Freeform manufacturing of three-dimensional objects

Abstract

The application regards a system for manufacturing a three- dimensional object, the system comprising an irradiation system comprising one or more energy sources; a control system arranged to freely control the orientation and the three-dimensional position of the one or more energy sources, by at least one actuator.

Description

[0001] Freeform manufacturing of three-dimensional objects

[0002] Technical field

[0003] The present disclosure relates to methods and systems for volumetric additive manufacturing.

[0004] Background

[0005] Additive manufacturing, commonly referred to as 3D printing, has dramatically transformed the manufacturing landscape by enabling the creation of intricate and complex three-dimensional objects from digital models. This technology is utilized across various industries, including aerospace, automotive, healthcare, and consumer goods, for applications ranging from rapid prototyping to the production of final parts.

[0006] A key process in additive manufacturing involves the use of photosensitive materials that can be solidified or cured upon exposure to energy, such as light. This method, known as photopolymerization, allows for high precision and detail in the printed objects. Despite its advantages, the technique faces several significant challenges that hinder its broader application and efficiency.

[0007] One of the primary limitations is the difficulty in producing large objects with consistent material properties throughout the entire volume. Ensuring uniform curing across large dimensions is challenging, as variations in energy exposure can lead to discrepancies in the mechanical properties and accuracy of the final product. This issue is compounded when attempting to scale up the manufacturing process for larger objects, where maintaining uniformity and precision becomes increasingly complex.

[0008] Additionally, achieving highly detailed and complex geometries remains a significant hurdle. While photopolymerization can produce intricate designs, the precision required to accurately replicate such geometries often falls short due to limitations in current methods. Fine details and sharp edges can be particularly problematic, as inadequate curing can result in defects that compromise the structural integrity and aesthetic quality of the printed object.

[0009] Furthermore, the versatility of additive manufacturing is often constrained by the inability to efficiently manage multiple types of photosensitive materials within a single process. Different materials require specific curing conditions, such as varying wavelengths and / or intensities of energy, which complicates the manufacturing process. This challenge limits the capability to produce multi-material objects, which are increasingly in demand for advanced applications that require varying material properties within a single component.

[0010] Another significant challenge is the control and optimization of the curing process itself. Ensuring that each part of the photosensitive material is appropriately cured while minimizing waste and maximizing efficiency is a complex task. The dynamic nature of the photopolymerization process requires precise control mechanisms to adjust curing parameters in real-time, which current systems struggle to provide. This lack of control can lead to inefficiencies, increased production times, and higher costs.

[0011] Thus, while volumetric additive manufacturing offers tremendous potential, it is limited by challenges related to producing large objects with uniform properties, achieving fine detail in complex geometries, managing multi-material processes, and optimizing the curing process. Addressing these issues is crucial for advancing the field and expanding the practical applications of additive manufacturing technology.

[0012] Summary

[0013] The present disclosure overcomes the challenges of the prior art, and allows for an efficient method of forming accurate reproductions of a three-dimensional model. As an example, the present disclosure overcomes the limitations in the prior art related to producing large objects with consistent material properties, achieving highly detailed geometries, managing multiple types of photosensitive materials, and optimizing the curing process. The present disclosure provides for a novel system and method for manufacturing three-dimensional objects that overcomes the drawbacks of the prior art by enhancing precision, uniformity, and efficiency in the curing process.

[0014] An important challenge in current photopolymerization techniques is to ensure uniform curing across large objects, as variations in energy exposure can lead to discrepancies in mechanical properties and accuracy. For example, as measured by the Jaccard Index, also known as the Jaccard similarity coefficient. The present disclosure relates to systems and methods that allows for controlling the orientation and the three- dimensional position of energy sources, ensuring consistent energy distribution throughout the curing volume.

[0015] Additionally, the present disclosure enhances the ability to produce complex geometries with fine details, as it allows for irradiation of a curing volume from any angle and position, thereby allowing for providing exact energy doses to specific areas of the curing volume, wherein the energy sources are not bound to any specific plane and axial orientation.

[0016] Thus, there exists a need for a system and method that can reliably produce large and detailed objects while optimizing the curing process. Therefore, the present disclosure relates, in a first aspect, to a system for manufacturing a three-dimensional object, the system comprising: an irradiation system comprising one or more energy sources; and a control system arranged to control the orientation and the three-dimensional position of the one or more energy sources, by at least one actuator. The irradiation system is preferably suitable and / or configured to illuminate the curing volume with the one or more energy sources to cure a photosensitive material, typically located in the curing volume.

[0017] This solves the problem of inconsistent energy distribution in traditional methods by ensuring precise control over energy exposure, allowing for precise curing of, for example, large objects. Large objects, as used herein, typically refer to objects having at least one dimension with a length of at least 20 cm, such as at least 50 cm, such as at least 100 cm. Large objects can also be referred to by their volume, which may be at least 50 cl, such as 100 cl, such as 500, such as 1000 cl.

