Digital manufacturing methods and apparatus, and structures manufactured using said methods and apparatus

Abstract

The manufacturing device includes a structured surface that receives layers of material to produce a three-dimensional solid representation of a digital model, and an imaging unit that combines each portion of build material into a cross section that represents a portion of the data contained in the digital model. The device may include a system for recycling and / or homogenizing material prior to use in the manufacturing process. The device may include a system for controlling the density of printed parts. Exemplary objects produced by the manufacturing device may include powder composite parts using any of a variety of powder materials. The exemplary objects may be further post-processed to produce high-precision metal or ceramic parts. The manufacturing device may include a selective deposition unit that selectively deposits auxiliary build material with high resolution. The manufacturing device may include an extended-life imaging unit.

Description

Cross - reference to related applications

[0001] This application claims the priority of U.S. Provisional Patent Application No. 63 / 089,405, filed on October 8, 2020. This application is a continuation - in - part of U.S. Patent Application No. 17 / 438,853, filed on September 13, 2021, and is the national stage application of Patent Cooperation Treaty (PCT) Patent Application PCT / US2020 / 021378, filed on March 6, 2020, which claims the priority of U.S. Provisional Patent Application No. 62 / 817,431, filed on March 12, 2019. Priority to provisional and non - provisional patent applications is expressly claimed, and the disclosures of the provisional and non - provisional patent applications are incorporated herein by reference in their entirety and for all purposes.

Technical Field

[0002] The disclosed embodiments of the present application generally relate to solid freeform fabrication of objects, and more specifically, but not limited to, methods and apparatuses for digital manufacturing of high - density objects using dynamic density control.

Background Art

[0003] Additive manufacturing (AM) - also known as solid freeform fabrication (SFF), 3D printing (3DP), direct digital manufacturing (DDM), and solid imaging - has been increasingly widely adopted as a method for prototyping both visually - indicative parts and functional parts. In some cases, this has also become a cost - effective means of manufacturing products. There are various means for manufacturing parts based on digital models, and each means has reduced the time and cost required for the complete design cycle. As a result, the pace of technological innovation has been improved in many industries.

[0004] Generally, SFF (Slice-Filled Frame) is implemented layer by layer. A digital model is divided into horizontal slices, each slice generating a 2D image on a structural surface. These slices are then manufactured sequentially, creating a collection of thin layers that together constitute the three-dimensional object represented by the digital model. In contrast to conventional manufacturing techniques—such as computer numerical control (CNC) machining, injection molding, and other methods—SFF has significantly reduced manufacturing time and cost, making it widely adopted for research and development purposes where small-volume manufacturing by conventional methods is extremely expensive. Furthermore, SFF generally requires less specialized skill to operate compared to CNC machines. Individual parts manufactured by CNC machines are generally more expensive due to the longer setup time and higher costs. CNC-manufactured parts often have stronger and more detailed features than SFF-manufactured parts. Therefore, for some applications, CNC-manufactured parts are preferable. Until the SFF method can produce parts with the resolution and functionality of CNC-manufactured parts, its use in part manufacturing will remain limited.

[0005] Powder injection molding (PIM) is a mass production method that has been widely adopted as a means of manufacturing high-precision parts from materials that could not be produced by conventional molding methods. The injection material is created by mixing powder with a resin binder. The injection material is injected into a mold, similar to plastic injection molding. The manufactured part is a powder-composite part called a "green" part. The green part undergoes a process called degreasing, in which most of the binder is removed. The resulting part is called a "brown" part. This brown part is then heat-treated to sinter the powder particles into a single mass. The part shrinks during this process, and the voids between the powder particles are removed. The final result is a part with nearly perfect density. Further post-processing can be used to achieve a density of over 99.5%, depending on the composition of the powder material used.

[0006] Some of the most common methods for SFF (Surface-Filled Frame) include stereolithography (SLA), selective deposition modeling (SDM), fused deposition modeling (FDM), and selective laser sintering (SLS). These methods vary depending on the type of material available, the method by which layers are generated, and the resolution and quality of the resulting parts. Typically, layers are generated by bulk material deposition or selective material deposition. In techniques employing bulk deposition to generate layers, layer imaging is typically achieved by thermal, chemical, or optical processes. There is a technique—binder spraying—that uses an inkjet printhead to deposit a binder onto a powder bed to produce parts similar to the aforementioned green parts in PIM (Particle Injection Manufacturing) processes. This green part can then be post-processed in the same way to produce the final part. Unfortunately, because the process for producing the green part is imperfect, the final parts produced through this process often fail to meet the tolerances required for high-precision applications—especially surface finishes. In addition, the precision and speed of the binder spraying process are limited. [Overview of the project] [Problems that the invention aims to solve]

[0007] The limitations of existing technologies for SFF (Small Scale Fossil) impose constraints on the structures that can be manufactured using SFF. Some microscale medical devices cannot be manufactured cost-effectively or at all using SFF. Furthermore, existing medical devices cannot be improved using SFF because the manufacturing technology cannot be used to implement these improvements. [Means for solving the problem]

[0008] According to the first aspect disclosed in this application, a method for creating a three-dimensional object is provided. This method is A step of homogenizing a construction material containing a mixture of powder material and photopolymer resin, The steps include: depositing the aforementioned construction materials onto the construction platform, The process includes the step of forming the three-dimensional object by selectively processing the aforementioned construction material.

[0009] In some embodiments of the disclosed method, the homogenization step is performed during the deposition step, during the settling time prior to the deposition step, or between these steps.

[0010] In some embodiments of the disclosed method, the selective processing step includes a step of curing at least a portion of the construction material at least partially by irradiation.

[0011] In some embodiments of the disclosed method, the construction material is densified after being deposited on the construction platform.

[0012] In some embodiments of the disclosed method, the construction material is densified by removing at least a portion of the photopolymer resin by differential pressure.

[0013] In some embodiments of the disclosed method, the depositing step includes the step of generating one or more layers of the construction material using a slot die.

[0014] In some embodiments of the disclosed method, the slot die is adjusted to improve the uniformity of one of the layers over a wide range of deviations in the flatness of previously deposited layers.

[0015] In some embodiments of the disclosed method, the adjustment of the slot die includes a step of expanding the stable bead region of the slot die.

[0016] In some embodiments of the disclosed method, The aforementioned deposition step includes the step of generating a layer of the construction material, The selective processing step includes a step of curing at least a portion of the construction material at least partially by irradiation, wherein the construction material includes a photosensitive component that changes state under irradiation. Forming the three-dimensional object by repeating the depositing step and the selectively processing step is included.

[0017] In some embodiments of the disclosed method, the change in state includes a change in color that detects whether the curing is effective.

[0018] According to another aspect disclosed herein, a method of making a three-dimensional object is provided. The method includes depositing a construction material on a construction platform, densifying the construction material, forming the three-dimensional object by selectively processing the construction material.

[0019] In some embodiments of the disclosed method, the depositing step includes depositing a layer of the construction material on the construction platform, the densifying step includes densifying the layer of the construction material, the selectively processing step includes selectively processing the layer of the construction material, and the method further includes forming the three-dimensional object by repeating the deposition, densification, and selective processing of one or more layers of the construction material deposited on the layer.

[0020] In some embodiments of the disclosed method, the construction material includes a mixture of a powder material and a carrier fluid.

[0021] In some embodiments of the disclosed method, the depositing step includes depositing the construction material by slot die coating.

[0022] In some embodiments of the disclosed method, the depositing step includes depositing the construction material by blade coating.

[0023] In some embodiments of the disclosed method, the depositing step includes depositing the construction material by patch coating.

[0024] In some embodiments of the disclosed method, the densifying step includes increasing the packing density of the powder material in the construction material.

[0025] In some embodiments of the disclosed method, the densifying step includes removing at least a portion of the carrier fluid from the construction material.

[0026] In some embodiments of the disclosed method, the removing step includes sucking at least a portion of the carrier fluid from the construction material through the construction platform.

[0027] In some embodiments of the disclosed method, the removing step includes removing at least a portion of the carrier fluid from the construction material by applying ultrasonic waves to the construction platform.

[0028] In some embodiments of the disclosed method, the removing step includes thermally evaporating at least a portion of the carrier fluid from the construction material.

[0029] In some embodiments of the disclosed method, the carrier fluid includes a filling material and a main material, and the removing step includes removing only at least a portion of the filling material.

[0030] In some embodiments of the disclosed method, the removing step includes removing at least a portion of the filling material by evaporation.

[0031] In some embodiments of the disclosed method, the method includes consolidating the powder material by applying ultrasonic waves to the construction platform before the selectively processing step.

[0032] In some embodiments of the disclosed method, the construction material includes a foam that defines a plurality of bubbles inside.

[0033] In some embodiments of the disclosed method, the densification step includes a step of crushing at least some of the bubbles in the foam.

[0034] In some embodiments of the disclosed method, the crushing step includes a step of applying an attractive force to the construction material through the construction platform.

[0035] In some embodiments of the disclosed method, the crushing step includes the step of applying ultrasonic stirring to the building material.

[0036] In some embodiments of the disclosed method, the crushing step includes a step of applying heat to the construction material.

[0037] In some embodiments of the disclosed method, the densification step includes adding a densifying fluid to the construction material, the densifying fluid reacting with the carrier fluid to produce gaseous products and reduce the volume of fluid in the construction material.

[0038] In some embodiments of the disclosed method, the carrier fluid comprises a photopolymer resin, and the selective processing step includes a step of curing at least a portion of the construction material at least partially by irradiation.

[0039] In some embodiments of the disclosed method, the step of at least partially curing includes irradiating the construction material according to a two-dimensional slice of a digital model of the three-dimensional object.

[0040] In some embodiments of the disclosed method, the selective processing step includes depositing an auxiliary construction material on at least one target region of the construction material.

[0041] In some embodiments of the disclosed method, the densification step includes a step of circumferentially densifying the construction material such that the construction material remains substantially wet after densification.

[0042] In some embodiments of the disclosed method, the densification step includes densifying the construction material such that, after densification, the construction material defines a plurality of voids internally and the powder material remains substantially wet.

[0043] In some embodiments of the disclosed method, the auxiliary building material is configured to enable a curing reaction, a solidification reaction, or a bonding reaction that binds the powder material in the target region.

[0044] In some embodiments of the disclosed method, the target region corresponds to a two-dimensional slice of the digital model of the three-dimensional object.

[0045] In some embodiments of the disclosed method, the auxiliary building material is configured to enable a photocuring reaction that binds the powder material in the target region.

[0046] In some embodiments of the disclosed method, the selective processing step includes a step of non-selectively irradiating the construction material.

[0047] In some embodiments of the disclosed method, the auxiliary building material includes a photocurable resin.

[0048] In some embodiments of the disclosed method, the auxiliary building material and the carrier fluid together provide a photocurable resin comprising a main resin and a photoinitiator.

[0049] In some embodiments of the disclosed method, the auxiliary building material is configured to enable a thermosetting reaction that bonds the powder material to the target region.

[0050] In some embodiments of the disclosed method, the selective processing step includes a step of non-selectively heating the construction material.

[0051] In some embodiments of the disclosed method, the auxiliary building material includes a thermosetting resin.

[0052] In some embodiments of the disclosed method, the auxiliary building material and the carrier fluid together provide a thermosetting resin comprising a main resin and a photoinitiator.

[0053] In some embodiments of the disclosed method, the auxiliary building material is configured to enable a passive curing reaction that binds the powder material to the target region.

[0054] In some embodiments of the disclosed method, the auxiliary building material includes a passively curable resin.

[0055] In some embodiments of the disclosed method, the auxiliary building material and the carrier fluid together provide a thermosetting resin comprising a main resin and a photoinitiator.

[0056] In some embodiments of the disclosed method, the auxiliary building material comprises a wax that melts during deposition and solidifies upon cooling by at least the absorption of heat by the carrier fluid.

[0057] In some embodiments of the disclosed method, the auxiliary building material comprises monomers that melt during deposition and harden during deposition by photocuring, thermal curing, or a combination thereof.

[0058] In some embodiments of the disclosed method, the auxiliary building material is configured to suppress the curing reaction, and the carrier fluid includes a curable material.

[0059] In some embodiments of the disclosed method, the target region corresponds to a complementary image of a two-dimensional slice of a digital model of the three-dimensional object.

[0060] In some embodiments of the disclosed method, the auxiliary building material is configured to suppress the photocuring reaction, and the carrier fluid comprises a photocurable resin.

[0061] In some embodiments of the disclosed method, the selective processing step includes a step of non-selectively irradiating the construction material.

[0062] In some embodiments of the disclosed method, the auxiliary building material includes a sintering inhibitor, and the method further includes a step of sintering the powder material after the selective processing step.

[0063] In some embodiments of the disclosed method, the target region corresponds to a two-dimensional slice of a digital model of the support surface layer between the three-dimensional object and the support structure.

[0064] In other embodiments disclosed herein, a system for creating a three-dimensional object is provided. The system comprises means for carrying out the disclosed method.

[0065] According to other embodiments disclosed herein, an apparatus for making a three-dimensional object is provided. The apparatus is Construction platform and A deposit module configured to translate across the aforementioned construction platform and deposit layers of construction material on the aforementioned construction platform or on layers previously deposited, A material supply unit that communicates with the aforementioned deposition module, A storage unit that includes the aforementioned construction materials and is in communication with the material supply unit, The projection module defines one layer of the three-dimensional object by at least partially hardening at least one of the aforementioned deposited layers. The material supply unit is configured to homogenize the construction material within the storage unit, supply the construction material from the storage unit, or combine these functions.

[0066] In some embodiments of the disclosed apparatus, the material supply unit comprises at least one circulation pump that supplies the construction material from the storage unit to the deposition module.

[0067] In some embodiments of the disclosed apparatus, the material supply unit comprises one or more homogenizing pumps for continuously homogenizing the construction material within the storage unit.

[0068] In some embodiments of the disclosed apparatus, the construction platform and the storage unit are positioned such that the storage unit receives the construction material injected from the deposition module, the construction material discharged from the side of the construction platform, or a combination thereof.

[0069] In some embodiments of the disclosed apparatus, the construction platform includes a construction platform work surface that defines a plurality of pores.

[0070] In some embodiments of the disclosed apparatus, the construction material comprises a mixture of a powder material and a photopolymer resin, wherein the photopolymer resin of the deposited layer of the construction material is removed at least partially through the plurality of pores so that the layer becomes densified.

[0071] Other embodiments disclosed herein provide a method for creating a solid freeform system. This method is The stage of setting up the construction platform, The steps include constructing a construction material section for depositing construction materials onto the aforementioned construction platform, The method includes the step of constructing a selective processing unit that selectively processes the aforementioned construction material to form a three-dimensional object.

[0072] In some embodiments of the disclosed method, The construction material section is configured to deposit layers of the construction material on the construction platform and to densify the layers of the construction material. The selective processing unit is configured to selectively process the layers of the construction material, The construction material section and the selective processing section are configured to form the three-dimensional object by repeatedly performing the deposition, densification, and selective processing of one or more layers made of the construction material stacked on the layer.

[0073] In some embodiments of the disclosed method, the construction material comprises a mixture of a powder material and a carrier fluid.

[0074] In some embodiments of the disclosed method, the construction material section is coupled to the construction platform and configured to remove at least a portion of the carrier fluid from the construction material via the construction platform.

[0075] In some embodiments of the disclosed method, the carrier fluid comprises a photopolymer resin, and the selective processing unit is configured to cure at least a portion of the construction material at least partially by irradiation.

[0076] In other embodiments disclosed herein, a system for creating a solid freeform system is provided. The system comprises means for carrying out the disclosed method.

[0077] In other embodiments disclosed herein, a device is provided for illuminating an image onto an image-generating surface with high resolution. The device comprises an array of multiple illumination sources aligned in the scanning direction and a projection optical system. Each of the aforementioned group of irradiation sources includes an array of subgroups consisting of a portion of the plurality of irradiation sources aligned in a direction intersecting the scanning direction, Each of the aforementioned subgroups of irradiation sources includes multiple irradiation sources, Within each of the subgroups of the plurality of irradiation sources, the plurality of irradiation sources are arranged in the scanning direction and shifted in the intersecting direction by an offset distance greater than 0 and not exceeding the width of each of the plurality of irradiation sources in the intersecting direction. The projection optical system is positioned between the array of the plurality of illumination sources and the image generating surface, and is configured to illuminate the image generating surface from the array of the plurality of illumination sources. The image generating surface defines an array of multiple pixel regions on the surface, each of the multiple pixel regions includes an array of multiple images, and each of the multiple images is image-generated by at least one of the multiple illumination sources. The illumination is translated in the scanning direction such that an array of the plurality of illumination sources generates an image in the plurality of pixel regions, and each of the plurality of pixel regions is imaged as a whole by at least one of the subgroups of the plurality of illumination sources.

