a remote device controller.

[0086] In some embodiments, the method may further include relaying, by a microcomputer coupled to the microprojector and / or the multi-axis micropositioning system, data received from the remote device controller to the microprojector or the multi-axis micropositioning system. In some embodiments, the method may further include encrypting data sent between the microcomputer and the remote device controller. In some embodiments, the multi-axis micropositioning system may automatically control the placement of the microprojector relative to other microprojectors included in other patterning modules in the patterning module array and automatically align the fields of view of the microprojectors of the patterning module array to generate a continuous display area.

[0087] In some embodiments, it may further include using sensory elements to collect data, determining the relative positions of the patterning modules, and aligning the field of view of the microprojector with the microprojectors of at least one other patterning module in the array. In some embodiments, the control of the multi-axis micropositioning system may be performed using a feedback loop including the microprojector and / or the micropositioner.

[0088] The present disclosure is not limited to the exemplary embodiments described herein. There is a scope of various adaptation embodiments and modification embodiments that those skilled in the art will also consider to belong to the present disclosure due to their expertise.

Explanation of Reference Numerals

[0089] 100, 300, 300’, 410A, 410B, 410C, 410A’, 410B’, 410C’, 410A”, 410B”, 410C”, 1000, 1100 Patterning Module, Module 110, 310, 310’ Microprojector, Projector 120 Microcomputer 130 Micropositioning System, Micropositioner, Micropositioning Component 140 Stepping Motor 360, 360’ Field of View 363 Footprint 400 3D Printing System 405 Array, Patterning Module Array 410B’ Patterning Module, Central Projection Module 420 Observation Sensor 430 Position Indicator Marker 505 Projector Array 605 Array 1112 Control Board 1140 Base Mount 1142 Guide 1144 Connector 1146 mating connector

Claims

1. 1. A method for performing additive manufacturing, comprising: controlling emission of projected energy by an array of patterning modules by a device controller remote to the patterning module array to initiate solidification of a polymerizable material, each of the patterning modules in the array including a microprojector configured to project energy to perform energy patterning, and a microcomputer including a microprocessor having data memory storage capabilities; controlling the positioning of each microprojector relative to microprojectors included in other patterning modules in the patterning module array using a multi-axis micropositioning system, the micropositioning system including a plurality of actuators operated based on use of corresponding microprocessor position data provided by the remote device controller for storage by a corresponding microprocessor; controlling, by each microprojector, the projection of patterned energy onto the microprojectors included in other patterning modules in the patterning module array to solidify successive layers of polymerizable material based on use of corresponding microprocessor projection data provided by the remote device controller for storage by a corresponding microprocessor; Equipped with control of the positioning and projection of each microprojector of the patterning modules in the patterning module array is synchronized with the positioning and projection of other patterning modules in the patterning module array based on use of corresponding synchronization data provided by the remote device controller for storage by a corresponding microprocessor of the patterning module. method.

2. The method of claim 1 , further comprising the step of transmitting at least one of the position data, patterning data, and synchronization data from the remote device controller for storage by a corresponding microcomputer.

3. 3. The method of claim 2, further comprising the step of encrypting the data transmitted between the microcomputer and the remote device controller.

4. 2. The method of claim 1 , wherein the multi-axis micropositioning system automatically controls the positioning of the microprojector relative to microprojectors included in other patterning modules in the patterning module array to automatically align the fields of view of the microprojectors of the patterning module array to generate a contiguous display area.

5. 5. The method of claim 4, further comprising using a sensory element to collect data to determine a relative position of the patterning module to align the field of view of the microprojector with a microprojector of at least one other patterning module in the array.

6. The method of claim 4 , wherein control of the multi-axis micro-positioning system is performed using a feedback loop that includes the micro-projector and / or the micro-positioner.

7. A controller; an array of patterning modules, the array including as part of the patterning modules at least one patterning module under remote control by the controller separate from the array of patterning modules; a microprojector configured to project energy to perform energy patterning for additive manufacturing; a microcomputer having a microprocessor with data memory storage capability, the microcomputer configured to receive patterning data in the form of at least one of position data, patterning data, and synchronization data from the remote controller for storage; a multi-axis micro-positioning system for controlling positioning of the micro-projector relative to other micro-projectors in the array of patterning modules, the multi-axis micro-positioning system including a plurality of actuators operated based on position data received by the microcomputer from the remote controller; An additive manufacturing system comprising:

8. 8. The additive manufacturing system of claim 7, wherein the multi-axis micropositioning system performs positioning of the microprojector relative to other patterning modules of the array to align fields of view of the microprojectors of the array to generate a contiguous viewing area.

9. 10. The additive manufacturing system of claim 8, wherein the multi-axis micropositioning system performs positioning of the microprojector according to automated control commands from the remote controller to automatically align a field of view of the microprojector with a field of view of at least one of the other patterning modules of the array.

10. 10. The additive manufacturing system of claim 9, wherein the remote controller is configured to communicate with at least one sensor for collecting data and to determine a relative position of one or more of the other patterning modules to align the field of view of the microprojector with the microprojector of at least one other patterning module of the array.

11. 10. The additive manufacturing system of claim 9, wherein the remote controller generates automated control commands for the multi-axis micro-positioning system using feedback control information that takes into account at least one of the micro-projector and the micro-positioning system.

12. The additive manufacturing system of claim 7 , wherein the position data received by a microcomputer from the remote controller includes position commands for the multi-axis micro-positioner.

13. 8. The additive manufacturing system of claim 7, wherein at least one of the position data, projection data, and synchronization data includes patterning data received by a microcomputer from the remote controller, and the projection data includes a projection data set to be projected by the microprojector for additive manufacturing.

14. The additive manufacturing system of claim 7 , wherein communications between the microcomputer and the remote controller are encrypted.

15. 15. The additive manufacturing system of claim 14, wherein encrypting the communications between the microcomputer and the remote controller comprises encrypting a vector string sent to an address associated with the patterning module.

16. The additive manufacturing system of claim 15 , wherein the encryption comprises application of a symmetric cipher.

17. The additive manufacturing system of claim 14 , wherein the encryption comprises application of one or more of a cryptographic key and a token unique to the additive manufacturing system.

18. 15. The additive manufacturing system of claim 14, wherein the encryption comprises scrambling at least one of the xy image plane data and the z image stack based on at least one of a data buffering frequency and a data transmission rate.

19. 8. The additive manufacturing system of claim 7, wherein at least one of the position data, patterning data, and synchronization data comprises synchronization data received by a microcomputer from the remote controller, the synchronization data comprising synchronization data for synchronizing projections between different patterning modules of the array.

20. 8. The additive manufacturing system of claim 7, wherein a field of view of the at least one patterning module is larger than a footprint of the at least one patterning module.

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