[0018] The control system can, individually, control each energy source's orientation and position, enabling the precise targeting of energy to specific areas. Each energy source, can for example be individually controlled with six degrees of freedom. In this way detailed geometries and sharp edges can be achieved, which are often problematic in conventional photopolymerization techniques. Additionally, by controlling the energy sources with six degrees of freedom, the system ensures comprehensive coverage of the curing volume, reducing the likelihood of defects.

[0019] The system may include a feedback mechanism, such as a closed-loop feedback system. For example, the control system may be arranged to take into account a feedback signal ability, when controlling the multiple energy sources, synchronously and / or independently. Therefore, the control system may be arranged to control the energy sources, such as the actuators, based on a predetermined sequence and / or based on real-time feedback of the curing process, which further enhances the system's versatility. The feedback mechanism ensures real-time optimization, adjusting the curing process based on sensor data to improve efficiency and accuracy. The feedback mechanism may further be arranged to take into account the real-time position of each energy source, in order to optimize the irradiation process, for example to decrease the irradiation time.

[0020] In a further aspect, the present disclosure relates to use of a system for manufacturing a three-dimensional object as disclosed herein, for manufacturing a three-dimensional object. The system may for example be arranged for manufacturing a three- dimensional object, and the system may comprise an irradiation system comprising one or more energy sources; and a control system arranged to freely control the orientation and the three-dimensional position of the one or more energy sources, by at least one actuator.

[0021] In yet a further aspect, the present disclosure relates to a method of manufacturing a three-dimensional object by additive manufacturing, the method comprising:

[0022] • positioning one or more energy sources around a curing volume;

[0023] • controlling, by a control system in communication with at least one actuator, the orientation and the three-dimensional position of one or more energy sources;

[0024] • illuminating the curing volume with the one or more energy sources to cure a photosensitive material.

[0025] This method addresses the challenges of inconsistent curing and intricate geometries by allowing for exact and dynamic adjustment of energy sources during the curing process. By controlling each energy source individually, for example in six degrees of freedom, the method ensures a uniform curing pattern, which is essential for maintaining the structural integrity and aesthetic quality of the printed object. In one example the method is a computer-implemented method.

[0026] In a further aspect, the present disclosure relates to a control system for additive manufacturing, the control system comprises a memory having instructions that, when executed, carries out the method of manufacturing a three-dimensional object by additive manufacturing, as disclosed herein.

[0027] Description of the drawings

[0028] In the following embodiment and examples will be described in greater detail with reference to the accompanying drawings: Fig. 1 shows a schematic view of an embodiment of an irradiation system comprising multiple energy sources and actuators for positioning and controlling the energy sources, as disclosed herein,

[0029] Fig. 2 illustrates a schematic view of an irradiation system with energy sources associated with unmanned aerial vehicles (UAVs), arranged to irradiate a curing volume, as disclosed herein,

[0030] Fig. 3 illustrates a flowchart outlining an example of a method for manufacturing a three-dimensional object by additive manufacturing, including steps for positioning energy sources, controlling their orientation and position, illuminating the curing volume, and optionally providing feedback, as disclosed herein.

[0031] Detailed description

[0032] The term actuator, as used herein, refers to a device, system, or mechanism that is capable of moving and / or controlling a system or mechanism. For example, the actuator may be arranged to control said system or mechanism by controlling, for example adjusting, the position and / or orientation. Actuators can be any type of device, system, or mechanism that possess these properties, including but not limited to robotic arms, unmanned aerial vehicles (UAVs), gantry systems, linear actuators, pneumatic actuators, hydraulic actuators, and magnetic levitation systems.

[0033] The actuator type that is used may be selected based on the specific requirements for the resulting system. For example, in terms of precision, speed, controllability, and / or range of motion. Robotic arms can for example provide a high precision and flexibility, making them suitable for intricate and complex tasks. Gantry systems can offer stability and can be suitable for larger scale operations. In certain examples of the present disclosures, different types of actuators are combined, thereby allowing for a system that is a combination of actuators with different advantages. The versatility of actuators in this system allows for the dynamic adjustment of the energy sources' positions and orientations, which is suitable for achieving a uniform energy distribution and high- fidelity reproduction of the digital model in the final manufactured object. Thus, orientation as used herein, in the context of the energy sources, also refers to the irradiation angle (angle of incidence) of the energy source.

[0034] The term energy source, as used herein, refers to any device or mechanism capable of emitting energy that can be used to cure photosensitive materials during an additive manufacturing process. In this context, energy sources are crucial for solidifying or curing the material layer by layer to create three-dimensional objects. Examples of energy sources include, but are not limited to, lasers, light-emitting diodes (LEDs), organic light-emitting diodes (OLEDs), digital light processing (DLP) projectors, liquid crystal display (LCD) projectors, vertical-cavity surface-emitting lasers (VCSELs), xenon arc lamps, metal-halide lamps, halogen lamps, fiber optic sources, and various types of radiation emitters such as radiation emitters based on ultraviolet (UV) light, visible light, infrared (I R) light, microwave radiation, electron beams, acoustic energy (such as ultrasound energy), radiofrequency (RF) energy, magnetic fields (e.g. use of a magnetic field to transfer energy), and X-rays. These energy sources can emit different types of energy at various wavelengths and intensities, enabling the system to cure a wide range of photosensitive materials with high precision. The ability to precisely control these energy sources in terms of their position, orientation, and emission characteristics makes them suitable for achieving detailed geometries, fine surface finishes, and the overall accuracy of the additive manufacturing process.