[0078] In some embodiments of the disclosed apparatus, the number of pixels in the intersecting direction does not exceed the number of subgroups of illumination sources within each of the plurality of illumination sources.

[0079] In some embodiments of the disclosed apparatus, the offset distance is equal to the width of each of the plurality of irradiation sources in the intersecting direction.

[0080] In some embodiments of the disclosed apparatus, the offset distance is shorter than the width of each of the multiple irradiation sources in the intersecting direction.

[0081] In some embodiments of the disclosed apparatus, the array of the plurality of irradiation sources is integrated on a microlight-emitting diode (microLED) chip, and each irradiation source includes a microLED.

[0082] In some embodiments of the disclosed apparatus, the micro-LED chip and the projection optical system are simultaneously translated in the scanning direction relative to the image generating surface.

[0083] In some embodiments of the disclosed apparatus, the microLED chip is translated relative to the image-generating surface in the scanning direction, and the projection optical system is stationary relative to the image-generating surface.

[0084] In some embodiments of the disclosed apparatus, the apparatus further comprises at least one reflective element provided between the image generating surface and the micro-LED chip, configured to rotate around an axis parallel to the intersecting directions, the reflective element being configured to translate the illumination from the micro-LED chip in the scanning direction.

[0085] In some embodiments of the disclosed apparatus, a selected group of irradiation sources includes a defective irradiation source, and the region of the image-generating surface corresponding to the defective irradiation source is image-generated by a non-defective irradiation source in another group of irradiation sources aligned with the selected group of irradiation sources in the scanning direction.

[0086] According to other embodiments disclosed herein, a system for creating a three-dimensional object is provided. The system is A construction material section comprising one or more layers of photocurable resin, The disclosed apparatus includes a device for curing each of the layers according to a slice of a digital model of the three-dimensional object.

[0087] Other embodiments disclosed herein provide a method for curing a photocurable material. This method is: The step of irradiating the photocurable material with an array of multiple irradiation sources aligned in the scanning direction, Each of the aforementioned group of irradiation sources includes an array of smaller groups of irradiation sources aligned in a direction intersecting the scanning direction, Each of the aforementioned subgroups of irradiation sources includes multiple irradiation sources, Within each of the subgroups of the plurality of irradiation sources, the plurality of irradiation sources are distributed in the scanning direction and are shifted in the intersecting direction by an offset distance greater than 0 and not exceeding the width of each of the plurality of irradiation sources in the intersecting direction. The photocurable material defines an array of multiple pixel regions on the material, each of the multiple pixel regions includes an array of multiple images, and each of the multiple images is image-generated by at least one of the multiple irradiation sources. Stages and The process involves translating the irradiation from the array of multiple irradiation sources in the scanning direction, thereby causing the array of multiple irradiation sources to generate an image in the multiple pixel regions, and each of the multiple pixel regions to be imaged as a whole by at least one of the subgroups of the multiple irradiation sources.

[0088] According to other embodiments disclosed herein, a needle having a porous tip is provided that penetrates the skin of a living organism.

[0089] In some embodiments of the disclosed needle, the tip does not define a passage through the tip.

[0090] In some embodiments of the disclosed needle, the tip comprises a plurality of pores internally, and defines a flow path for one or more of the plurality of pores that allows a fluid to pass through the tip.

[0091] In some embodiments of the disclosed needle, the tip defines a plurality of pores smaller in size than the solid components of blood. As a result, the solid components do not pass through the plurality of pores.

[0092] In some embodiments of the disclosed needle, each of the plurality of pores has a diameter of 100 nm to 10 μm.

[0093] In other embodiments disclosed herein, a microneedle is provided that penetrates the skin of a living organism. The microneedle comprises a tip that defines one or more pores in a direction perpendicular to the direction of insertion of the microneedle during operation.

[0094] In some embodiments of the disclosed microneedles, each of the pores has a diameter of 100 nm to 50 μm, the microneedle is shorter than 3 mm, the tip has a length of 10 μm to 250 μm, and the tip radius is not greater than 10 μm.

[0095] According to other embodiments disclosed herein, an apparatus for making a three-dimensional object is provided. The apparatus is Construction platform and A deposition module configured to deposit multiple layers of construction material on the aforementioned construction platform or on layers deposited in the past, The device includes a selective processing unit that defines the three-dimensional structure by adjusting at least a portion of at least a portion of the layers among the aforementioned deposited layers. The construction material comprises a mixture of powder material and liquid components, and the layer is densified by removing at least a portion of the liquid component of the construction material from the deposited layer.

[0096] In some embodiments of the disclosed apparatus, the liquid component comprises a photopolymer resin.

[0097] In some embodiments of the disclosed apparatus, the selective processing unit is configured to irradiate the photopolymer resin.

[0098] According to other embodiments disclosed herein, an apparatus for making a three-dimensional object is provided. The apparatus is Construction platform and A deposition module configured to deposit multiple layers of construction material on the aforementioned construction platform or on layers deposited in the past, The device includes a selective processing unit that defines the three-dimensional structure by adjusting at least a portion of at least a portion of the layers among the aforementioned deposited layers. The construction platform defines a construction platform work surface that defines multiple pores, The construction material comprises a mixture of powder material and liquid components, and the layer is densified by removing at least a portion of the liquid component of the construction material from the deposited layer.

[0099] In some embodiments of the disclosed apparatus, the liquid component comprises a photopolymer resin.

[0100] In some embodiments of the disclosed apparatus, the selective processing unit is configured to irradiate the photopolymer resin.

[0101] Other embodiments disclosed herein provide a method for creating a three-dimensional object. This method is A step of making at least one part and a parts tray using the disclosed method described above, The step of sintering the component tray, wherein the geometric shape of the sintered component tray is complementary to the geometric shape of the component before sintering. The steps include: transporting the aforementioned parts into the aforementioned parts tray, The process includes the step of sintering the components in the component tray.

[0102] In some embodiments of the disclosed method, the loading step includes loading the parts into the parts tray by vacuum suction applied to the parts tray.

[0103] In some embodiments of the disclosed method, the step of sintering the parts tray includes a step of sintering the parts tray so that the sintered parts tray becomes porous and defines pores having a size smaller than the size of each of the at least one parts. The vacuum suction is applied through the pores.

[0104] In some embodiments of the disclosed method, The aforementioned manufacturing stage includes the stage of manufacturing multiple parts, The aforementioned loading step includes the step of simultaneously loading the multiple parts into the parts tray.

[0105] Other embodiments disclosed herein provide a method for creating a three-dimensional object. This method is The steps include: making tools and parts using the methods disclosed above; The method includes the step of adjusting the geometric shape of the part using the aforementioned tool.

[0106] In some embodiments of the disclosed method, the adjustment step is: The steps include immersing the aforementioned tools and the aforementioned parts in an electrolyte solution, The process includes the step of removing at least a portion of the material from the component by applying an electric current across the tool and the component.

[0107] In some embodiments of the disclosed method, the step of making the tool includes determining the surfaces of the tool necessary to give the tool the target geometry by determining in a digital model the geometry of the tool to be complementary to one or more surfaces of the target geometry of the part.

[0108] In some embodiments of the disclosed method, the tool is porous.

[0109] In some embodiments of the disclosed method, the step of making the tool includes a step of controlling the porosity of the tool by controlling the sintering temperature of the tool.

[0110] In some embodiments of the disclosed method, the tool defines the size of the pores such that the geometric shape of the pores is not given to the component by the adjustment step, and the electrolyte flows through at least a portion of the pores during the adjustment step.

[0111] Other embodiments disclosed herein provide a method for creating a three-dimensional object. This method is The process involves creating at least one part and a parts tray using freeform molding, The step of sintering the parts tray, wherein the geometric shape of the sintered parts tray is complementary to the geometric shape of the parts before sintering. The steps include: transporting the aforementioned parts into the aforementioned parts tray, The process includes the step of sintering the components in the component tray.

[0112] In some embodiments of the disclosed method, the loading step includes loading the parts into the parts tray by vacuum suction applied to the parts tray.

[0113] In some embodiments of the disclosed method, the step of sintering the parts tray includes a step of sintering the parts tray so that the sintered parts tray is porous and defines pores having a size smaller than the size of each of the at least one parts. The vacuum suction is applied through the pores.

[0114] In some embodiments of the disclosed method, The aforementioned manufacturing stage includes the stage of manufacturing multiple parts, The aforementioned loading step includes the step of simultaneously loading the multiple parts into the parts tray.

[0115] Other embodiments disclosed herein provide a method for creating a three-dimensional object. This method is The process involves creating tools and parts using free-form molding, The method includes the step of adjusting the geometric shape of the part using the aforementioned tool.

[0116] In some embodiments of the disclosed method, the adjustment step is: The steps include immersing the aforementioned tools and the aforementioned parts in an electrolyte solution, The process includes the step of removing at least a portion of the material from the component by applying an electric current across the tool and the component.

[0117] In some embodiments of the disclosed method, the step of making the tool includes determining the surfaces of the tool necessary to give the tool the target geometry by determining in a digital model the geometry of the tool to be complementary to one or more surfaces of the target geometry of the part.

[0118] In some embodiments of the disclosed method, the tool is porous.

[0119] In some embodiments of the disclosed method, the step of making the tool includes a step of controlling the porosity of the tool by controlling the sintering temperature of the tool.

[0120] In some embodiments of the disclosed method, the tool defines the size of the pores such that the geometric shape of the pores is not given to the component by the adjustment step, and the electrolyte flows through at least a portion of the pores during the adjustment step.

[0121] Further features of the present invention will become readily apparent from the accompanying drawings and the subsequent detailed description of the invention. [Brief explanation of the drawing]

[0122] Preferred embodiments of the present invention will be described below with reference to the drawings. [Figure 1] This is a front right-side perspective view of a machine for freeform molding of solid materials according to one embodiment of the subject disclosed in this application. [Figure 2] Figure 1 is a front left perspective view of the machine. [Figure 3] Figure 1 is a cross-sectional view of the machine. [Figure 4] Figure 2 is a cross-sectional view of the machine. [Figure 5] Figure 1 is a front perspective view of the material deposition system used in the machine. [Figure 6] Figure 5 is a cross-sectional view of the material deposition system. [Figure 7] This is a cross-sectional view of a portion of the material deposition system in the first configuration shown in Figure 5. [Figure 8] This is a cross-sectional view of a portion of the material deposition system in the second configuration, as shown in Figure 5. [Figure 9] This is a cross-sectional view of a portion of the material deposition system in the third configuration, as shown in Figure 5. [Figure 10] This is a cross-sectional view of a portion of the material deposition system in the fourth configuration, as shown in Figure 5. [Figure 11] Figure 1 is a bottom view of the first pumping system from the machine. [Figure 12] Figure 1 is a bottom view of the second pumping system from the machine. [Figure 13] Figure 1 is a schematic diagram of the first stage of a material processing process that may be used by the machine shown. [Figure 14] Figure 1 is a schematic diagram of the second stage of the material processing process available through the machine. [Figure 15] Figure 1 is a schematic diagram of the third stage of the material processing process available through the machine. [Figure 16] Figure 1 is a front perspective view of an embodiment of a build platform available by machine. [Figure 17] Figure 16 is a cross-sectional view of the construction platform. [Figure 18] Figure 16 is a front perspective view of the construction platform with a partially completed structure. [Figure 19] Figure 16 shows a front perspective view of the completed construction platform. [Figure 20] Figure 16 is a front perspective view of the first configuration of the system that processes the completed structure on the construction platform. [Figure 21] Figure 21 is a cross-sectional view of the system shown in Figure 20. [Figure 22] Figure 16 is a front perspective view of the top of the construction platform with the completed structure. [Figure 23] Figure 16 is a front perspective view of the top of the construction platform with the completed structure after the process of removing excess material has been completed. [Figure 24] This is a bottom-up perspective view of the first configuration of a system for removing batches of printed parts for sintering. [Figure 25] This is a bottom-up perspective view of the second configuration of the system for removing batches of printed parts for sintering. [Figure 26] Figure 25 is a cross-sectional view of the system. [Figure 27] Figure 1 is a schematic diagram of the first stage of a parts finishing process that can utilize parts and / or tools manufactured by the machine shown. [Figure 28] This is a schematic diagram of the second stage in a parts finishing process where parts and / or tools manufactured by the machine shown in Figure 1 are available. [Figure 29]This is a schematic diagram of the third stage in a parts finishing process that utilizes parts and / or tools manufactured by the machine shown in Figure 1. [Figure 30] This is an illustrative diagram representing a solid freeform molding system for objects. [Figure 31] This is an exemplary top-level flowchart illustrating one embodiment of a solid freeform fabrication method based on the system shown in Figure 30. [Figure 32] This is an illustrative diagram showing an alternative embodiment of the system in Figure 30. In the diagram, the object includes one or more layers. [Figure 33] This is an illustrative flowchart showing one embodiment of a solid freeform fabrication method based on the system shown in Figure 32. [Figure 34] Figure 32 is an exemplary flowchart illustrating an alternative embodiment of a solid freeform fabrication method based on the system shown. This method includes a step of densifying the construction material. [Figure 35] Figures A and B illustrate another alternative embodiment of the system in Figure 32, showing the construction materials before and after the use of the ultrasonic section, respectively. [Figure 36] Figures A and B are exemplary diagrams showing another alternative embodiment of the system in Figure 32, with the construction material before and after the use of the ultrasonic section, respectively. The ultrasonic section solidifies the powder. [Figure 37] This is an illustrative diagram showing yet another alternative embodiment of the system shown in Figure 32. This system includes an evaporation unit. [Figure 38] Figures A through C are illustrative diagrams showing an exemplary process of densifying the building material within the system shown in Figure 32. [Figure 39] Figures A and B are exemplary diagrams showing another alternative embodiment of the system in Figure 32, with the construction materials before and after the application of the densifying fluid, respectively. [Figure 40] This flowchart illustrates an alternative embodiment of the solid freeform fabrication method based on the system shown in Figure 30. This method is irradiation-based. [Figure 41]This figure illustrates yet another alternative embodiment of the system shown in Figure 32. This system includes a selective deposit section. [Figure 42] Figures A and B are illustrative diagrams illustrating the system in Figure 41, showing the deposition of auxiliary building materials on dry and wet powders, respectively. [Figure 43] Figure 30 is an illustrative flowchart illustrating another alternative embodiment of a solid freeform fabrication method based on the system shown. This method includes a step of depositing auxiliary construction material. [Figure 44] This figure illustrates an alternative embodiment of the system shown in Figure 41. In the figure, the object is formed based on the target region. [Figure 45] Figure 41 is an exemplary perspective view showing another alternative embodiment of the system. In the figure, the object is formed based on a non-target region. [Figure 46] Figure 41 is an illustrative perspective view showing yet another alternative embodiment of the system. In the figure, the object is formed based on a supporting surface layer. [Figure 47] Figure 41 shows various detailed diagrams illustrating an embodiment of the system. [Figure 48] Figure 41 shows various detailed diagrams illustrating an embodiment of the system. [Figure 49] Figure 41 shows various detailed diagrams illustrating an embodiment of the system. [Figure 50] Figure 41 shows various detailed diagrams illustrating an embodiment of the system. [Figure 51] Figure 41 shows various detailed diagrams illustrating an embodiment of the system. [Figure 52] Figure 41 shows various detailed diagrams illustrating an embodiment of the system. [Figure 53] Figure 41 shows various detailed diagrams illustrating an embodiment of the system. [Figure 54] Figure 41 shows various detailed diagrams illustrating an embodiment of the system. [Figure 55] Figure 41 shows various detailed diagrams illustrating an embodiment of the system. [Figure 56]Figure 41 shows various detailed diagrams illustrating an embodiment of the system. [Figure 57] This is an illustrative diagram showing one embodiment of a manufacturing system. The system includes an image generation unit. [Figure 58] Figure 57 is an illustrative diagram showing an embodiment of the image generation unit. The image generation unit includes a plurality of irradiation source groups. [Figure 59] Figure 58 illustrates the group of images generated by the image generation unit. [Figure 60] Figure 58 illustrates the pixel region generated by the image generation unit. [Figure 61] This figure illustrates an alternative embodiment of the image generation unit shown in Figure 57. In the figure, the image generation unit includes multiple irradiation source groups, and the size of the irradiation sources differs between Figure 61 and Figure 58. [Figure 62] This is an illustrative diagram showing a group of images generated by the image generation unit in Figure 58. [Figure 63] Figure 58 illustrates the pixel region generated by the image generation unit. [Figure 64] This is an illustrative diagram showing an array of images generated by another alternative embodiment of the image generation unit in Figure 57. [Figure 65] This figure illustrates an array of images generated by yet another alternative embodiment of the image generation unit in Figure 57. The image sizes differ between Figure 65 and Figure 64. [Figure 66] This is an illustrative diagram illustrating various embodiments of the system shown in Figure 57. [Figure 67] This is an illustrative diagram illustrating various embodiments of the system shown in Figure 57. [Figure 68] This is an illustrative diagram illustrating various embodiments of the system shown in Figure 57. [Figure 69] This is an illustrative diagram illustrating various embodiments of the system shown in Figure 57. [Figure 70] This is an illustrative diagram illustrating various embodiments of the system shown in Figure 57. [Figure 71] This is an exemplary diagram showing an embodiment of a component produced by the system in Figure 30. [Figure 72] This is an illustrative diagram showing an alternative embodiment of the part shown in Figure 71. In the diagram, the part defines pores within the part. [Figure 73] This is an illustrative diagram showing another alternative embodiment of the part shown in Figure 71. In the diagram, the part has pores defined at its tip. [Figure 74] Figure 30 is an illustrative diagram showing an embodiment of a component created by the system. In the diagram, the component is configured to enter a blood vessel. [Figure 75] This is an illustrative diagram showing an alternative embodiment of the part shown in Figure 74. In the diagram, the part has pores defined at its tip. [Figure 76] This figure illustrates an embodiment of a part produced by the system shown in Figure 30. In the figure, the part defines one or more pores oriented laterally. [Figure 77] This is an illustrative diagram showing an embodiment of a microneedle array produced by the system shown in Figure 30. [Figure 78] This is an illustrative diagram showing one embodiment of a control system for controlling the system shown in Figure 30.