[0035] The term three spatial dimensions, as used herein, refers to the Cartesian coordinate system comprising three orthogonal axes (X, Y, and Z), which define the positional space of an object in three-dimensional space. In the context of the present disclosure the position of each energy source is defined with respect to these three axes, such that each energy source may be located at a unique point in three-dimensional space within or around the curing volume.

[0036] The term degrees of freedom, as used herein, refers to the number of independent parameters that define the configuration or state of a mechanical system. In the present context, the system allows the control of the energy sources with, for example, at least four degrees of freedom, comprising three translation degrees of freedom (movement along the X, Y, and Z axes), and at least one rotational degree of freedom (rotation along one of said axes). In an embodiment, the system may be configured to allow movement in six degrees of freedom, including three translational degrees of freedom and three rotational degrees of freedom (pitch, yaw, and roll).

[0037] The term adjust, as used herein, refers to the capability to modify, control, or alter a parameter, typically an operational parameter of a component within the system. For example, such a parameter can be the position, orientation, intensity, wavelength, and / or or other operational parameters of a component within the system. This includes but is not limited to the manipulation of energy sources in terms of their spatial location and angular direction, for example a manipulation with six degrees of freedom. Alternatively or additionally, the output characteristics such as energy intensity and emission spectra of the one or more energy sources can be adjusted. For example, the energy sources can be adjusted to move along various axes, rotate to specific angles, or change their emission intensity to target different areas within the curing volume accurately. Adjustments can be performed in real-time based on feedback from sensors, allowing for dynamic optimization of the curing process to ensure uniformity and precision in the creation of three-dimensional objects. This ability to adjust components is suitable for achieving high fidelity to the original digital design and maintaining the desired material properties throughout the manufactured object.

[0038] The term six degrees of freedom, as used herein, refers to the ability of an object or component to move and be manipulated in three-dimensional space along six independent axes. These six degrees of freedom can include three translational movements along the X, Y, and Z axes (up / down, left / right, and forward / backward) and three rotational movements around these axes (pitch, yaw, and roll). In the context of the present disclosure, this term can apply to the control and positioning of energy sources, e.g. by actuators, within the manufacturing system. By allowing movement and orientation adjustments along and around all six axes, the system can precisely target specific areas within the curing volume, ensuring accurate and uniform energy distribution. This comprehensive control is suitable for creating complex geometries and intricate details in the three-dimensional objects, maintaining high fidelity to the digital model, and achieving optimal curing conditions for diverse photosensitive materials.

[0039] The term three-dimensional object, as used herein, refers to any physical item that has measurable dimensions in length, width, and height. The objects can be suitable for a wide range of applications such as prototypes, end-use parts, medical implants, automotive components, aerospace parts, consumer goods, aesthetic creations, and architectural models. The objects are typically generated based on a model, such as a CAD (Computer-Aided Design) model or other computer-generated models. The present disclosure is typically adapted such that the final physical object closely matches the original digital design, maintaining fidelity to the specified dimensions and intricate details. In a first aspect, the present disclosure relates to a system for manufacturing a three- dimensional object. The system can include an irradiation system comprising one or more energy sources and a control system arranged to control the one or more energy sources. The control system may for example be arranged to control the orientation and / or the three-dimensional position of the energy sources.

[0040] The control system may be arranged in many different ways, in a particular example, the control system is arranged to control the energy sources by at least one actuator. For example, each energy source may be associated with a unique actuator. Alternatively or additionally, a plurality of energy sources may be associated with a single actuator. Each actuator is typically arranged for adjusting the position and / or orientation of energy sources it is associated with. Thus, the control system may be arranged to control the position and / or orientation of a plurality of energy sources via the actuators.

[0041] The control system can for example be arranged to control the orientation and the three-dimensional position of each energy source individually, allowing for dynamic positioning and reorientation of energy sources in a fully three-dimensional workspace. For example, the control system may be arranged to control the position and / or orientation of one or more energy sources along and / or about each of four degrees of freedom, or six degrees of freedom, comprising three translational axes (X, Y, and Z) and three rotational axes (pitch, yaw, and roll). At least four degree of freedom control may facilitate precise targeting of emitted energy towards specific regions within the curing volume, enhancing conformity to digital model and reducing geometrical inaccuracies or material inconsistencies in the final object. This capability allows precise targeting of energy, which may be suitable for achieving detailed geometries and sharp edges, often problematic in conventional photopolymerization techniques. For example, the control system could comprise software algorithms for managing the position and orientation of multiple energy sources at the same time. In specific examples, as disclosed elsewhere herein, the control system may be arranged to control said position and orientation in a feedback control system, for example a closed-loop feedback system. An individual control of each energy source can minimize the risk of defects, improves the overall quality of the manufactured object, offer a higher flexibility, and can also result in a reduced manufacturing time. The irradiation system can comprise a plurality of energy sources. For example, the irradiation system can comprise a plurality of lasers, light-emitting diodes (LEDs), organic light-emitting diodes (OLEDs), digital light processing (DLP) projectors, liquid crystal display (LCD) projectors, vertical-cavity surface-emitting lasers (VCSELs), xenon arc lamps, metal-halide lamps, and / or halogen lamps. The irradiation system may comprise a plurality of the same type of energy source, or alternatively may comprise a plurality of different types of energy sources.

[0042] The energy sources can be arranged to emit different, or the same, type of energy, such as thermal energy, visible light, ultraviolet light, infrared radiation, electron beams, microwave radiation, acoustic energy, radiofrequency energy, magnetic fields, and X- rays.

[0043] The control system may be arranged such that the plurality of energy sources can be independently controlled, for example by controlling their orientation and / or position. In this way the system is suitable for optimal curing conditions across the entire curing volume. This configuration can allow for precise targeting of energy to specific areas, enabling the creation of intricate details and complex geometries within the three- dimensional object. Additionally, the use of multiple energy sources can improve the efficiency and speed of the manufacturing process by allowing simultaneous curing of different regions of the object. In specific example, the system is arranged to dynamically adjust one or more properties of each energy source, collectively or individually, such as the energy intensity, the wavelength, and exposure time. For example, said dynamical adjustment can be based on real-time feedback from sensors monitoring the curing process. This ensures uniform material properties and high fidelity to the original digital design, resulting in a final product that closely matches the specified dimensions and intricate details of the model.

[0044] In addition, the different energy sources can be positioned and controlled to optimize the curing process for each material type, thereby increasing efficiency and reducing curing time. This arrangement facilitates multi-material processing within a single system, making it more versatile and efficient.

[0045] Therefore, the system can be adapted such that the orientation and the three- dimensional position of each energy source can be adjusted by a different actuator. This feature further improves the precision and control over the curing process, ensuring consistent quality across the entire object. For example, a robotic arm could adjust the position of a UV light source while another actuator adjusts an IR light source, allowing for complex geometries to be accurately cured. This level of control is particularly advantageous in applications requiring high precision, acting to enhance the ability to achieve precise and complex geometries. It is also possible to combine an actuator that focuses on finer details, and / or complex geometries with a separate actuator that focuses on coarser details, for faster manufacturing and / or for processing of larger sized objects. Each actuator may be associated with an individual energy source. In this way, the process can be optimized for time-efficient manufacturing, while at the same time being able to produce complex geometries with a high degree of fidelity.

[0046] The control system can be arranged to control the energy sources with six degrees of freedom, enabled by the actuators. This level of control ensures comprehensive coverage of the curing volume, reducing the likelihood of defects. For example, the control system can manage the movement of energy sources in all directions (up / down, left / right, forward / backward) and their rotation (pitch, yaw, roll), ensuring optimal energy distribution. This comprehensive control is both beneficial for manufacturing large objects where uniform curing is critical, as well as the curing of more complex objects, thus enhancing the overall efficiency and effectiveness of the manufacturing process.

[0047] The control system can control the energy sources in many different ways. In one example, the control system is arranged to control the energy sources in the three- dimensional space and orientation, such that the energy sources can take any three- dimensional position and / or orientation, depending on for example a predetermined optimized manufacturing process, or a continuous optimization of the manufacturing process. However, in other alternatives, the control system is arranged to control the energy sources along one or more surfaces, also referred to as a trajectory surface herein, such as one or more curvilinear or curved surfaces. For example, each energy source may be associated with a different surface. Alternatively or additionally, the system may comprise one or more energy sources that are associated with one or more surfaces (i.e. to be translated along said surfaces), while the system further comprises one or more energy sources that can be moved independent of any predetermined surfaces. One example of a curved surface is a hemisphere. The curved or curvilinear surfaces are typically arranged around the curing volume, for example with its centre partially (i.e. along one axis or two axis) or completely overlapping with the centre of the curing volume. For instance, one or more energy sources could be associated with a gantry system or a robotic arm (i.e. attached or positioned in such a way that the robotic arm or gantry system can adjust its orientation and / or position) that is arranged to adjust the orientation and / or three-dimensional position of the one or more energy sources. This configuration ensures that complex shapes and fine details can be accurately cured, making the system suitable for a wide range of applications. It can also be useful in situations where the curing volume is contained by a container that has a shape corresponding to the trajectory surface of the one or more energy sources. For example, the trajectory surface may be an expanded version of an outer surface of the container. This can make it easier to ensure that the energy source is spaced at a suitable distance from the curing volume and can improve the irradiation of the curing volume in situations where the incidence angle of the irradiation is substantially perpendicular to the outer surface of the container. In other examples of the present disclosure, the energy is provided from a position and at an angle that considers the different materials, such as refractive indices, that the radiation travels through. Such an approach can be referred to as a ray-tracing approach.