[0123] Please note that the figures are not drawn to scale, and components of similar structure or function are generally represented by similar reference numerals throughout the figures for illustrative purposes. Also note that the figures are intended solely to facilitate the description of preferred embodiments. The figures do not illustrate all aspects of the described embodiments, nor do they limit the scope of this disclosure. [Modes for carrying out the invention]

[0124] The embodiments described herein generally relate to apparatus and methods for fabricating objects in solid freeform from a wide variety of materials. Exemplary materials may include metals, plastics, ceramics, and / or composite materials consisting of combinations of one or more types of materials.

[0125] Stereolithography (SLA) fabrication utilizes photopolymer resins and polymerization radiation sources to manufacture three-dimensional objects. Approaches have also been developed to produce powder composite parts using slurry raw materials, which can then be further processed to produce solid metal or ceramic parts. Many of these approaches have inherent design trade-offs between speed and part quality. Figures 1–4 show a system (100) designed to overcome these limitations.

[0126] This system can be used to process any mixture of photopolymer resin and powder. In some embodiments, the mixture may be in the form of a slurry. In some cases, this method can be used to produce powder composites, which are then post-processed to remove the polymer binder and sinter the powder material into a solid component. The powder material may be any combination of metal, ceramic, or sinterable material(s).

[0127] In exemplary embodiments, the system includes a material deposition system (130) and optionally one or more air blades (140, 150) for depositing material and controlling where the material accumulates on the build platform work surface (162). In various embodiments, processes as defined in this disclosure can be performed on an active work surface (167). The active work surface (167) may include a surface on which material is being deposited or is to be deposited. In some embodiments, the active work surface (167) may include, for example, the build platform work surface (162) during the deposition of a first layer. Additionally and / or alternatively, the active work surface (167) may include, for example, the outermost deposited layer as each subsequent layer after the first layer is deposited. In some embodiments, the deposition system (130) may be mounted on linear guides (103, 105) to allow the deposition system (130) to be linearly translated across the build platform work surface (162). Generally, it is understood that any system that achieves the motion of the deposition system (130) relative to the construction platform work surface (162) so that the material is deposited onto the active work surface (167) is considered to be within the scope of the present disclosure. After the material has been deposited, a projection module (106) is used to define one layer of a printed part or array of printed parts by curing at least a portion of the deposited layer at least partially. The image of this layer can be obtained by calculating the intersection of the horizontal plane and the three-dimensional digital representation of the object. Furthermore, this image may be modified to have a grid structure, or other support parts may be added, including but not limited to non-contact support parts. As will be described in more detail in the following figures, the support parts are designed within the image(s) of the layer. Gaps exist in the image that separate the support parts from the printed part. It may be sufficient to use generally accepted methods for generating the image of the layer, or it may be necessary to include any combination of the modifications mentioned above. This process is repeated until the fabrication is complete.

[0128] The process may be monitored by a camera (104) that can provide data for feedback and / or for quality control purposes in a configuration utilizing closed-loop control. In particular, for certain photopolymer resin formulations, a change in color may be observed during the curing process to control and / or verify the integrity of the curing process. For example, some resin formulations containing phosphine-based photopolymerization initiators may change from transparent or light translucent yellow to dark yellow during curing. In this example, a specific wavelength of light corresponding to the change in absorption by the resin during curing may be shone onto the structural region. The light emitted from the structural region may be imaged by the camera (104), and the luminance of this wavelength measured in the camera image may be used to verify the curing process. In some embodiments, the luminance level can be measured by control software using data from the camera to determine the degree of curing that has occurred. In a control configuration, this may be used to determine when to stop the curing process after a brightness threshold has been observed by the camera and detected by the control software. In another embodiment, the luminance level can be measured and stored as quality control data. Metadata indicating whether this level exceeds a predetermined minimum can be added to confirm that proper curing has occurred. Furthermore, by comparing the acceptable range with the brightness levels observed by the camera and measured by the control software, it is possible to determine whether the layer has been sufficiently cured but not over-cured.

[0129] When using a slurry of photopolymer resin and powder as feedstock, it may be useful to homogenize the material by means including, but not limited to, circulating, stirring, and / or agitating the material to limit the extent to which the powder material settles from the slurry and / or forms aggregates that may impair the quality of the material layers or the quality of the printed parts or the arrangement of parts as a whole. While the use of dispersed powder in slurry is common in industry, it is worth noting that many slurries use nanoparticles that can be incorporated into stable suspensions that do not require a certain degree of homogenization to maintain material quality and uniformity. In many cases of additive manufacturing, larger (e.g., in the range of 0.5 to 50 microns in diameter), higher density particles (e.g., metals and / or ceramics) may be used, which makes it much more difficult to create a stable suspension. Exemplary particles used in various embodiments are 1.5 grams / cubic centimeter (g / cm³). 3 ) ~20g / cm 3 Or 1.5 g / cm³ 3 ~25g / cm 3It is considered to be within this range. In a suspension, there is considered to be a settling time, which represents the time (e.g., 30 seconds) from when the homogenization process stops until the slurry or suspension is no longer homogenized to a degree sufficient to feed a layer of acceptable quality. By continuously homogenizing the slurry during the construction process, higher quality and more reproducible results can be achieved than if all suspensions were simply pre-mixed. In various embodiments, the settling time of the disclosed process can be significantly shorter than the settling time of many existing slurries using nanoparticles. Exemplary settling times can range from 1 second to 5 minutes, so homogenization is required in some actual manufacturing processes such as those disclosed. A specific settling time may depend on the particle size and / or density, as well as the properties of the fluid (such as viscosity). For example, the settling time may be shorter when the fluid viscosity is low and longer when the fluid viscosity is high. For example, the settling time of a metallic material in a low-viscosity fluid may be 2 seconds. In another example, the settling times of various types of metallic materials may be 10 seconds, 30 seconds, or 5 minutes, respectively. In another example, the settling time for a ceramic material can be 2 minutes.

[0130] In various embodiments, continuous homogenization can be performed by using homogenizing means without interruption during the printing process. In addition and / or alternatively, continuous homogenization can be performed by using homogenizing means at least immediately before and / or during the deposition of the printed object, with possible pauses at other times. In some embodiments, if there are pauses in the process, the pause time between the homogenization stop and layer deposition must be less than the settling time. In various embodiments, this circulation can be achieved with a set of multiple pumps (110, 112, 114, 116, 118). Four of these pumps (110, 112, 114, 116) are homogenization pumps, and one pump (118) is used for circulation and to supply material to the deposition module (130). As shown in further figures, the outflow from the supply pump (118) flows through a pipe (e.g., the outlet port 121 shown in Figure 11) which can be connected to an inlet (e.g., the input line 132 shown in Figure 5) for the deposition module (130). Although a complete tubular circuit is not depicted, it can be understood from the diagram that such connections are easily achievable. During the printing process, the slurry storage unit (102) may be filled with slurry. Homogenization pumps (110, 112, 114, 116) may be configured to homogenize the slurry within their respective regions such that inflow and outflow occur in close proximity to the pumps. In addition and / or alternatively, the homogenization pumps (110, 112, 114, 116) may be configured to circulate the slurry around the storage unit (102) such that the outflow from one homogenization pump is directed to the inflow of another homogenization pump. As shown in further figures, the exemplary homogenization pumps (110, 112, 114, 116) may be hammer mill pumps capable of creating localized toroidal flows in the homogenization process. In some embodiments, additional feature parts (not depicted) may be added to direct the output flow from the pump in a specific direction, such as a shroud or other flow deflection structure, as may be implemented in an impeller pump system.In some embodiments, the reservoir (102) comprises an inner wall, an outer wall, and a bottom surface, which together form an annular storage section for receiving excess slurry from the deposition module (130) and any excess slurry flowing out from the sides of the construction platform (160). When the deposition module (130) is placed on the storage section (102), the slurry can flow out of the deposition module (130) and into the storage section (102). When the deposition module (130) is translated across the construction platform work surface (162), this generates a layer of material for printing. An exemplary printing process may include translating a deposition module (130) in one direction across a construction platform work surface (162) to generate a layer of material on an active work surface (167), subsequently processing the layer of material with a projection module (106), then lowering the construction platform (160) by the thickness of one layer, and then translating the deposition module (130) back across the construction platform work surface (162) to generate another layer of material that can then be processed by the projection module (106). This configuration and style of pump is intended to be illustrative but not limiting, and any suitable circulation and homogenization system for supplying material to the deposition module (130) is understood to be included herein. In some embodiments, the translation of the deposition module (130) can be achieved by a combination of linear actuators, rotary actuators driving screw drives or belt drives, or any other method of achieving linear motion as commonly understood by those skilled in the art. Furthermore, in some embodiments, control of the pump motor, the motion of the construction platform, and the motion of the deposition module can be achieved by standard means. Figures 1-4 show system (100) for illustrative purposes only, including a pump system with pumps (110, 112, 114, 116, 118) having the functions described above, but system (100) can perform such functions(s) with any suitable parts and / or structure of material supply unit (108) without limitation.The exemplary material supply unit (108) may include any suitable type of pump, conveyor, vacuum, fan, turbine, mixer, blender, processor, and / or combination thereof. Figures 1-4 show the system (100) as including pumps (110, 112, 114, 116, 118) each having the functions described above, for illustrative purposes only, but the system (100) may include one pump, or without limitation, any suitable number (other than five) of identical and / or different pumps. The functions of the pumps(s) can be carried out through any configuration and / or combination. In one example, one or more pumps may each provide homogenization and circulation functions. In another example, one or more pumps may be homogenization pumps and one or more other pumps may be circulation pumps.

[0131] In one configuration, the deposition module (130) may be a slot die, the details of which are shown in Figures 5 and 6. The slot die functions to feed the slurry through an input line (132) into a central cavity (131) and to exit the slurry between two opposing surfaces (133, 134). The deposition process can be improved by using two vacuum regions (137, 138) by applying vacuum pressure through a right vacuum line (135) or a left vacuum line (136), as illustrated in Figure 8.

[0132] As will be further explained below, it may be desirable to restrict where on the construction platform work surface (162) the deposit material accumulates. For example, it may be desirable to restrict the accumulation of deposit material on the cut / cut edges (or surface or area) (164,166) (shown in Figures 16 and 17) of the construction platform work surface (162). Air blades (140,150) including inlet lines (142,152) that supply to the central cavity (144,154) and allow air to flow out through the outlet slots (146,156) may be used to blow excess material from the construction platform work surface (162) back into the storage (102) for reuse in subsequent layers.

[0133] Figures 7–10 illustrate a process in which a slot die may be used in a deposition module (130), and adjustments that may be made to improve the performance of such a slot die system. Figure 7 shows a typical slot die exit path, showing that after the slurry (201) is allowed to pass between the opposing faces (133, 134) of the slot die, it forms a bead with a leading meniscus (202) and a trailing meniscus (204), thereby generating a layer (206) of deposited material. The volume of the bead between the leading meniscus (202) and the trailing meniscus (204) can define the stable bead region of the bead. In this description and in Figures 8–10, the slot die moves to the left, leaving the layer (206) of material behind it. As understood in slot die coating, when operating conditions are fixed and the process occurs at atmospheric pressure, there are limitations on the ratio of bead height to layer height. In this example, the bead height is considered to be the height of the leading meniscus (202). This ratio can be increased by exposing the leading meniscus (202) to vacuum pressure, as shown in Figure 8, to produce a thin layer while maintaining a high level of cleanliness between the slot die and the substrate, thereby reducing shear stress on the substrate. The increase in the ratio of bead height to layer height can be at least partially attributable to the forward shift of the bead under exposure to vacuum pressure. Also, since the flow within the bead is typically laminar, a change occurs in the velocity profile within the bead, which is a major factor determining the shear stress. These characteristics are generally understood in existing applications of slot die coating and can be advantageously applied in several embodiments. In some embodiments, the vacuum pressure can be provided by the left vacuum region (138), as shown in the previous figure.

[0134] In some embodiments, controlling conditions (flow rate, lateral speed, etc.) can provide a stable bead during deposition, resulting in the production of a very uniform layer (206). However, if there are deviations in the previous layer, the nature of the slot die deposition process allows for some compensation for these deviations. If the area of ​​the previous layer is small, the gap between the slot die and the substrate (200) is large, which is the case with the previous layer in this example. This large gap draws more material from the bead, creating a thicker layer (206). This thicker layer (206) will at least partially compensate for the smaller area. If the area is large, the opposite behavior is observed. The limits of this behavior are at least partially determined by the size of the bead. If too much material is drawn from the bead, the tip meniscus (202) is no longer stable, and air bubbles may be incorporated into the layer (206). Conversely, if too little material is drawn from the bead, the tip meniscus (202) may spread too far beyond the slot die, causing wetting of the angled outer surface of the slot die. This additional material could directly cause imperfections in layer (206), and could also generate residual material that could drip onto the next layer as the slot die moves in the opposite direction on the build platform, potentially causing imperfections in the following layer.

[0200] Figures 9 and 10 show that the opposing surfaces (133, 134) defining the slurry (201) flow path were modified to increase the bead size without fundamentally altering other aspects of the deposition process, thereby introducing greater tolerance to deviations in the system. If the flow rate ratio to linear velocity of the deposition module (130) (shown, e.g., in Figure 6) is kept within a range that prevents excessive flow from over-enlarging the bead, it is possible to prevent the leading meniscus (202) from overextending beyond the slot die and resulting in wetting of the angled outer surface of the slot die. For this purpose, chamfers (210, 212) or fillets (214, 216) can be added to the slot die surface (133, 134). Additionally and / or alternatively, other cutout shapes can be used to achieve the desired effect. Chamfers (210, 212), fillets (214, 216), and / or other cutout shapes formed on the slot die surfaces (133, 134) enlarge the size of the opening defined in the edge region of the slot die surfaces (133, 134), and the stable bead region can be enlarged. The inventors have found that enlarging the bead size can improve the stability and / or uniformity of the deposition by the deposition module (130). Conventional slot die coating applications involve coating only a limited number of layers, on the order of five or less, such as a single layer on a sheet of paper to make the paper glossy, or a series of layers such as multiple colors or coatings. In contrast, the disclosed system (100) (shown in Figures 1-4) can be used for slot die coating in SFF. When depositing multiple layers, for example, including hundreds or thousands of layers, it is important to ensure that the system (100) is stable to such a high level of repeatability. Therefore, by modifying the slot die to improve stability in the use of SFF, system (100) solves a problem that is unique to the use of SFF but not necessarily present in other uses of slot die coating. The exemplary number of layers required to create a three-dimensional object can be equal to or of the order of 10, 20, 50, 100, 200, 500, and 1000.Such numbers are significantly larger than in any other technique that uses slot die coating. Therefore, using slot die coating in SFF may encounter unique technical problems that were not encountered or resolved in conventional slot die coating techniques. Methods and systems as provided in this disclosure can solve such technical problems.

[0135] Figure 11 shows a circulation pump (118) that may be used to supply the previously depicted deposition module (130). This pump (118) may include an outer shroud (120), a rotor (119), and an outlet port (121). In this configuration, the pump (118) can be an impeller pump and can be operated continuously to circulate the slurry through the deposition module (130). Figure 12 shows a homogenization pump (110) including a shroud (115) with an outlet slot (117) and a rotor (111) with a pumping slot (113). In this configuration, the homogenization pump (110) can be a hammer mill and uses centrifugal pump motion to facilitate collisions between suspended particles in the slurry and the outlet slot (117) of the shroud (115). This has the effect of breaking up powder agglomerates and homogenizing the slurry. Continuously circulating the slurry through these pumps helps maintain slurry quality and prevent sedimentation and / or aggregation.

[0136] Figures 13-15 show schematics of material processing methods that can be used in the aforementioned system. As illustrated in further figures, the construction platform work surface (162) may be porous to allow fluid flow through the platform. In this configuration, a low-density mixture of powder (310) and resin (312) is deposited on the active work surface (167). Vacuum pressure is applied to the slurry through the porous construction platform work surface (162) and, if present, previously deposited layers to remove excess resin (312), increase the effective powder loading density of the slurry, and densify the powder (310). In extreme cases, as shown in Figure 15, all excess resin (312) can be removed so that resin (312) is only found at the contact points between powder particles (310). If not all resin (312) is removed (for example, as shown in Figure 14), the layer can be imaged using a lattice structure to allow fluid flow and removal of fluid from subsequent layers. In other words, the layer can be imaged according to a lattice pattern. Advantageously, the resin in areas of the layer that are not imaged can be removed, allowing fluid pathways to open up within the layer. If the size and boundaries of the grid are properly designed, for example, if there are few holes and it is almost solid, the grid can trap uncured powder within the three-dimensional part, and a solid part can be created by the sintering process despite the use of the grid during exposure. In the example depicted in Figure 15, it may not be necessary to use these grid imaging techniques. Since this fluid drainage process can leave an inherently porous structure, fluid pathways within the part can still be utilized even if solid curing imaging is used.

[0137] The value of densifying the deposition layer lies in enabling the use of low-viscosity feedstocks during deposition, which can deposit rapidly, while producing highly homogeneous, high-density pre-printed parts. Achieving high density after sintering requires a minimum density requirement for the pre-printed part; therefore, using feedstocks with insufficient powder loads may result in improper sintering. Conversely, using feedstocks with high powder loads leads to very high viscosity, severely slowing the layer deposition (and thus printing) process. Furthermore, metal powders, in particular, tend to settle rapidly from the slurry, and layers with insufficient powder loads may result in pre-printed layers with more powder at the bottom than at the top. This affects the mechanical properties of the sintered part, potentially resulting in parts that are weaker under vertical tensile loads compared to horizontal loads. Densifying the layer eliminates density variations within the layer, resulting in isotropic sintered parts. Additionally, high-density pre-printed parts exhibit less shrinkage during sintering, allowing for greater control over dimensional tolerances. Furthermore, when slurry is deposited onto a porous substrate without vacuum pressure, the fluid may be passively absorbed by the substrate, causing the layer to densify. However, this densification process can occur very slowly compared to when the process is assisted by vacuum pressure. Moreover, the speed of this densification process can decrease significantly and even stop completely as additional layers are deposited.

[0138] In some embodiments, the suction process can be controlled and / or verified by image generation by a camera (104) (shown in Figure 1). The active work surface (167) may be illuminated (and / or irradiated) by a light source absorbed by the resin material and reflected by the powder material, and the emitted light can be image-generated by the camera (104) to determine the relative amounts of resin and powder in a given construction layer. This data obtained based on image generation by the camera (104) can be used as feedback to control the level of vacuum pressure applied during densification. For example, it is possible to initially apply a very high vacuum pressure and then decrease the vacuum pressure as the amount of resin in the layer decreases to maintain the resin level in the layer at a stable target value. In some embodiments, the maximum vacuum pressure (about 14.7 psi in a non-limiting example) may not necessarily be suitable for achieving densification of the layer at the desired rate. In this example, it may be desirable to enclose the entire construction process in a sealed container that can be pressurized to increase the effective differential pressure near the active work surface (167) relative to the pressure near the construction platform work surface (162) on the opposite side from the active work surface (167). In various embodiments, “vacuum pressure” can be understood to mean the magnitude of the applied differential pressure as described herein. For example, “high vacuum pressure” may include high differential pressure.

[0139] Figures 16 and 17 show a construction platform (160) having a construction platform work surface (162) that may be used in the system described above. The construction platform work surface (162) may be removable and may have a central porous region (165) similar to the cut / cut surfaces (164, 166). As previously mentioned, the porous region (165) allows for densification of the slurry deposited on the construction platform work surface (162) or the active work surface (167). Given that densification may not occur in the cut / cut zones (164, 166), this further highlights the advantages of using an air blade to remove excess material, as previously described.

[0140] The construction platform (160) may also have an open cavity having a porous top surface (161). In this example, the porous region (165) of the construction platform work surface (162) may have pores small enough to prevent printed parts from falling through, but large enough to allow powder to flow through, while the porous top surface (161) of the construction platform (160) may have pores small enough for resin to flow through but not for powder. In some embodiments, the size (e.g., diameter) of each pore in the porous region (165) may be smaller than the size of each printed part but larger than the size of the powder, while the size (e.g., diameter) of each pore in the porous top surface (161) may be smaller than the size of the powder. During the printing process, powder and resin may fill the pores in the construction platform work surface (162), but powder will not fall into or below the construction platform (160). A construction platform work surface (162) having a porous region (165) may allow the construction platform work surface (162) to be removed to wash away excess material (e.g., powder contained in uncured resin material) from a batch of parts and / or from the construction platform work surface (162), as will be further described in subsequent figures. During the washing process, excess unbound powder can fall through the construction platform work surface (162), thus facilitating the washing process. During washing, the pores defined in the construction platform work surface (162) can be smaller than the printed parts and / or support structures so that only unbound powder and resin can be removed. In various embodiments, the unbound powder may include a portion of powder blended with a resin that is not solid and is not exposed to UV light. The unbound powder may include a portion of powder blended with a resin that is solid and is exposed to UV light.

[0141] Figures 18 and 19 depict the construction platform (160) and construction platform work surface (162) during the construction process. A partially completed structure is shown in Figure 18 and consists of a part cake (assembly of part and / or support structure and uncured material) (170) with a partially completed part (190) and a support structure (192). In this example, a densified construction material (520) (shown in Figure 30) (e.g., deposited in the form of a slurry) can provide adequate support for the printed part (190), so that the support structure (192) is not bonded to the part (190) and does not necessarily serve the purpose of a particular conventional support material or structure. In various embodiments, bonding may include being fixedly and / or rigidly attached, connected, or adhered. To put it somewhat differently, even if the support structure (192) can contact and / or abut the part (190) at a selected position on the part (190) to hold the part (190) in place, there may be gaps between the part (190) and the support structure (192) that arise during the printing process, so the support structure (192) is not fixedly attached, connected, or bonded to the part (190). In some embodiments, the gap can be defined by modifying the layer image(s) input to the projection module (106). For example, modifying the layer image(s) may include defining one or more image pixels between the support structure (192) and the part (190). The support structure (192) can play a role in maintaining the positioning of the part (190) during post-processing, which may include a cleaning process and / or removal for sintering.

[0142] Figures 20 and 21 illustrate systems and methods for pre-treating a part cake (170) before additional steps are taken to remove excess material and sinter the part. Removing uncured resin from the part cake (170) before further processing may be advantageous as it may help to fluidize (and / or loosen) any unbound powder to facilitate the removal of this powder. In some embodiments, the removal of uncured resin does not necessarily result in a visible change in the appearance of the part cake (170). In this example, a shroud (180) is placed around the part cake (170). The shroud (180) may be filled with a solvent that is drawn through the part cake (170) through the same system used for layer densification during the printing process. This may include performing the pre-treatment step within the printer itself, or at a separate station which may have its own suction system, or by completely removing the build platform (160) from the printer. Any form of modularization, including moving the build platform working surface (162) or build platform (160) or other components in either of the aforementioned systems, is understood to be within the scope of the disclosed subject.

[0143] Figure 22 depicts the construction platform work surface (162) and parts cake (170) removed from the printer after the construction is complete. This may be performed before or after the aforementioned pretreatment steps, or it may not involve pretreatment steps. As previously mentioned, the porosity of the construction platform work surface (162) may be such that the powder flows through it, but the parts are still held in place. Thus, the assembly may be placed in a cleaning tank with a cleaning solution and the parts cake (170) may be subjected to ultrasonic treatment, heat, a flow of cleaning solution induced by a pumping system, agitation, etc., to fluidize the unbound powder and remove excess material containing the unbound powder. The final result of such a process is shown in Figure 23, where the parts (190) are held in place by the support structure (192), although they do not necessarily need to be bonded to it. In some embodiments, the component (190) and / or the support structure (192) can be internally coupled, but the component (190) is not coupled to the support structure (192) at any point on the component (190).

[0144] Figures 24-26 illustrate a system and method for removing parts (190) in preparation for sintering. The vacuum module (196) may have a porous ceramic tray (194) mounted therein, which has a shape that matches the top of the parts (190) and provides support for those parts (190) during sintering. Vacuum suction may be performed through the parts tray (194) to remove the parts (190) from their support structure (192). This parts tray (194) can then be inverted and loaded into the furnace for sintering. In some embodiments, the parts (190) may be printed upside down (or in any other desired orientation) so that when the parts tray (194) is inverted, it will be in the desired orientation for sintering. This ceramic parts tray (194) can also be printed and sintered using the system described above, after the optimal orientation of these parts for sintering has been determined, so that its shape is a geometric shape complementary to the downward surface of the parts or assembly of parts. Since the sintering temperature of ceramics is considerably higher than that of metal materials, printed ceramic trays can be reused multiple times to run batches of metal parts. In this way, a low-cost tool is obtained that automates part handling for the production of metal parts and increases the overall efficiency of the process for producing metal parts through the system described above, particularly through the reduction of labor costs. In some embodiments, the part tray (194) may have holes therein that are smaller in size than each of the parts (190). For example, a controlled level of porosity in the part tray (194) can be achieved by adjusting the sintering cycle to reduce the peak temperature and / or soak time. By using a porous part tray (194), multiple parts (190) can be loaded into the part tray (194) at the same time. Conventionally, when parts are very small (e.g., on the order of millimeters), manual operation is required to load the parts one by one for sintering. Such operation is inefficient and prone to errors.In contrast, the disclosed method specified above can advantageously load the component (190) in an efficient and accurate manner. Therefore, the speed and volume of production can be greatly improved.

[0145] Figures 27–29 illustrate systems and methods for refining specific shapes of pre-printed parts in a scalable and cost-effective manner. In some examples, it may be desirable to manufacture parts with sharp points or edges, where these points or edges may be in areas that are not easily reachable by standard grinding methods, or where there are numerous such areas requiring refinement where conventional methods are not cost-effective when there is a need to manufacture parts in large quantities. In this example, the conventional method can be replaced by electrochemical machining using a pre-printed tool (410), the shape of which is determined to grind all relevant features in a single process. In this example, a part (400) with a blunt point (402) is represented. The shapes of the tool (412, 414) can be determined by extrapolating from the desired final shape (404, 406, 408). The desired final shape of part (400), or target shape, may include the shape of part (400) that is the target of modifying part (400) via electrochemical machining. In this example, the modified surfaces (404, 406, 408) are directly affected by the portion of the tool (410) (412, 414) closest to the part (400), which is where the current density is highest during electrochemical machining and therefore determines which material is removed. Depending on the current level, the proximity of the tool's shape to the part's shape, and possibly the waveform used during machining, features of the tool (410) further away from the part (400) can have a negligible influence on the part's shape and can therefore be ignored when determining the tool's shape. This provides a simple method for determining the tool's shape based on features on a particular part (400) that need modification. This method can be applied to many features on a part or an array of parts. The tool (410) for printing can be used to improve a part (400) or multiple parts (400) simultaneously, thus providing a method for achieving very fine shapes in a scalable and cost-effective manner. In some embodiments, the part (400) may have multiple features that need modification.The tool (410) is printed on multiple feature parts having geometric shapes complementary to the geometric shapes of multiple feature parts of the part (400), and / or other suitable geometric shapes, allowing all desired feature parts of the part (400) to be modified simultaneously. This can be extrapolated to provide methods for modifying multiple parts (400) using multiple tools (410), modifying one part (400) using multiple tools (410), and / or modifying multiple parts (400) using a single tool (410). The shape of the tool (410) can be automatically generated by modeling software after the user specifies the faces that need to be processed. By modifying multiple parts (400) simultaneously, the process can be easily scaled and implemented cost-effectively in mass production.

[0146] Furthermore and / or alternatively, it may be desirable to manufacture a porous tool (410) through which the electrolyte can flow to remove waste during the electrochemical machining process. A tool (410) having pores (not shown) large enough to allow the flow of the electrolyte and small enough to generate a uniform current density in the relevant region between the tool (410) and the part (400) may be suitable for this type of electrochemical machining process because the pores can directly allow for optimal thermal control of the tool (410) and the flow of the electrolyte on the machined surface of the part (400) to efficiently remove increases in ion concentration during the machining process. In some embodiments, the pores may be less than half the average diameter of the powder particles and / or about an order of magnitude smaller than the average diameter of the powder particles. In addition and / or alternatively, the pores may have a diameter of at least 50 nanometers (nm). While it may be desirable to achieve the highest possible density when sintering a printed three-dimensional object, in some embodiments, if porosity is desired, the sintering cycle may be adjusted to reduce the peak temperature and soak time to achieve a controlled level of porosity in the final three-dimensional object. The electrochemical machining process described above may be further improved by sintering the part (400) to maximum density, sintering the tool (410) to a low density such that the tool (410) has a predetermined porosity high enough for fluid to flow through it, and flowing an electrolyte through the tool (410) while applying an electric current to remove material from the part (400). In some embodiments, the porosity can be high such that the pores are of the size(s) described above and / or the pores connect internally to form passages and / or networks within the tool (410). In some embodiments, the pores can be small enough, of the size(s) described above, so that they have a negligible effect on the geometric shape of the part (400) in the electrochemical machining process.In some embodiments, the pores can be uniformly distributed through the tool (410) so that the heat generated in the electrochemical machining process can be uniformly and efficiently dissipated from the tool (410) through the pores, thus achieving uniform cooling. Furthermore, and / or alternatively, the increase in ion concentration adjacent to the tool (410) can be uniformly and efficiently eliminated. In contrast, any conventional tool for electrochemical machining, even if made with openings of a particular structure, cannot achieve the same level of porous uniformity and therefore effective electrochemical machining as achieved by the methods described above.

[0147] Turning to Figure 30, an exemplary diagram of system (101) is shown, including a construction platform (163). In some embodiments, system (101) may include system (100) (for example, shown in Figure 1). In some embodiments, the construction platform (163) may include construction platform (160) (for example, shown in Figures 1 and 17). System (101) may include a construction material section (500) and a selection section (600). The construction material section (500) is configured to place construction material (520) on the construction platform (163). The exemplary construction material section (500) may include a deposit module (130) (shown in Figure 1) and / or any other suitable components related to the placement of construction material (520). Exemplary building materials (520) may include a slurry (201) (shown in Figure 7), or a blend of powder (or powder material) (310) (shown in Figure 13) and resin (312) (shown in Figure 13).

[0148] The selective processing unit (600) is configured to selectively process the construction material (520) such that a portion of the construction material (520) can form a three-dimensional object (800). The selective processing may include applying at least one process to modify only the selected portion of the construction material (520) such that one or more properties of the selected portion can differ from the properties of the rest of the construction material (520). In one embodiment, the selective processing unit (600) can modify the photosensitive material by irradiating the selected portion. In one embodiment, the selective processing unit (600) can modify the photosensitive material by irradiating all areas except the selected portion. In one embodiment, the selective processing unit (600) can modify the ability of the selected portion to harden, solidify, sinter, or a combination thereof. In one example, the selective processing unit (600) can modify a selected portion of the construction material (520) such that the unmodified portion of the construction material (520) cannot harden (or sinter), while the selected portion can harden (or sinter). During modification, the selected portion can form a three-dimensional object (800) after any other and / or appropriate post-processing. In another example, the selection processing unit (600) can modify a selected portion of the construction material (520) such that the unmodified portion of the construction material (520) can be hardened (or sintered), while the selected portion cannot be hardened (or sintered). During modification, the remaining portion of the construction material (520), excluding the selected portion, can form a three-dimensional object (800) after any other and / or appropriate post-processing. The selection processing unit (600), and / or any other appropriate apparatus, may apply additional processing(es) as needed to achieve or complete hardening (and / or sintering).