[0048] The control system can further be arranged to control the energy sources according to a sequence of positions and orientations, which may be predetermined and / or determined based on a feedback mechanism. Thus, the sequence of positions and orientations may be predetermined. Alternatively, the control system may comprise a feedback mechanism that continuously optimizes the build process based on the progress and / or momentary state of the build process. This approach allows for realtime adjustments and optimization of the curing process. Thus, sensors, for example one or more image capturing devices, could monitor the curing process and adjust the energy source positions accordingly, ensuring consistent quality and reducing waste.

[0049] The sequences of positions and / or orientations may be predetermined. However, it may, additionally or alternatively be generated during the curing process. For example, said sequences may be updated. The control system can for example be arranged to generate the sequence(s) of positions and orientations based on an optimization algorithm. Typically, each energy source is associated with a unique sequence, Thus, in case the system comprises a plurality of energy sources, a plurality of sequences may be required. However, said sequences may be similar or even identical, in case the position and / or orientation of the energy sources overlap or partially overlap. The energy sources may, as disclosed elsewhere herein, be arranged as single-point or multi-point energy sources, that are clustered together in order to increase the number of pixels used to irradiate the curing volume.

[0050] For optimization of the one or more sequences, an algorithm may be used. The algorithm may for example be arranged to minimize the manufacturing time and / or reduce the movement of energy sources, for example the total distance travelled for manufacturing the three-dimensional object. For instance, the algorithm could optimize the path of the energy sources to ensure the shortest and most efficient curing process, akin to solving a traveling salesman problem. By optimizing the sequence of energy source movements, the system significantly reduces production time and energy consumption, thereby making the manufacturing process more sustainable and cost- effective. Various optimization algorithms are known to skilled persons, particularly those for identifying short paths between a number of points. Thus, the optimization algorithm can be an algorithm for solving the traveling salesman problem, using exact, heuristic, or metaheuristic algorithms. This optimization can for example identify the most efficient path for energy source movements, and thereby enhance the system efficiency. For example, the control system could utilize genetic algorithms to determine the optimal sequence of energy source movements, ensuring each part of the object is cured in the most efficient manner. This sophisticated optimization approach can be particularly advantageous for large-scale manufacturing where time and efficiency can be a limiting factor.

[0051] The control system can be adapted for wired or wireless communication with the actuators. The communication can for example facilitate real-time control and adjustment of the energy sources, enhancing the system's responsiveness and flexibility. However, in other examples, the control system can be arranged to set a predetermined sequence of positions and / or orientation to the actuators, which thereafter can, independent of the control system, irradiate the curing volume. It should also be noted that the control system may be arranged as a part of each actuator. For example, the actuator may be an autonomous UAV. As such, the control system is a part of the UAV itself. It is therefore not a requirement that the control system is physically separated from the actuators. However, the control system can also be arranged in wireless communication with the actuators. In any event, the control system can be arranged to dynamically adjust the position and / or orientation of the one or more energy sources based on real-time data. In some examples, wired connections can be impractical or pose a safety risk, and wireless, including autonomous actuators (e.g. a system wherein each actuator comprises an individual control system), can allow for a more practical and safer manufacturing processes.

[0052] The control system can be arranged to synchronize the movement and orientation of the one or more energy sources, typically via controlling the one or more actuators, to achieve a desired curing pattern within the curing volume. This synchronization ensures uniform curing and reduces the risk of defects. For example, multiple laser sources could be synchronized to cure different sections of an object simultaneously, ensuring consistent quality and reducing curing time. The position of each energy source can be given by an azimuthal angle and an elevational angle, and their orientation can for example be given by Euler angles or quaternions. In a similar way, the positions and / or orientations of a predetermined sequence or as continuously determined by a feedback system, can use a similar system for describing the positions and orientations.

[0053] The control system can comprise, or be in communication with a device comprising, 3D model processing software to convert digital models into curing instructions for the actuators and / or the energy sources. The control system may alternatively or additionally have been provided with the curing instructions prior to starting the curing process. The curing instructions may be continuously updated, for example by a feedback system, that monitors the curing process. For example, in a closed-loop feedback mechanism.

[0054] The system can be arranged for manufacturing multiple three-dimensional objects in parallel or in series, in order to increase productivity and efficiency in the manufacturing process. For example, the system could cure multiple objects simultaneously. For example in a single container of the curing volume. The multiple objects may be cured using different energy sources, or it could cure objects one after the other in a continuous process. It can also be possible to cure multiple objects in parallel by the same, single or multiple, energy sources. Curing multiple objects in parallel by the same, single or multiple, energy sources, can decrease the curing time, as one can take advantage of the position of the energy sources in a more efficient way. For example, instead of solving a traveling salesman problem for optimizing the sequence of positions and orientations of the energy sources for manufacturing single objects in series, the same problem can be solved for multiple objects in parallel. This can significantly reduce the curing time, and can allow for high-throughput manufacturing, making the system suitable for industrial-scale production.

[0055] The control system can include a feedback mechanism for adjusting the manufacturing process, continuously and / or iteratively. The feedback mechanism can for example ensure real-time optimization and control of the curing process, thereby enhancing the quality and efficiency of the curing process. For example, sensors can be used to monitor the curing process and provide data to the control system, which could then adjust the position, the orientation and / or the intensity of the energy sources accordingly. For example, the sequence of positions, orientations, and / or intensities, can be adjusted. This real-time feedback ensures consistent quality and reduces waste, making the system more efficient and reliable.

[0056] In one embodiment of the present disclosure, the control system comprises sensors, such as optical sensors, temperature sensors, pressure sensors, and / or chemical sensors, for obtaining manufacturing data / curing data. These sensors can be used to obtain information for real-time adjustments and optimization. For example, optical sensors could monitor the curing process to ensure that the object is cured correctly, while temperature sensors could ensure that the energy sources do not overheat the material. The control system can be arranged to adjust the manufacturing process based on data obtained from the sensors. For example, if the sensors detect that a particular area is not curing correctly, the control system could adjust the position, orientation and / or intensity of the one or more energy sources to correct the issue.

[0057] The feedback mechanism can be a closed-loop system. The system may be arranged to continuously monitor and adjust the curing process, by the feedback mechanism.

[0058] For example, the system could continuously monitor the curing process and adjust the energy sources in real-time to ensure consistent quality. The feedback mechanism may be arranged to adjust the energy intensities, dosages, orientations, and / or positions of the one or more energy sources, based on the manufacturing data (curing data), ensuring optimal curing conditions. The feedback mechanism may rely on real-time monitoring of the curing process.

[0059] Various feedback mechanisms are known to skilled persons; for example, the feedback mechanism can be closed-loop control, PID control, adaptive control, model predictive control, feedforward control, fuzzy logic control, neural network control, statistical process control, digital twin technology, and event-driven control. The system can for example continuously monitor process parameters such as temperature, light intensity, and position, using sensors to gather data that is then fed back to the control system. This system processes the data and adjusts the energy sources' parameters to maintain consistent quality and accuracy.

[0060] Proportional-lntegral-Derivative (PID) control is a widely used method that minimizes error by adjusting inputs based on the difference between a desired setpoint and the measured variable. Adaptive control systems adjust their parameters in real-time to cope with changes in process dynamics, making them suitable for example for varying material properties or environmental conditions. Model Predictive Control (MPC) uses a process model to predict future outcomes and optimize control moves at each step, enhancing the curing process by predicting patterns and adjusting energy sources accordingly. Feedforward control anticipates disturbances and adjusts control inputs before deviations occur, complementing feedback control for improved accuracy. Fuzzy logic control systems handle imprecise inputs and model complex variable relationships, and are in general suitable for processes with high variability. Neural network control uses Al to learn from historical data, and can be used for optimizing the curing process by predicting optimal parameters based on previous successes. Statistical Process Control (SPC) monitors process stability and signals when adjustments are needed to maintain quality. Digital twin technology creates a virtual model running parallel to the physical process, allowing real-time optimization and troubleshooting through simulations. Event-driven control systems respond to specific conditions detected during the process, such as temperature spikes, by adjusting energy sources immediately to correct issues. Incorporating one or more of these feedback mechanisms can help ensure that the manufacturing process is precise, efficient, and produces objects that closely match their digital designs.

[0061] The control system can for example be arranged to dynamically adjust properties of the energy sources based on the progress of the curing process, for example the positions and / or orientations of the one or more energy sources, and / or the sequences thereof. For example, the system could adjust the position of the energy sources to ensure even coverage, or it could adjust the orientation to target specific areas. This dynamic control enhances the precision and reliability of the curing process, making the system more efficient and effective. In one embodiment of the present disclosure, the one or more energy sources can be configured to emit a type of energy, such as thermal, visible light, ultraviolet light, infrared radiation, electron beams, microwave radiation, acoustic energy, radiofrequency energy, magnetic fields, and / or X-rays. The energy sources can all emit the same energy, such as the same wavelength, or alternatively, one or more energy sources can be arranged to emit different energies, such as different wavelengths. Moreover, it is also possible to have energy sources that emit different a plurality of different energies, e.g. wavelengths, in series or in parallel. For example, a projector that emits colour-images.

[0062] For example, the system could use one or more energy sources arranged to emit a first energy (e.g. UV light) to cure one material and one or more other energy sources arranged to emit a second energy (e.g. infrared radiation) to cure another material, ensuring that each material is cured correctly. This flexibility enhances the versatility and adaptability of the system.