[0149] In another embodiment, the selective processing unit (600) can modify the state of a selected portion of the material. For example, the selective processing unit (600) can harden and / or solidify at least a selected portion of the construction material (520) according to the shape of a three-dimensional object (800). An exemplary selective processing unit (600) may include a projection module (106) (shown in Figure 1).

[0216] Looking at Figure 31, an exemplary flowchart of one embodiment of a method (700) for creating a three-dimensional object (800) is shown. Construction material (520) can be placed on a construction platform (163) in (720). Construction material (520) can be selectively processed in (740) to form a three-dimensional object (800).

[0150] Turning to Figure 32, the construction material (520) is shown as containing one or more layers (522). The layers (522) extend in the x and y directions (perpendicular to the plane of the figure) and can be stacked in the z direction. Each of the layers (522) can be selectively processed. According to the selective processing, a portion of each of the layers (522) can form a layer (820). The layers (820) of layers (522) can be stacked to form an object (800).

[0151] Turning to Figure 33, an exemplary flowchart of an alternative embodiment of method (700) is shown. A layer (522) of construction material (520) can be placed on the construction platform (163) in (720A). The layer (522) can be the initial layer and / or first layer of construction material (520). The layer (522) can be selectively processed in (740A) to form a layer (820) of a three-dimensional object (800). The placement and selective processing can be repeated in (760) for one or more layers 820 to be stacked. More precisely, (760) can include repeating the placement and selective processing a selected number of times each time for subsequent layers (522) to be stacked on top of the previous layer (522).

[0152] In various embodiments, the construction material (520) may include mixtures and / or blends of powder (310) (e.g., shown in Figure 35A) and carrier fluid (320) (e.g., shown in Figure 35A). An exemplary carrier fluid (320) may include resin (312) (shown in Figure 13). The blend may be in the form of a slurry (201) (e.g., shown in Figure 7). In some embodiments, the construction material may further include a gas (or gas phase) consisting of bubbles that can be blended with the fluid and solid components (520) of the construction material.

[0153] In one embodiment, a layer (522) of the construction material (520) can be arranged via slot die coating.

[0154] Furthermore, and / or alternatively, layers (522) of the construction material (520) can be arranged via blade coatings. Blade coatings may be advantageous in particular for various disclosed processes in which layer arrangement and processing can be repeated many times, as they have self-leveling properties. To put it somewhat differently, the surface height produced by a given layer arrangement can be largely unaffected by the irregularities of the previous layers.

[0155] Furthermore, and / or alternatively, layers (522) of the construction material (520) may be deposited via patch coating. Patch coating may involve utilizing a slot die or other similar apparatus, where the flow of the construction material (520) may be interrupted at selected intervals to deposit the material only within a specific target region. For example, the construction material (520) may be deposited on an array of sub-regions. By utilizing patch coating, material waste can be limited.

[0156] Furthermore, and / or alternatively, layers (522) of the construction material (520) can be laid via a continuous flow coating. In some embodiments, the continuous flow coating may include utilizing a slot die or other similar device, so that the flow of the construction material (520) is not interrupted and the construction material (520) can be deposited over the entire work area.

[0157] Turning to Figure 34, an exemplary flowchart of an alternative embodiment of method (700) is shown. A layer (522) of construction material (520) can be densified in (730A). Densification in 730A) may occur after placement in (720A) and before selective processing in (740A). Densification can be carried out using any suitable apparatus, including, for example, a construction material section (500) (shown in Figure 30), a selective processing section (600) (shown in Figure 30), a construction platform (163) (shown in Figure 30), and / or any other apparatus. Placement, densification, and selective processing can be repeated in (760). To put it somewhat differently, 760 may include repeating placement, densification, and selective processing a selected number of times, each time for a subsequent layer (522) to be laminated on the previous layer (522). The process of forming the construction material (520) or layer (522) is described in various embodiments using different terms such as dispos, deposit, or coating, for illustrative purposes only, but the characteristics of the process of forming the construction material (520) or layer (522) are defined through the description in each embodiment and are not limited solely by the use of any of the terms dispos, deposit, or coating. In some embodiments, the terms placement, deposit, coating, and / or other appropriate terms used to describe forming the construction material (520) or layer (522) on the activated work surface (167) may be interchangeable.

[0158] Densification can include increasing the loading density (or loading ratio) of powder (310) (e.g., shown in Figure 35A) in the placed layer (522). More precisely, densifying the construction material (520) can include increasing the proportion of powder (310) deposited in the construction material (520). In some embodiments, densification can include at least partially removing the carrier fluid (320) (e.g., shown in Figure 35A) from the blend. In one embodiment, vacuum pressure and / or differential pressure can be applied to the layer (522) via a porous construction platform work surface (162) (shown in Figures 13-15) to remove the carrier fluid (320). More precisely, vacuum pressure and / or differential pressure can be generated between the construction platform work surface (162) and the side of the construction platform (163) opposite to the construction platform work surface (162).

[0159] Looking at Figures 35A and 35B, the construction material (520) before and after the application of ultrasound is shown, respectively. The system (101) may include an ultrasonic unit 540. In various embodiments, the ultrasonic unit 540 may be integrated with and / or coupled to the construction platform (163). The ultrasonic unit 540 may generate ultrasound. The ultrasonic unit 540 may be mechanically connected directly to the construction platform (163) via an acoustically conductive medium (not shown) so that the ultrasound can be transmitted to the construction platform (163) and result in ultrasonic agitation of the construction platform (163). Exemplary acoustically conductive mediums may include solids and / or liquids. The ultrasonic unit 540 may apply ultrasound to a placed layer (522) to densify the layer (522). The ultrasound can cause the carrier fluid (320) to break down into droplets and thus accelerate the evaporation of the carrier fluid (320). By using the ultrasonic section 540, the construction material (520) can be made denser in a simplified manner.

[0160] Furthermore, and / or alternatively, ultrasound can agitate the powder (310) and thus cause it to settle so that it sinks closer to the construction platform (163) by gravity and packs more tightly. Thus, the uniformity of the powder (310) can be improved. By using the ultrasonic section 540, the powder (310) in the construction material (520) can be settled in a novel manner. Thus, the uniformity of the placed layer (522) can be improved. It should be noted that ultrasound has not conventionally been used to remove fluid from a slurry to increase slurry density or to settle powder deposited through a slurry.

[0161] Looking at Figures 36A and 36B, the fabricated object (520) is shown before and after the application of ultrasound, respectively. The powder (310) settles via ultrasound, but the carrier fluid (320) does not necessarily decrease significantly. In various embodiments, ultrasound can be applied to settle the powder (310) regardless of how the construction material (520) is densified. For example, the carrier fluid (320) can be removed by methods that do not necessarily use ultrasound, but ultrasound can be applied to settle the powder (310). Advantageously, if the selected carrier fluid (320) does not decrease readily by ultrasound, another method such as evaporation or suction can be applied to remove the carrier fluid (320) in a more rapid manner.

[0162] Turning to Figure 37, the system (101) is shown to include an evaporator 560. The evaporator 560 can heat the placed layer (522) and evaporate the carrier fluid (320). The evaporator 560 can heat through conduction, convection, radiation, or a combination thereof. Radiation can include any suitable type of radiation, such as microwaves, lasers, infrared (IR), and / or any other optical radiation. In various embodiments, the evaporation process may be utilized to the extent that most of the fluid is removed from the material layer, but a sufficient amount remains in the layer, such that it can be used during selective processing (740) (shown in Figure 31). In this regard, the carrier fluid (320) can serve the additional purpose of being selectively processed to define the component to be constructed.

[0163] In one embodiment, evaporation may be applied to a multi-component system including a filler and a backbone. In this embodiment, the filler material requires less energy to evaporate than the backbone material, and the backbone material may remain in the layer (522) after the evaporation process is complete. The backbone material may be further processed during selective processing (740) to define the component to be constructed.

[0164] Looking at Figure 38A, the construction material (520) is shown as a foam. More precisely, the carrier fluid (320) may contain multiple bubbles. Bubbles can be introduced into the construction material (520) by adding a suitable foaming agent and / or foaming agent, by agitating the construction material (520) through the construction material section (500) (shown in Figure 30) before deposition, or by a combination of these. In one embodiment, the construction material (520) may include a slurry (201) (shown in Figure 7), so bubbles can be introduced into the slurry (201).

[0165] Turning to Figure 38B, the carrier fluid (320) is shown without bubbles. In some embodiments, densification of the molded object (520) may include collapsing and / or destroying at least some of the bubbles. Collapse of bubbles reduces or eliminates the amount of air in the build material (520), increases the amount of powder (310) per unit volume of the build material (520), and can densify the build material (520). In one embodiment, bubbles can be collapsed by suction. For example, suction can be applied directly to the build material (520) and / or via low pressure or differential pressure through the build platform (163). To put it somewhat differently, low pressure or differential pressure can be established between the proximal and distal sides of the build platform (163) to the build material (520), respectively. In another embodiment, ultrasonic stirring may be applied to collapse the bubbles. In yet another embodiment, heat may be applied to collapse the bubbles. In addition and / or alternatively, the bubbles can collapse naturally (i.e., without suction) over a period of time. In any of these embodiments, the relative volume of air in the original molded object may be sufficiently high so that after the powder (310) settles into a dense layer, the collapsed layer leaves a certain amount of porosity.

[0166] Turning to Figure 38C, it is shown that the carrier fluid (320) is further reduced. Thus, the number and / or size of voids between the wetted powder (310) can increase, and the porosity in the building material (520) can be increased. Such a reduction in the carrier fluid (320) can be carried out through any suitable densification method as defined above, including but not limited to the collapse of bubbles. Figures 38B and 38C do not show bubbles for illustrative purposes only, but even if the total amount of bubbles is reduced, bubbles may still be present in the carrier fluid (320) at any stage of densification.

[0167] Turning to Figure 39A, the system (101) is shown to include a densifying fluid deposit section (510). The densifying fluid deposit section (510) can be used to apply a densifying fluid (340) to a building material (520). In various embodiments, the densifying fluid (340) can react with a carrier fluid (320) to produce one or more products that are in a gaseous state. For example, the densifying fluid (340) may contain acidic components and the carrier fluid (320) may contain carbonates, or vice versa. In various embodiments, the densifying fluid (340) can be applied uniformly to the building material (520). The densifying fluid (340) can be applied in any preferred manner. In one embodiment, the densifying fluid (340) can be deposited via spraying. Advantageously, the layer (520) can be reacted with the densifying fluid (340) at all locations and densified in a uniform manner. Figure 39A shows, for illustrative purposes only, the densifying fluid (340) separated from the carrier fluid (320), but the densifying fluid (340) may be miscible with the carrier fluid (320) in order to chemically react with the carrier fluid (320), but this is not limited to the case.

[0168] Looking at Figure 39B, the volumes of the carrier fluid (320) and the densifying fluid (340) are shown to be significantly reduced compared to Figure 39A. To put it another way, during the reaction between the densifying fluid (340) and the carrier fluid (320), the fluid volume within the molded object (520) decreases, the amount of powder (310) per unit volume of the molded object (520) increases, and it becomes possible to densify the molded object (520).

[0169] Turning to Figure 40, an exemplary flowchart of an alternative embodiment of method (700) is shown. The construction material (520) may be placed on the construction platform (163) in (722) and may optionally be densified using the method described herein. The construction material (520) may include a photosensitive material. The photosensitive material may change its chemical composition and / or properties when exposed to electromagnetic radiation. At least a portion of the photosensitive material may be modified by irradiation in (742). In various embodiments, a selective processing unit (600) (shown in Figure 30) may irradiate the photosensitive material. In one embodiment, the modified portion may form at least a portion of a three-dimensional object (800) (shown in Figure 32) or a layer (820) (shown in Figure 32). For example, the photosensitive material may include a resin (312) (shown in Figure 13). The resin (312) may be cured, for example, by irradiation with UV (ultraviolet) light. Therefore, the irradiated portion of the resin (312) can solidify to form a layer (820) of the three-dimensional object (800). The construction material (520) can be irradiated according to a 2D image corresponding to a slice of the digital model of the three-dimensional object (800).

[0170] Turning to Figure 41, the selective processing unit (600) is shown to include a selective deposition unit (620). The selective deposition unit (620) may be configured to deposit auxiliary construction material (360) onto one or more target regions (524) on the construction material (520). Non-target regions (526) are regions of the construction material (520) where the auxiliary construction material (360) is not deposited. The properties of the target regions (524) may differ from those of the non-target regions (526). Exemplary properties may include the ability to harden, the ability to sinter, or a combination thereof. In various embodiments, the auxiliary construction material (360) may include a fluid. The selective deposition unit (620) may deposit the auxiliary construction material (360) in any suitable manner. In one embodiment, the selective deposition unit (620) may deposit the auxiliary construction material (360) via jet injection and / or ink injection.

[0171] The building material (520) is shown as powder (310) wetted with a carrier fluid (320). The amount of carrier fluid (320) can be small enough so that the building material (520) can define voids 380 between the particles of the powder (310). In various embodiments, the building material (520) can be densified to a suitable extent by reducing the amount of carrier fluid (320) so that the powder (310) can be wetted with the carrier fluid (320), but to define voids 380 to accommodate more material (to accommodate auxiliary building material (360)). In various embodiments, densification can be limited by the tap density of the powder (310). The tap density can be controlled by the particle size distribution and morphology of the powder (310). One goal of the densification process may be to approach the tap density as closely as possible.

[0172] The resolution of the SFF may be influenced by how precisely the target region (524) can be defined by the deposition and / or wetting of the supplemental constructor (360) on the constructor (520). In various embodiments, droplet size and the reaction kinetics of the binder activation reaction can be designed to optimize the resolution among other properties.

[0173] Looking at Figure 42A, the system (101) is shown as depositing auxiliary builder material (360) onto powder (310) without a carrier fluid (320). To put it slightly differently, the powder (310) can be dry. The auxiliary builder material (360) is shown forming a bead on top of the powder (310) because the auxiliary builder material (360) does not easily wet the powder (310). As a result, some waiting time is required for the auxiliary builder material (360) to permeate the powder (310). In many SFF processes, small droplets are desired because large droplets forcefully collide with the dry powder layer, creating craters in the powder (310). Small droplets are also sometimes desired to achieve high resolution. Craters reduce the resolution of the formed three-dimensional object and negatively affect the density of the powder within the part and the uniformity of the powder filling within the part. However, the effect of surface tension is greater for smaller droplets, and therefore a long waiting time is required to wet the powder with small droplets (310). For at least the reasons mentioned above, conventional binder jetting processes are not practical for high-resolution SFF.

[0174] Turning to Figure 42B, the system (101) is shown to deposit auxiliary building material (360) onto powder (310) blended with an appropriate amount of carrier fluid (320). In other words, the powder (310) can be wet. The auxiliary building material (360), in contrast to Figure 42A, is shown to quickly permeate into the voids (380). In other words, the carrier fluid (320) can facilitate the wetting of the auxiliary building material (360). As a result, there is little to no waiting time for the auxiliary building material (360) to permeate into the powder (310). Thus, the auxiliary building material (360) can be deposited in very small droplets without significantly increasing the immersion time. Thus, high resolution of SFF can be achieved in a practical and cost-effective manufacturing process.

[0175] Turning to Figure 43, an exemplary flowchart of an alternative embodiment of method (700) is shown. The construction material (520) can be placed on the construction platform (163) in (724). The construction material may include a powder material (310) and a carrier fluid (320), and may optionally be densified using the method described herein. The auxiliary construction material (360) can be deposited on one or more target regions (524) on the construction material (520) in (742). Although method (700) as shown in Figure 40 can achieve high resolution SFF, the high resolution is achieved via irradiation, and such method is not necessarily suitable for all types of construction material (520). For example, if the powder material (310) contains certain reactive metals such as titanium, the powder material (310) may react with the photosensitive (or photocurable) material and thus adversely affect the sintering process. For example, most photocurable materials have a certain amount of oxygen content, which can be extracted from the polymer during sintering, react with the metal to form oxides, and potentially damage the final properties of the sintered metal. In contrast, the method shown in Figure 43 (700) allows for high-resolution SFF with a wide variety of binder materials when there is no suitable photosensitive (or photocurable) material available for the constructor material (520).

[0176] Turning to Figure 44, the three-dimensional object (800) is shown to be formed based on a target region (524). In some embodiments, auxiliary building materials (360) can induce and / or accelerate curing reactions and / or changes of state. Examples of auxiliary building materials (360) include azo compounds or organic peroxides to promote thermal free radical polymerization and / or basic aqueous solutions when curing a cyanoacrylate binder. Any polymerization initiator suitable for a given binder material that may be present in the carrier fluid (320) is understood to be within the scope of this embodiment. Thus, powder (310) can be bonded in the target region (524). In one embodiment, powder (310) within the target region (524) can form at least a portion of the three-dimensional object (800) or a layer (820). The auxiliary building materials (360) can be deposited according to a 2D image corresponding to a slice of a digital model of the three-dimensional object (800).

[0177] In one embodiment, the curing reaction may include a photocuring reaction. The photocuring reaction can be induced by irradiation, for example, UV light irradiation. For example, the entire layer (522) of the construction material (520) may be irradiated in a non-selective manner. In one example, the auxiliary construction material (360) may include a photocurable resin. The photocurable resin may include a skeletal resin and a photopolymerization initiator. In another example, the auxiliary construction material (360) may include a skeletal resin and the carrier fluid (320) may include a photopolymerization initiator. In yet another example, the carrier fluid (320) may include a skeletal resin and the auxiliary construction material (360) may include a photopolymerization initiator. Generally, in this embodiment and other embodiments, there may be multiple components, all of which may be required to produce or enable a chemical reaction and / or a change of state, one or more of these components may be contained in the carrier fluid (320) and the remaining components may be contained in the auxiliary construction material (360).

[0178] In another embodiment, the curing reaction and / or phase change may include a thermosetting reaction and / or phase change. Thermosetting can be induced by a temperature change (e.g., exposure to heat). For example, an entire layer (522) of the building material (520) can be heated in a non-selective manner. In one example, the auxiliary building material (360) may include a thermosetting resin. The thermosetting resin may include a skeletal resin and a thermal initiator. In another example, the auxiliary building material (360) may include a skeletal resin and the carrier fluid (320) may include a thermal initiator. In yet another example, the carrier fluid (320) may include a skeletal resin and the auxiliary building material (360) may include a thermal initiator.

[0179] In yet another embodiment, the curing reaction may include a passive curing reaction. A passive curing reaction may occur under suitable conditions and be completed within a certain period of time. In one example, the auxiliary building material (360) may include a passively curable resin. The passively curable resin may include a backbone resin and an initiator. In another example, the auxiliary building material (360) may include a backbone resin and the carrier fluid (320) may include an initiator. In yet another example, the carrier fluid (320) may include a backbone resin and the auxiliary building material (360) may include an initiator. In yet another embodiment, the auxiliary building material may include a binder material that is liquid during deposition but becomes solid shortly after deposition. In this embodiment, the carrier fluid (320) does not chemically interact with the auxiliary building material (360). This may be achieved by using an auxiliary building material (360) such as a wax and / or other polymer that can be melted in the selective deposition section (620) and cooled during deposition. The carrier fluid (320) may be selected to optimize its ability to absorb thermal energy from the auxiliary building material (360). An exemplary carrier fluid (320) may include one or more components having high heat capacity. For example, the carrier fluid (320) may include water and / or oil.

[0180] In some embodiments, the auxiliary building material (360) may include a binder that does not react with the carrier fluid (320). In one embodiment, the auxiliary building material (360) may include a wax (and / or polymer). The building material (520) may be deposited at a high temperature so that the wax can be in a molten state. Upon cooling, the wax may become solid. In one embodiment, the carrier fluid (320) may include a component that can absorb thermal energy from the wax so that the solidification of the wax can be promoted. Thus, the wax can bind the powder (310).

[0181] Furthermore, and / or alternatively, the auxiliary building material (360) may include a monomer. In one embodiment, the monomer may be solid at room temperature. An exemplary monomer may include norbornene. The building material (520) may be heated and deposited so that the monomer may be in a molten state. Once deposited, the monomer may be polymerized and / or solidified through a polymerization process including, for example, irradiation, chemical treatment, and / or heat treatment. Thus, the polymer may bind the powder (310), and the bond strength may be increased through polymerization. In some embodiments, the resulting polymer may decompose during sintering.

[0182] Furthermore, and / or alternatively, the auxiliary building material (360) can be deposited in a grid structure. Before depositing the auxiliary building material (360), fluid pathways within the part may be available, even when using a solid-hardened image, because the densification process can leave an inherently porous structure. However, after depositing the auxiliary building material (360), any material binding the powder (310) may obstruct the fluid flow. Therefore, the auxiliary building material (360) can be deposited using a grid structure to allow fluid flow and fluid removal from subsequent layers.

[0183] Turning to Figure 45, the three-dimensional object (800) is shown to be formed based on a non-target region (526). In some embodiments, the carrier fluid (320) (e.g., shown in Figure 35A) may contain a curable material, and the auxiliary constructor (360) may inhibit the curing reaction and / or state change of the curable material. In non-limiting examples, an acrylate or methacrylate resin and a photoinitiator may be used as the carrier fluid (320), and a solution of any known free radical photoinhibitor, e.g., bis[2-(o-chlorophenyl)-4,5-diphenylimidazole] or other analogues complementary to the initiator may be used as the auxiliary constructor (360). Thus, the powder (310) can be bound in the non-target region (526). In one embodiment, the powder (310) in the non-target region (526) can form at least a portion, i.e., a layer (820), of the three-dimensional object (800). Auxiliary construction material (360) can be deposited according to complementary images of 2D images corresponding to slices of a digital model of a three-dimensional object (800).

[0184] In one embodiment, the curing reaction may include a photocuring reaction. The photocuring reaction can be induced by irradiation, for example, UV light irradiation. For example, the entire layer (522) of the construction material (520) may be irradiated in a non-selective manner. In one example, the carrier fluid (320) may include a photocurable resin. The photocurable resin may include a skeletal resin and a photopolymerization initiator.

[0185] In another embodiment, the curing reaction may include a thermosetting reaction and / or a change of state. Thermosetting can be induced by a temperature change (e.g., exposure to heat). For example, an entire layer (522) of the building material (520) can be heated in a non-selective manner. In one example, the carrier fluid (320) may include a thermosetting resin. The thermosetting resin may include a skeletal resin and a thermal initiator.

[0186] In yet another embodiment, the curing reaction may include a passive curing reaction and / or a change of state. A passive curing reaction may occur under suitable conditions and be completed within a certain period of time. In one example, the carrier fluid (320) may include a passively curable resin. The passively curable resin may include a skeletal resin and an initiator.

[0187] Furthermore, and / or alternatively, as described above, the auxiliary construction material (360) may be deposited in a grid structure and / or any other suitable porous structure to allow fluid flow and fluid removal from subsequent layers.

[0188] Looking at Figure 46, the fluid deposition section (620) is shown as depositing auxiliary construction material (360) onto one or more target regions (524) of each layer (522), where the target regions (524) correspond to a support surface layer (198). The support surface layer (198) can be located between the part (190) and the support structure (192). The auxiliary construction material (360) may include a sintering inhibitor (330). An exemplary sintering inhibitor (330) may, at least in part, include a peroxide solution, another oxidizing agent, or another agent for inhibiting sintering. The support surface layer (198) can be cured in the same manner as the part (190) and / or the support structure (192). Thus, before sintering, the part (190) and the support structure (192) can be connected by the support surface layer (198) to facilitate handling. The sintering inhibitor (330) can prevent the sintering of the support surface layer (198), so that the part (190) does not permanently adhere to the support structure (192) and can be easily separated therefrom. An exemplary sintering inhibitor (330) may include hydrogen peroxide.

[0189] Figures 47–53 show detailed drawings of an exemplary system (101). Figures 49 and 50 are cross-sectional views. The material deposition system (130) is shown positioned between two selective deposition sections (620), including selective deposition sections (620A) and (620B). During operation, the material deposition system (130) and selective deposition section (620A) can scroll to the right while the material deposition system (130) deposits one layer of construction material (520) (shown in Figure 32). The selective deposition section (620B) can scroll to the right while depositing auxiliary construction material (360) (shown in Figure 41). The material deposition system (130) and selective deposition section (620B) can scroll to the left while the material deposition system (130) deposits the next layer of construction material (520). The selective deposition unit (620A) can be scrolled to the left while depositing the auxiliary construction material (360). This operation can be repeated until all layers are deposited, depositing the auxiliary construction material (360) therein as needed. Advantageously, each translational trip can complete a layer, which can improve the efficiency of the SFF. Figures 54 and 55 are detailed illustrations and cross-sectional views of the material deposition system (130) and the selective deposition units (620A) and (620B), respectively. Figure 56 is a detailed drawing of the selective deposition unit (620). The selective deposition unit (620) may include an array of injection heads (or print heads) (622). Those skilled in the art will recognize that the material deposition system (130) and the selective deposition unit(s) (620) can be moved at separate times and / or by separate motors.

[0190] Referring to Figure 40, the state of the construction material (520) can be altered by irradiation according to method (700). Embodiments such as those shown in the following figures illustrate, for illustrative purposes only, an exemplary implementation of irradiation for SFF fabrication. Those skilled in the art will understand that any other suitable type of image-generating and / or irradiation system can be implemented in the system (101) shown in the figures above. Exemplary types of such image-generating systems may include commercially available digital micromirror device (DMD) image-generating systems, liquid crystal display (LCD) masks, and / or such. Irradiation may include visible or invisible light irradiation (and / or irradiation) of any suitable wavelength, electron beam radiation, ion beam radiation, neutron beam radiation, X-ray radiation, and / or other forms of radiation, in which an image can be formed and which suitably modifies the material being irradiated. Thus, in various embodiments, illumination is used to provide electromagnetic waves (or energy) for illustrative purposes only, but any irradiation of a suitable wavelength (plural) may be used without limitation to provide electromagnetic energy. Looking at Figure 57, the exemplary image generating unit (640) may be configured to translate over the image generating surface (521) in direction (s)(648) (or scan direction) while irradiating a selected area on the image generating surface (521) with electromagnetic energy. For illustrative purposes only, the x direction may be parallel to the scan direction (648) and the y direction may be the cross-scan direction. In various embodiments, the scan direction and the cross-scan direction may be any other suitable direction relative to the x and y directions. Direction (648) may include two opposite directions and / or a single direction. In various embodiments, direction (648) may be parallel to the image generating surface (521) or the construction platform work surface (162). In some embodiments, direction (648) may be parallel to the translation direction of the construction material unit (500) (shown in Figure 30). In some embodiments, the image generating unit (640) may be at least part of the selective processing unit (600) (shown in Figure 30).The image generation surface (521) may include any substrate and / or material irradiated by the image generation unit (640). In some embodiments, the image generation surface (521) may include an active work surface (167), a construction material (520) (shown in Figure 30), the upper surface region of the construction material (520), or substantially (e.g., to a depth of 3 to 50 microns) of the upper surface of the construction material (520), or a construction platform work surface (162). However, the image generation unit (640) can be implemented in any other system, not limited to system (101).

[0191] The image generating unit (640) can be moved relative to the image generating surface (521) in any suitable manner. In one embodiment, the image generating unit (640) may be housed in a housing (not shown) fixed to the image generating surface (521), and the image generating unit (640) can be scrolled relative to the housing. In another embodiment, the image generating unit (640) is fixed relative to the housing, and the housing can be scrolled relative to the image generating surface (521). In yet another embodiment, the image generating unit (640) can be moved relative to the image generating surface (521). In yet another embodiment, the image generating surface (521) can be moved relative to the image generating unit (640).

[0192] Looking at Figure 58, a schematic diagram of the image generating unit (640) as seen in the z direction is shown. The image generating unit (640) is shown to include a plurality of illumination source groups (646) indicated as 646A to D. The illumination source groups (646) are shown to be distributed in the x direction. In some embodiments, the illumination source groups (646) may be aligned along the x direction. Each of the illumination source groups (646) is shown to include, for example, an array of illumination sources (642) including illumination sources (642A) to (642E). In the example shown, the alphabetical order A to E may indicate the order in which they approach the image generating surface (521). To put it somewhat differently, of the selected illumination source groups (646), illumination source (642A) may be the first to approach a predetermined location on the image generating surface (521) in the x direction, and illumination source (642E) may be the last to approach that predetermined location on the image generating surface (521) in the x direction. The array of illumination sources (642) can generate an array of images (662) (partially shown in Figure 59) on the image generation surface (521) (shown in Figure 57). The array of illumination sources (642) can directly correspond to the array of images (662). To put it slightly differently, at a given moment during the operation of the image generation unit (640), each illumination source (642) illuminating the image generation surface (521) can generate an image (662).

[0193] In some embodiments, the shape, dimensions, and / or size of the array of illumination sources (642) and the array of images (662) may be the same. Optionally, the image generating unit (640) may include projection optics (645) (including, for example, optical lenses (es) and / or mirrors, as shown in Figure 66) in the illumination path to decrease and / or increase the distance between the generated images and / or between them. For example, the projection optics (645) can change the linear size of the images (662) corresponding to the illumination sources (642) such that the ratio between the linear size of the illumination sources (642) and the corresponding images (662) is greater than or less than 1. Thus, although Figure 58 shows illumination sources (642) of a size, spacing, and shape selected for illustrative purposes only, the image generating unit (640) may use any other suitable arrangement and / or size of illumination sources (642) and projection optics (645) to generate the array of images (662) as shown in Figure 59.

[0194] Each of the irradiation source groups (646) is shown as comprising a plurality of subgroups (641) of irradiation sources distributed along the y-direction. In some embodiments, the plurality of subgroups (641) of irradiation sources can be aligned along the y-direction. For example, in one irradiation source group (646), a designated irradiation source (642) of a selected subgroup (641) (e.g., an irradiation source (642A) of the selected subgroup (641), or an irradiation source (642B) of the selected subgroup (641)) can be arranged along a line parallel to the y-direction.

[0195] Each group of illumination sources (641) includes multiple illumination sources (642). For example, illumination sources (642A) to (642E) can form one of the groups of illumination sources (641). Each group of illumination sources (641) is configured to generate an image (662) that can illuminate at least the entire pixel region (664) via the translation of the image generating unit (640) (for example, as shown in Figure 60). In some embodiments, the number of groups of illumination sources (641) in an illumination source group (646) may be greater than or equal to the number of pixel regions (664) across the width of a target region (not shown) illuminated by the image generating unit (640), where the width is measured perpendicular to the direction (648). Thus, the target region can be fully imaged via the scrolling of the image generating unit (640) in a single pass. In other embodiments, the number of subgroups (641) of illumination sources in a group of illumination sources (646) can be smaller than the number of pixel regions (664) across the width of the target region, so that the target region can be fully imaged via an image generating unit (640) that scrolls in multiple passes. In some embodiments, the groups of illumination sources (646) can be aligned along the x-direction so that a subgroup (641) of illumination sources selected from each group of illumination sources (646) can be positioned along the x-direction. For example, a designated illumination source (642) of a subgroup (641) selected from each group of illumination sources (646) (an illumination source (642A), or an illumination source (642B), etc.) can be positioned along a line parallel to the x-direction.

[0196] In various embodiments, the image generating unit (640) may include a micro-light-emitting diode (micro-LED) chip or array, and each irradiation source (642) may include a micro-LED. In addition and / or alternatively, the image generating unit (640) may include a digital micromirror device (DMD) chip configured to reflect radiation from the incident light source. Additionally and / or alternatively, the image generating unit (640) may include a combination of a light source and a liquid crystal display (LCD) mask. The LCD mask may include an array of LCD lenses (or LCD apertures), and each irradiation source (642) may include an LCD lens having transparency that can be turned on / off via an electronic control signal.

[0197] In some embodiments, when the size of the light source (642) is smaller than the pitch size between adjacent light sources (642), the microLEDs can be a preferred configuration because illumination (and / or irradiation) can be limited to only the desired area of ​​each light source (642). In contrast, both DMD and LCD configurations provide illumination to the area between the light sources (642), which wastes some of the light energy and can cause unnecessary overheating of the DMD chip or LCD mask.

[0198] The projection optical system (645) may include any suitable optical device that modifies the size, shape, and / or position of the incident light beam from the illumination source (642) via any mechanism including, for example, reflection, refraction, astigmatism, and / or aberration. In some embodiments, for any selected type of illumination source (642), the image generating unit (640) may include an array of microlenses, each corresponding to a micro-LED, which can direct the radiation from the micro-LEDs to the image generating surface (521) or further optical devices, and to focus (and / or defocus) the radiation to achieve the size of the image (662).

[0199] Looking at Figure 59, a portion of the image group (666) generated by the illumination source group (646) (shown in Figure 58) is shown in a magnified view for clarity and explanatory purposes. In the example shown, image groups (666A) and (666B) are generated by illumination source groups (646A) and (646B) (shown in Figure 58), respectively. The image group (666) is shown as being distributed and aligned along the x-direction. The image group (666) formed by all the illumination source groups (646) can constitute a complete image (660) (partially shown) after repeated exposure and relative motion in the x-direction between the illumination source group (642) and the image generation surface (521).