[0063] The energy sources can be adapted to irradiate one or more curing volumes accommodated by one or more containers. The energy sources may for example be arranged to irradiate curing volumes that are in motion, such as wherein the curing volumes are being displaced. The curing volumes may for example be positioned on a moving stage or belt, while the energy sources irradiate the curing volumes, in order to manufacture the three-dimensional object(s). For example, the system could cure multiple objects simultaneously in different containers, or it could cure different materials within a single object.

[0064] The irradiation system can comprise a single or multiple energy sources. In case the system comprises only a single energy source, the system may also comprise a single actuator. However, in case the system comprises a plurality of energy sources, the system may comprise one or more actuators. For example, wherein each energy source is associated with a different actuator.

[0065] Various energy sources are known to skilled persons; for example, the energy source can be lasers, light-emitting diodes (LEDs), organic light-emitting diodes (OLEDs), digital light processing (DLP) projectors, liquid crystal display (LCD) projectors, verticalcavity surface-emitting lasers (VCSELs), xenon arc lamps, metal-halide lamps, halogen lamps, fiber optic sources, ultraviolet (UV) light, infrared (IR) light, microwave radiation, electron beams, acoustic energy, radiofrequency (RF) energy, magnetic fields, and X- rays, or a combination thereof. The energy sources may further be part of optical systems, comprising of for example mirrors, lenses, and pinholes, in order to irradiate the curing volume, for example in order to focus the irradiation onto the curing volume.

[0066] As also mentioned elsewhere herein, each individual energy source can for example be arranged such that they can be moved and / or oriented in three dimensions. The energy sources can, thus be moved in three dimensions, for example freely moved, without any restrictions, as well as be oriented along the three corresponding axes, e.g. freely moved.

[0067] The control system can be arranged such that it can control the one or more energy sources with respect to the curing volume(s). For example, the system could adjust the position and orientation of the energy sources to ensure even coverage, reducing the risk of defects and improving the quality of the final product. This comprehensive control enhances the efficiency and effectiveness of the curing process.

[0068] The one or more energy sources can for example be arranged to irradiate the curing volume with a single point-source of energy, such as a single pixel of energy. This configuration allows for precise curing of specific areas within the volume. For example, the system could use a single laser source to cure a small, detailed area, ensuring precise targeting and even coverage. However, the irradiation system may, at the same time, comprise one or more energy sources arranged to irradiate the one or more curing volumes with a plurality of pixels of energy, for example using one or more projectors. Thus, different energy sources may be used in the irradiation system, thereby increasing its versatility. Thus, one or more energy sources can, in combination with the single-point energy sources mentioned above or alternative to such an arrangement, be arranged to irradiate the curing volume with a plurality of pixels of energy, providing a pattern of irradiation.

[0069] The one or more energy sources can be arranged to irradiate the curing volume with multiple wavelengths of energy. For example, one or more sources can be arranged to, each, irradiate the curing volume with multiple wavelengths of energy, in series or in parallel. Alternatively, the irradiation system may comprise a plurality of energy sources that are arranged to irradiate the one or more curing volumes by different energies. For example, each energy source may be arranged to irradiate the curing volume with a different energy, e.g. different wavelength and / or different type of energy (thermal, visible light, microwave, x-ray). This capability allows the system to cater to the specific curing needs of different materials. For example, the system could use UV light to cure one material and infrared radiation to cure another, ensuring that each material is cured correctly. This versatility enhances the adaptability and flexibility of the system, making it suitable for multimaterial manufacturing. Thus, the system may comprise a plurality of energy sources, with at least two energy sources arranged to irradiate the curing volume with different wavelengths. This configuration supports multi-material manufacturing and enhances system versatility.

[0070] The irradiation system can for example comprise energy sources selected from projection units, laser sources, LEDs, OLEDs, DLP projectors, LCD projectors, VCSELs, xenon arc lamps, metal-halide lamps, halogen lamps, fiber optic sources, micro-optoelectromechanical systems, and combinations thereof. This diverse selection ensures compatibility with various manufacturing requirements. For example, the system could use LEDs for general irradiation and lasers for precise targeting, ensuring optimal curing conditions. This versatility enhances the flexibility and adaptability of the system.

[0071] Therefore, the energy source can be arranged to emit energy selected from a wide range of energies. For example, the energy sources could be arranged to be capable of emitting energy in the UV, visible, and / or infrared spectra. This capability allows for the curing of a wide range of common photosensitive materials. For example, the system could use UV light to cure one material and visible light to cure another, ensuring that each material is cured correctly. This versatility enhances the adaptability and flexibility of the system, making it suitable for multi-material manufacturing. Other energies are disclosed elsewhere herein.

[0072] The irradiation of the energy sources can be controlled by the control system and / or the actuators. For example, the control system could be arranged to adjust the position and orientation of the energy sources to ensure even coverage and consistent quality. At the same time, the control system may be arranged to control the irradiation of the energy sources, i.e. the irradiated patterns of energy. This precise control enhances the quality and efficiency of the curing process, making the system suitable for high- precision applications.