[0200] The image set (666) may include an array of images (662) generated by the illumination source set (642) (shown in Figure 58). In this example, images (662A) to (662E) are generated by illumination sources (642A) to (642E) (shown in Figure 58), respectively. The array of images (662) is shown as containing a plurality of rows (668) which are shown to be parallel in the y direction. In a given row (668), the center-to-center distance D between two adjacent images (662) is shown to be greater than the width W of the image (662). Each of the plurality of rows (668) may be offset from an adjacent row (668) by an offset distance S which is greater than zero and not greater than the width W of each image (662). Therefore, when the illumination source (642) is translated in the x-direction, there can be no unilluminated gap between two images (662) that have an offset between them (for example, between images (662C) and (662D)).

[0201] The number of rows (668) can be selected such that the rows (668) can move linearly across the pixel region (664) (for example, shown in Figure 60) to at least completely image the pixel region (664). To put it somewhat differently, the number of rows (668) in a group of images (666) can be equal to the number of light sources (642) in a subgroup of light sources (641) (shown in Figure 58). This number can be based on the size of the image (662), the pixel region (664), and / or the offset distance S, all in the y-direction. In the illustrated example, the width W and offset distance S of each image (662) are both 1 / 5 of the width of the pixel region (664). Thus, the group of images (666) can contain at least five rows (668).

[0202] In one embodiment, the spacing between adjacent rows (668) can be equal to the size of the pixel region (664) in the x-direction. However, the spacing can be any appropriate value, larger or smaller than the size of the pixel region (664) in the x-direction. The spacing between adjacent rows (668) in the x-direction can be shortened to reduce the amount of movement required for a complete image, thereby reducing the size of the image generating unit (640). Increasing the spacing between adjacent rows (668) increases the size of the image generating unit (640), which can reduce the average thermal load per unit area on the micro-LED chip, but can increase the amount of movement required to complete the image. The spacing can be optimized for each specific application. By selecting the timing of turning the illumination source (642) on and off, a shift in the subpixel length in the X-direction can be achieved. In some embodiments, exposure does not need to be at discrete positions. The illumination source (642) can be turned on / off while the chip is moving continuously, similar to a laser raster ring system.

[0203] Looking at Figure 60, an exemplary pixel region (664) is shown illuminated by a small group of illumination sources (641) (shown in Figure 58) via translational motion. The pixel region (664) may contain multiple rows of images (662) illuminated by illumination sources (642A) to (642E) (shown in Figure 58), respectively. By switching the illumination sources (642A) to (642E) on and off during translation, the image resolution within the pixel region (664) can be based on the offset distance S of the images (662).

[0204] The image generating unit (640) described above in Figures 58 to 60 may be advantageous over other exposure and / or illumination systems for at least the following reasons: A small group of illumination sources (641) is configured to illuminate the entire pixel area (664). If one of the illumination sources (642A) to (642E) fails (cannot emit light or turn off), the corresponding illumination source(s) (642)(642)(646)(646)(642 In the case of illumination sources that cannot be switched off, the illuminance is reduced to 1 / 4 of the full value when it is desired not to illuminate the pixel area. The number of redundant illumination sources (646) can be selected to be large enough so that the effect of defective pixels is minimized to the extent that it does not have a substantially detrimental effect on the exposure of the material. Such redundancy can be crucial for ensuring a high yield in small SFFs where illumination failure in one location can result in a defective product. Furthermore, even new illumination sources (642) in image generation units (640), such as micro-LEDs provided on micro-LED chips, can have a certain failure rate due to the limitations of microelectronics manufacturing technology, and this failure rate increases with use. Incorporating illumination sources (646) allows for the acceptance of a failure rate, thus reducing the cost of illumination sources (642) by allowing the use of imperfect light sources, and extending the service life of the image generation unit (640).

[0205] Although the image generator (640) is shown for illustrative purposes only as being used with the SFF, the image generator (640) can be used in any suitable application that uses optical imaging. Illustrative applications may include plastic printing systems (such as stereolithography), printed circuit board (PCB) lithography, and / or any other systems for manufacturing polymer components using photocurable materials, or any other manufacturing process that uses irradiation-sensitive materials(s) that need to be selectively exposed to a desired shape.

[0206] Furthermore, by exposing small-sized images (662), the image forming unit (640) can achieve high resolution. Since only one or part of all the images (662) are formed for each pixel region (664) at any given moment, the number of effective pixels for the control / drive system can be reduced compared to a scenario where all images (662) for each pixel region (664) are exposed simultaneously. To put it another way, a control / drive system of a given capability can expose more pixel regions (664), thus increasing the exposure area and improving the productivity of the SFF. Such advantages can be achieved in the image forming unit (640) even when exposure does not require scrolling of the image forming unit (640), as in the examples shown in Figures 64 and 65.

[0207] Turning to Figure 61, another exemplary image generating unit (640) is shown. The image generating unit (640) in Figure 58 and Figure 61 are similar, except that the size of the irradiation source (642) is larger in Figure 61.

[0208] Looking at Figure 62, a portion of the image set (666) generated by the illumination source group (646) (shown in Figure 61) is shown enlarged for clarity and explanatory purposes. The image set (666) in Figure 59 and Figure 62 are similar except that the size of image (662) is larger in Figure 62. The offset distance S is shown as being smaller than the linear size (or width in the y-direction) of image (662). In the illustrated example, the width W of each image (662) is 2 / 5 of the width of the pixel region (664) (shown in Figure 63), and the offset distance S is 1 / 5 of the width of the pixel region (664). Therefore, the image set (666) can contain five rows (668) to expose five exposure positions within the pixel region (664).

[0209] Looking at Figure 63, an exemplary pixel region (664) is shown illuminated by a small group of illumination sources (641) (shown in Figure 61) via translational motion. The pixel region (664) may contain multiple rows of images (662) illuminated by illumination sources (642A) to (642E) (shown in Figure 62), respectively. By switching illumination sources (642A) to (642E) on and off during translation, the image resolution within the pixel region (664) can be based at least partially on an offset distance S (shown in Figure 62).

[0210] Therefore, the image generating unit (640) (shown in Figure 61) can achieve a resolution finer than the linear size of the image (662) by introducing an offset distance S smaller than the width W of the image (662). However, the resulting final image may have a gradient of light exposure intensity at the edges because the size of each image (662) is larger than the offset distance S (which can be the smallest interval achieved). While the sharpness of the final image may be reduced, such an image generating unit (640) can offer the advantage of increased optical power output (and thus exposure efficiency). In various embodiments, the area of ​​each image (662) and / or illumination source (642) in Figures 61-63 can be larger than the area of ​​each image (662) and / or illumination source (642) in Figures 58-60, thus increasing the optical power output. Somewhat differently, Figures 61-63 can utilize larger image (662) sizes and the offset distance S to achieve higher resolution. This increases the optical power output, while reducing image sharpness. Therefore, depending on the specific application, the image size (662) can be selected to achieve a trade-off between optical power output and image sharpness.

[0211] Figure 64 shows a full image (660) generated by an alternative image generator (not shown), the full image (660) includes an array of images (662). Images (662) can be formed within corresponding pixel regions (664), and the complete image (660) can be formed by shifting the images (662) within the pixel regions (664) in both the x and y directions. The size of the images (662) is smaller than the size of the pixel regions (664). Therefore, the illumination resolution can be determined based on the size of the images (662). Shifting the images (662) within the pixel regions (664) can be achieved, for example, by a projection optical system (645) (shown in Figure 66) in an illumination path including one or more rotatable refractive lenses. In addition and / or alternatively, image shifting can be achieved by mounting a micro-LED array on a two-axis motion stage (not shown) to move the chip to produce a shift proportional to the projected image.

[0212] Figure 65 shows a full image (660) generated by another alternative image generator (not shown). The image generators described in Figures 64 and 65 are similar except that the size of the image (662) is larger in Figure 65 than in Figure 64. The image (662) can be formed within the corresponding pixel region (664), and the full image (660) can be formed by shifting the image (662) within the pixel region (664) by a distance smaller than the width or length of the image (662) in both the x and y directions. Therefore, the resolution of the illumination can be determined based on the distance the image (662) is shifted. For the same reasons as described above, the image (660) realized in Figure 65 can have increased light output while reducing image sharpness compared to Figure 64.

[0213] The image generators described in Figures 64 and 65 similarly achieve the advantages of high resolution and larger exposure area. However, Figures 64 and 65 do not achieve the advantages of redundancy through the same motion control as described in Figures 58 and 61. To achieve redundancy, the image generators may require more motion and a wider range of motion on more axes than the diagonal pixel system (shown in Figures 58 and 61). The image generators may use a two-axis motion system instead of a one-axis system, which would therefore require the image generators to be larger, more expensive, and possibly more complex to control.

[0214] Looking at Figure 66, an exemplary implementation of the image generating unit (640) is shown. The image generating unit (640) is shown as including a chip (643) and a projection optical system (645), both of which are static relative to each other. The chip (643) may include an illumination source (642) mounted on it in the array described above. The exemplary chip (643) may include a micro-LED chip. The chip (643) and the projection optical system (645) can be simultaneously translated along a direction (648) on a printed area exemplified as an image generating surface (521). The projection optical system (645), shown as a single lens, may include multiple optical elements and may include a microlens array.

[0215] Looking at Figure 67, an alternative exemplary implementation of the image generation unit (640) is shown. The chip (643) may be movable relative to the image generation surface (521), while other components of the image generation unit (640), such as the projection optical system (645), may be static relative to the image generation surface (521). The image can be translated by the chip (643) being translated back and forth within the image generation unit (640). For example, the housing of the image generation unit (640) may be static, and the chip (643) may be movable within the housing.

[0216] Looking at FIG. 68, an array of image generation units (640) is shown. Each of the image generation units (640) can be similar to the example shown in FIG. 67. The array of image generation units (640) can cover an arbitrarily large image generation area. In many implementations, the image size can be larger than the footprint of a single image generation unit (640). Advantageously, a large image generation area can be exposed with high efficiency.

[0217] Looking at FIG. 69, another alternative exemplary embodiment of the image generation unit (640) is shown. The chip (643) can be stationary with respect to the image generation surface (521). The image generation unit (640) can include at least one refractive element (647) that can be rotated (or tilted) back and forth within the image generation unit (640). The refractive element (647) can provide a refractive window for translating the image through rotation. Advantageously, the image generation unit (640) can achieve a high-precision image shift with relatively simple and low-precision mechanical control. The refractive element (647) is shown as being disposed between the chip (643) and the projection optical system (645). However, the refractive element (647) can be disposed at any suitable position between the chip (643) and the image generation surface (521). For example, the refractive element (647) can be positioned between the projection optical system (645) and the image generation surface (521).

[0218] Looking at FIG. 70, an array of image generation units (640) is shown. Each of the image generation units (640) can be similar to the example shown in FIG. 69. The array of image generation units (640) can cover an arbitrarily large image generation area. In many implementations, the image size can be larger than the footprint of a single image generation unit (640). Advantageously, a large image generation area can be exposed with high efficiency.

[0219] Turning to FIG. 71, an exemplary component (400) is shown. The component (400) is shown as a needle including an elongated body (420). The needle can include any type of needle for entering the skin or tissue of a biological body (e.g., an animal or a human). The elongated body (420) can include a tip portion (440), a hub portion (460), and a shaft portion (480) between the tip portion (440) and the hub portion (460). The tip portion (440) is shown as being sharp with a cross-sectional area smaller than that of the shaft portion (480) for entering the skin. The hub portion (460) can be used for attachment to a syringe barrel (and / or any other suitable device not shown). The syringe barrel can supply a substance (not shown) into the living body through the needle and / or extract a substance from the living body. The shaft portion (480) can form the stem of the needle to form the distance between the tip portion (440) and the hub portion (460).

[0220] The tip portion (or the hub portion, or the shaft portion (480)) can be porous. Stated somewhat differently, the tip portion (440), the hub portion (460), and / or the shaft portion (480) can define a plurality of holes (430) therein. Conventionally, a needle has a solid outer wall and is surrounded by a solid wall, defining a single linear lumen extending through the entire length of the needle. In contrast, when the tip portion (440) (or the hub portion (460), or the shaft portion (480)) defines a plurality of holes (430), the tip portion (440) (or the hub portion (460), or the shaft portion (480)) does not necessarily define a lumen passing through the tip portion (440). The holes (430) can accommodate and / or receive a substance transported through the needle without requiring a lumen.

[0221] In various embodiments, pores (430) can be introduced digitally. To put it somewhat differently, a digital model of the needle can define the pores, so a part (400) made according to the digital model can have pores. In addition and / or alternatively, pores (430) can be defined by adjusting the sintering cycle of the part (400) (via incomplete sintering). As described above, the sintering cycle can be adjusted to reduce the peak temperature and soak time in order to achieve a controlled level of porosity in the final part (400). In addition and / or alternatively, at least a portion of the pores (430) can be filled by any suitable method, including, for example, plating. Thus, one or more selected portions of the needle can be solid or non-porous. In one embodiment, plating only a portion of the pores (430) can be achieved by partially immersing the part (400) in a plating solution.

[0222] In various embodiments, the pores (430) can have a diameter of 50 microns or less. At 50 microns, the pores (430) do not impose significant flow restrictions on most fluids. At smaller sizes (e.g., 10 microns or less), the pores (430) can offer the advantage of filtering cellular media. Preferably, the diameter can have a lower limit of 100 nanometers, as at that pore size, the flow rate can be significantly restricted even for low-viscosity fluids.

[0223] The shaft portion (480) may have a circular cross-section with a diameter in the range of 10 to 300 microns. The tip portion (440) may have a length in the range of 10 to 250 microns and a tip or tip edge radius not greater than 10 microns, preferably not greater than 5 microns. The needle may have a non-circular shape, in which case the maximum or minimum cross-sectional dimensions can be understood to be within the constraints previously described for the diameter of the circular cross-section needle. In various embodiments, the needle may be particularly useful for microneedle applications in drug or vaccine delivery.

[0224] Looking at Figure 72, the tip (440), hub (460), and shaft (480) are shown, each defining a hole (430) within it. In one embodiment, the needle does not define a lumen that runs through the entire needle. Without a lumen, the needle can be mechanically stronger. Thus, the needle can have sufficient strength even as the aspect ratio (length to diameter) increases. Advantageously, the needle can be made sharper and thinner, and therefore penetrate deeper into the skin, making it suitable for a wider variety of medical procedures.

[0225] At least some of the holes (430) in the tip (440), hub (460), and shaft (480) are shown as being in communication. More precisely, one or more passages (401) may be formed between the pores (430) so that a substance (not shown) can be transported between the tip (440) and the hub (460) via the passages (401). The pores (430) in the shaft (480) are shown as including pores (430A) as part of the passages (401).

[0293] In some embodiments, it may be desirable to isolate material from the outer surface of the shaft portion (480). Therefore, the holes (430) in the shaft portion (480) may include one or more holes (430B) that are not open to the outside of the shaft portion (480). Furthermore, and / or alternatively, the holes (430) in the shaft portion (480) may include one or more holes (430C) that are open to the outside of the shaft portion (480) but do not communicate with any of the passages (401).

[0226] Although the shaft portion (480) is shown for illustrative purposes only as defining a pore (430), the shaft portion (480) can define any other structure for receiving material without limitation. In one embodiment, the shaft portion (480) can define a pore (430) to form a passage (401) having a hole (430) in the tip portion (440) and / or hub portion (460). In another embodiment, the shaft portion (480) can define one or more lumens therein.

[0227] Looking at Figure 73, the shaft portion (480) and the hub portion (460) are shown defining a lumen (470) that communicates with at least a portion of the hole (430) in the tip portion (440). The lumen (470) can pass through the shaft portion (480) and the hub portion (460) to form a complete flow path from the hole (430) to the hub portion (460). Therefore, the tip portion (440) does not define the passage of the lumen. Without the lumen, the tip portion (440) can have increased mechanical strength. Thus, the tip portion (440) can have sufficient strength even if the aspect ratio (length to diameter) increases. Advantageously, the tip portion (440) can be sharper and thinner, and therefore can penetrate deeper into the skin and be suitable for a wider variety of medical procedures. Since the cross-section of the needle is typically smallest at the tip (440), even if the shaft (480) and hub (460) still define lumens (470) there, eliminating the need for lumens in at least a portion of the tip (440) can result in significant improvements.

[0228] Although both the shaft portion (480) and the hub portion (460) are shown for illustrative purposes only to define a lumen (470), the lumen (470) may be defined within, without limitation, at least a portion of the shaft portion (480), at least a portion of the hub portion (460), and / or a portion of the tip portion (440). Although both the shaft portion (480) and the hub portion (460) are shown for illustrative purposes only to define one lumen (470), one or more uniform and / or different lumens (470) may be defined in the needle without limitation.

[0229] The needle shown in Figure 73 can be fabricated by any suitable method. In various embodiments, the pore (430) can be introduced digitally. Furthermore, and / or alternatively, the pore (430) can be defined (by incomplete sintering) by adjusting the sintering cycle of the component (400). At least a portion of the pore (430) can be filled by any suitable method, including, for example, plating. For example, the wall surrounding the lumen (470) can be made solid or non-porous by plating.

[0230] Referring to Figure 74, another exemplary component (400) is shown. The component (400) is shown as a needle that enters a blood vessel (450) surrounding blood. The blood comprises one or more solid components (452) suspended in a liquid component (454). In various embodiments, the solid components (452) may include blood cells and / or platelets. The liquid component (454) may include plasma. The tip (440), hub (460), and / or shaft (480) may be formed in a structure suitable for filtering blood so that only the liquid component (454) exits the hub (460). For various medical diagnostic purposes, it is necessary to sample only the liquid component (454), and the liquid component (454) has a longer shelf life than the solid component (452). Advantageously, the disclosed needle can sample the liquid component (454) in a simplified manner, extending the shelf life of blood samples and thus facilitating medical laboratory operations.

[0231] In various embodiments, the shaft portion (480) can have a circular cross-section with a diameter ranging from 10 to 300 microns. A shaft portion (480) with a diameter of less than 300 microns can be smaller than a standard gauge needle and approach a painless size. A diameter of less than 10 microns is not particularly useful even as a solid needle, as it becomes more difficult to produce a needle long enough to penetrate the stratum corneum.

[0232] The tip portion (440) may have a length ranging from 10 to 250 microns and a tip radius of 10 microns or less. The needle may have a non-circular cross-sectional shape, in which case the maximum or minimum cross-sectional dimensions may range from 10 to 300 microns.

[0233] Referring to Figure 75, the tip (440) is shown defining a plurality of pores (430) that open into the blood in the blood vessel (450). Each of the pores (430) may be smaller than the size of a blood cell so that blood cells do not enter the pore (430). Thus, the pores (430) can function as filters. The pores (430) can communicate with a suitable outlet of the hub (460) via any suitable passage, pore, lumen, etc., though not limited to these. In various embodiments, the pores (430) may have a diameter of 5 microns or less in order to function as filters.

[0234] While the pores (430) of the tip (440) are shown for illustrative purposes only as filtering blood, any part of the needle (such as the shaft (480) and / or hub (460)) can be structured to filter blood without limitation. The disclosed needle can filter any other suitable substance from the body without limitation. Furthermore, and / or alternatively, the disclosed needle can filter a substance injected into the body from a syringe. In this case, the substance can flow from the hub (460) to the tip (440). Thus, larger or solid contents can be removed and smaller or liquid contents can be introduced into the body.

[0235] Referring to Figure 76, the tip portion (440) is shown as defining a pore (430) within it. One or more pores (430) can be oriented transversely (490). The transverse direction (490) can include any direction perpendicular to the insertion direction (492). The insertion direction (492) may be the direction in which the needle is inserted into the body during surgery. The insertion direction (492) is shown as being parallel to the shaft portion (480). Conventional needles have an opening that opens in a direction at least partially aligned with the insertion path of the needle. Thus, cellular tissue and / or areolar tissue can clog the opening, preventing fluid from passing through the needle. Advantageously, the needle shown in Figure 76 can define a pore (430) that is not open in the insertion path, and thus can prevent clogging. In some embodiments, the pore (430) can communicate with a central lumen (not shown) of the tip portion (440) via a passage (401) of the tip portion (440). In some embodiments, the passage (401) extends to the surface of the tip (440) to form an opening without forming a pore (430).

[0236] In various embodiments, the pore (430) may have a diameter of 50 microns or less. In one embodiment, the pore (430) may have a diameter of 5 microns or less in order to function as a filter. The needle may be shorter than 3 mm. The shaft (480) may have a circular cross-section with a diameter ranging from 10 to 300 microns and an internal opening or lumen (central passage along the axis of the shaft (480)) of less than 100 μm. The internal opening being less than 100 microns allows for an overall needle size that allows liquid to pass through easily without causing pain. The tip (440) may have a length ranging from 10 to 250 microns and a tip radius of 10 microns or less. The needle may have a non-circular shape. In that case, the maximum or minimum cross-sectional dimensions may be understood to be within the constraints set forth above for the diameter of a circular cross-section needle.

[0237] The pore (430) of the tip portion (440) is shown as including a pore (430A) as part of a passage (401) that can extend into any passage and / or lumen within the shaft portion (480).). Thus, the pore (430) of the tip portion (440) can include one or more pores (430D) that do not open to the outside of the tip portion (440). In various embodiments, the shaft portion (480) and / or the hub portion (460) can have a suitable structure as shown in FIGS. 71-75.

[0238] The three lateral directions 490 are shown for illustrative purposes only, but the lateral directions 490 can include any direction within a plane perpendicular to the insertion direction 492 without limitation.

[0239] FIGS. 71-76 show the hub portion (460) and the shaft portion (480) for illustrative purposes only, but the hub portion (460) and / or the shaft portion (480) can be optional. For example, the needle can include a subcutaneous injection needle for reaching deep under the skin and may require the hub portion (460) and / or the shaft portion (480). In another example, the needle may include a microneedle having only a tip portion (440). In another example, the microneedle may taper seamlessly between parts such as a shaft portion and a tip portion without a distinct contour between them.

[0240] Referring to FIG. 77, the object (800) is shown as including a microneedle array. The microneedle array is shown as including a bottom plate (462) and a plurality of needles having the tip portion (440) coupled to the bottom plate (462) in a distal direction from the base plate (462). The bottom plate (462) can define a storage portion (not shown) that can communicate with the needle holes and / or lumens therein. The storage portion can be used to contain fluid extracted from the body by the needles and / or fluid supplied to the needles. The needles can be any of the components shown in FIGS. 7-76.

[0241] The parts 400 shown in Figures 71-77 can be manufactured using method (700) (shown in Figures 31, 33, 34, 40, and 43) and / or system (101) (shown in Figure 30). Without method (700) or system (101), it would be impractical or impossible to manufacture parts 400 using conventional methods or systems. Even if any of the parts 400 could be manufactured by a particular conventional method or system, the cost and manufacturing time of the parts 400 would be too high to be mass-produced. Method (700) and / or system (101) advantageously enable the mass production of parts 400 at low cost and high efficiency.

[0242] Referring to Figure 78, a control system (900) for the SFF is shown. The control system (900) can be configured to control the system (101) (as shown in Figure 30). The control system (900) may include a processor (910). The processor (910) may include one or more microprocessors (e.g., a single-core processor or a multi-core processor), an application-specific integrated circuit, an application-specific instruction set processor, a graphics processing unit, a physics processing unit, a digital signal processing unit, a coprocessor, a network processing unit, an encryption processing unit, etc.

[0243] The processor (910) can execute instructions to implement a computerized model (shown in Figure 30) of the control system (900) and / or the object (800). In a non-limiting example, the instructions include one or more SFF software programs. An exemplary SFF software program may include G-code for controlling the system (101). The program may operate to control the system (101) with multiple print options, settings, and techniques for performing additional prints.

[0244] The program may include CAD and / or CAM programs for generating 3D computer models of objects (800). Furthermore, and / or alternatively, 3D computer models can be imported from other conventional CAD and / or CAM programs and / or other computer systems. 3D computer models can be in industry-standard solid, surface, or mesh file formats. The program may include CAM slicing software for slicing the 3D computer model of an object (800) into layers (820) (as shown in Figure 30) and calculating toolpaths (820) to define each layer.

[0245] The program can generate machine code (e.g., including G-code) to control the system (101) to print an object (800). For example, the program can control the material deposition system (130) (shown in Figure 1) and air blades (140, 150) (shown in Figure 1) to deposit material and control the curing process via monitoring by a camera (104) (shown in Figure 1). Figure 1) Pump motor, operation of build platform, operation of deposition module, densification process via imaging by camera (104), electrochemical processing process, build material section (500), selection section (600) and / or imaging section (640).

[0246] As shown in Figure 78, the control system (900) may include one or more additional hardware components as needed. Examples of additional hardware components include, but are not limited to, memory (920) (also referred herein as non-temporary computer-readable media). Exemplary memory (920) may include, for example, random access memory (RAM), static RAM, dynamic RAM, read-only memory (ROM), programmable ROM, erasable programmable ROM, electrically erasable programmable ROM, flash memory, secure digital (ROM) card, etc. Instructions for implementing a computerized model of the control system (900) and / or object (800) may be stored in memory (920) to be executed by the processor (910).

[0247] In addition and / or alternatively, the control system (900) may include a communication module (930). The communication module (930) may include any conventional hardware and software that operates to exchange data and / or instructions between the control system (900) and another computer system (not shown) using any wired and / or wireless communication method. For example, the control system (900) may receive computer design data corresponding to an object (800) via the communication module (930). Exemplary communication methods include, for example, radio, radio fidelity (Wi-Fi), cellular, satellite, broadcast, or a combination thereof.

[0248] In addition and / or alternatively, the control system (900) may include a display device (940) which may include any device that operates to present programming instructions for operating the control system (900), display a 3D computer model of an object (800), and / or present data relating to components of the system (100) and / or system (101). Furthermore and / or alternatively, the control system (900) may optionally include one or more input / output devices (950) (e.g., buttons, keyboards, keypads, trackballs).

[0249] The processor (910), memory (920), communication module (930), display device (940), and / or input / output device (950) can be configured to communicate using, for example, hardware connectors and buses, and / or wirelessly.

[0250] This specification discloses embodiments of apparatus and related methods for solid free-form manufacturing for the production of parts for various applications (e.g., plastic, metal, and ceramic parts).

[0251] In some embodiments, the SFF method and apparatus disclosed herein include a surface for receiving layers of material to generate a three-dimensional solid representation of a digital model, one or more parts for depositing the required layers of construction material, and parts for image generation of the construction material into a cross-section representing the data contained in the digital model. In one embodiment, the fabrication material includes a particulate material and a photocurable resin material. The materials can be blended before the construction process, and the density of the mixture can be changed during the construction process to optimize the properties of the printed part.

[0252] Furthermore, in some embodiments, the methods and apparatus described below can utilize particulate materials (e.g., ceramics, plastics, or metals) as one of the construction materials. Parts manufactured in this apparatus may be treated after the construction process is complete to facilitate bonding between adjacent particles. Such treatments include, but are not limited to, heat treatment, chemical treatment, pressure treatment, and combinations thereof. The results of this manufacturing and processing process include, but are not limited to, solid metal parts, solid ceramic parts, porous metal parts, porous ceramic parts, porous plastic parts, solid composite plastic parts, and composite parts comprising one or more types of materials.

[0253] A method for producing a layer of a slurry mixture of powder and binder may include depositing the material via a pump system. This depositing system may include a function to reduce the shear stress imparted to the previous layer during depositing. Furthermore, and / or alternatively, the depositing system may include a function to enhance the system's ability to self-correct deviations in the flatness of the layers. Furthermore, and / or alternatively, the density of the deposited layer can be altered by removing a portion of the binder volume from the slurry. Furthermore, and / or alternatively, the slurry material can be continuously adjusted to provide a high degree of homogeneity in the slurry material and the parts produced therefrom.

[0254] Layer imaging can be achieved through several means, including but not limited to bulk imaging using programmable light sources such as digital light processing (DLP) projectors or laser imaging systems.

[0255] In one embodiment, a solid free-form manufacturing apparatus is provided that can manufacture an object using a photocurable resin material according to digital data representing a given three-dimensional object.

[0256] In another embodiment, an SFF apparatus is provided that can produce a composite object consisting of a particle material and a photocurable resin material.

[0257] In another embodiment, an SFF device is provided that utilizes bulk deposition technology for the fabrication of the material layer.

[0258] In another embodiment, an SFF apparatus is provided for processing a mixture of particulate material and photocurable resin material to produce a composite layer of materials.

[0259] In another embodiment, the object produced from the SFF device can be treated thermally, chemically, or mechanically to improve the internal adhesion of the material components.

[0260] In another embodiment, a mixed raw material that is modified during the construction process can be used to increase the particle packing density of the printed component.

[0261] In another embodiment, a feedback system can be used to optionally read one or more brightness values ​​from a camera monitoring the process, thereby verifying or controlling the increase in the packing density of the deposited mixture of particles.

[0262] In another embodiment, a method is provided for determining a favorable shape of a tool that can be used to sinter or finish printed parts that can be manufactured by the same process used to manufacture the printed parts.

[0263] The various embodiments described above include the use of “photopolymer resin,” “photosensitive material,” “photocurable material,” “radiosensitive material,” “radiocurable material,” and / or any other similar or related terms. Such terms can serve the same purpose in those embodiments and may refer to materials that, in response to irradiation, are modified, undergo physical changes, phase transitions, and / or chemical reactions, in order to enable desired modifications. These materials form a portion of the material in the manner described in these embodiments. In various embodiments, irradiation may include the emission of energy that is emitted and / or transmitted in the form of light rays, waves (e.g., electromagnetic waves), and / or particles.

[0264] The directions shown in the diagram can be any physical direction relative to gravity. For example, the system in Figure 30 can be oriented so that the active working surface is parallel to the local Earth's surface, or it can be oriented at other angles, such as a 30-degree inclination from the local Earth's surface. The use of directional words such as "up," "down," "up," "down," "up," "down" is understood to apply to systems with an active working surface parallel to the Earth's surface. If the system is at other angles, these directions must be changed accordingly.

[0265] While specific combinations of systems are shown herein, any combination of the subsystems described above can be implemented for similar purposes. Any system that provides slurry deposition, slurry densification, and irradiation according to any of the methods or systems described above can be understood to be an embodiment of the disclosed subject matter.

[0266] The subject matter of the present invention can be embodied in other forms without departing from its spirit and essential features. Therefore, the embodiments described should be considered in all respects to be illustrative and not limiting. While the subject matter has been described in relation to certain preferred embodiments, other embodiments that would be apparent to those skilled in the art are also within the scope of the subject matter.

Claims

1. A method for creating a three-dimensional object, The steps include: depositing a layer of construction material containing a mixture of powder material and carrier fluid onto a construction platform; The steps include: densifying the layers of the aforementioned construction material, A step of selectively processing the layer of the construction material, The process includes a step of forming the three-dimensional object by repeatedly depositing, densifying, and selectively processing one or more layers of the construction material stacked on the aforementioned layer. A method wherein the selective processing step includes depositing an auxiliary construction material on at least one target region of the construction material, and the densification step includes densifying the construction material so that it remains substantially wet with the carrier fluid after densification and when it receives the auxiliary construction material.

2. A method according to claim 1, wherein the depositing step includes depositing the construction material by slot die coating.

3. A method according to claim 1, wherein the densification step includes a step of densifying the building material such that the building material defines a plurality of voids inside and the powder material remains substantially wet even after densification.

4. A method according to any one of claims 1 to 3, wherein the auxiliary building material is configured to enable a curing reaction, a solidification reaction, or a combination thereof that binds the powder material in the target region.

5. A method according to claim 4, wherein the target region corresponds to a two-dimensional slice of a digital model of the three-dimensional object.

6. A method according to claim 4 or 5, wherein the auxiliary building material is configured to enable a photocuring reaction that binds the powder material in the target region.

7. A method according to claim 6, wherein the selective processing step includes a step of non-selectively irradiating the construction material.

8. A method according to claim 6 or 7, wherein the auxiliary building material comprises a photocurable resin.

9. A method according to any one of claims 6 to 8, wherein the auxiliary building material and the carrier fluid are integrated to provide a photocurable resin comprising a main resin and a photoinitiator.

10. A method according to any one of claims 4 to 9, wherein the auxiliary building material is configured to enable a thermosetting reaction that bonds the powder material to the target region.

11. A method according to claim 10, wherein the selective processing step includes a step of non-selectively heating the construction material.

12. A method according to claim 10 or 11, wherein the auxiliary building material comprises a thermosetting resin.

13. A method according to any one of claims 10 to 12, wherein the auxiliary building material and the carrier fluid are integrated to provide a thermosetting resin comprising a main resin and a photoinitiator.

14. A method according to any one of claims 4 to 13, wherein the auxiliary building material is configured to enable a passive curing reaction that bonds the powder material to the target region.

Images