[0073] The one or more actuators can for example be selected from unmanned aerial vehicles, cranes / jibs, robotic arms, gantry systems, linear actuators, pneumatic actuators, hydraulic actuators, magnetic levitation systems, cable-driven parallel robots, screw-driven systems, telescopic masts, wheeled mobile robots, Stewart platforms, hexapod robots, and / or combinations thereof. This selection ensures flexible and precise positioning of the energy sources. For example, the system could use robotic arms for precise targeting and UAVs for general irradiation, ensuring optimal curing conditions. Further, the curing volumes may be alternatively or additionally be arranged so that they can be adjusted, for example in terms of their position (e.g. onedimensional, two-dimensional and / or three-dimensional position, and / or orientation along one, two and / or three perpendicular axes. As mentioned elsewhere herein, the curing volume(s) may be arranged on a secondary actuator (e.g. a moving plane / belt), that can be moved during the curing process (i.e. while being irradiated), or alternatively, the secondary actuator can be arranged to move the curing volume from a first energy source to another energy source. Alternatively or additionally, the secondary actuator may be arranged to displace a container to make room for a second container. Thus, this arrangement allows for manufacturing of three- dimensional objects in an assembly line manner.

[0074] The actuators are typically arranged to be controlled by the control system, which may be arranged / located at a central position, or arranged / located in a distributed manner, for example wherein each actuator comprise a part of the control system. In this way, autonomous actuators may be enabled. However, the system can also be arranged such that the actuators are remotely controlled by the control system via wireless communication.

[0075] The control system may be arranged to adjust one or more parameters of the actuators, for example: the position, orientation, speed, acceleration, and / or force applied by the actuators. This allows precise control over the energy sources, ensuring they can accurately target specific areas within the curing volume. For instance, the control system can adjust the position of an actuator to move an energy source along the X, Y, and Z axes, ensuring optimal coverage of the curing area. The orientation can be fine-tuned to direct the energy source at the correct angle, maximizing the effectiveness of the energy delivery. Additionally, the control system can modulate the speed and acceleration of the actuators to ensure smooth and precise movements, avoiding any sudden jerks that could disrupt the curing process. It can also control the force applied by the actuators, which is particularly important when dealing with delicate or intricate parts that require gentle handling. Similarly, the control system can adjust various parameters of the energy sources themselves, such as the intensity, wavelength, patterns (or sequences thereof), focus, and duration of the emitted energy. This can be done continuously and / or iteratively. For example, as mentioned elsewhere herein by providing irradiation patterns for irradiation of the curing volume.

[0076] This enables the system to tailor the energy delivery to the specific requirements of different materials and geometries within the curing volume. For example, the control system can increase the intensity of the energy source for thicker sections of the object that require more energy to cure, or adjust the wavelength to match the absorption characteristics of different photosensitive materials. The focus can be modified to ensure that the energy is concentrated precisely where needed, enhancing the precision of the curing process.

[0077] These parameters can in some examples be dynamically adjusted, for example based on real-time feedback, in order to ensure optimal curing conditions, resulting in high- precision curing and uniform material properties throughout the three-dimensional object. Thus, the control system can be arranged to adjust, optimize or alter the energy sources in one or more ways. For example, the control system may be arranged to dynamically adjust a focal point of the energy source, for example based on the position of the energy source with respect to a centre of the curing volume. Focal point adjustment can for example be provided by means of an optical assembly known in the art, typically comprising one or more lenses adequately arranged and adjusted to provide the focusing. This dynamic adjustment ensures optimal curing conditions and enhances the quality of the final product. For example, the system could adjust the focal point of a laser source to ensure precise targeting and even coverage. This dynamic control enhances the efficiency and effectiveness of the curing process, making the system suitable for high-precision applications. However, it should be noted that the energy source could be arranged with a telecentric or an entocentric arrangement. Thus, for a telecentric arrangement, there may not be a need to adjust the focus point of the energy sources.

[0078] The system can comprise one or more containers for accommodating one or more curing volumes. This configuration allows for flexible and efficient curing of different materials and objects. For example, the system could cure multiple objects simultaneously in different containers, or it could cure different materials within a single object. As mentioned elsewhere herein, the system could be arranged in an assembly line manner, with multiple curing volumes being transported between different energy sources. However, alternatively or additionally, the energy sources could be arranged to move between the different curing volumes. Thus, the curing volumes / containers could be arranged to be moved while at the same time the energy sources are arranged to move between curing volumes / containers.

[0079] The control system can be arranged to control the position and / or orientation of the one or more containers. This control ensures consistent energy distribution and uniform curing. For example, the system could adjust the position and orientation of the containers to ensure even coverage, reducing the risk of defects and improving the quality of the final product. This can also enable the manufacturing of objects in an assembly line, wherein the curing volume is moved, while being irradiated, or in a stop and go manner. This comprehensive control enhances the efficiency and effectiveness of the curing process.

[0080] The control system can be arranged to control the position and / or orientation of the containers, for example be a secondary actuator. This secondary control can enhance the flexibility and precision of the curing process, and can for example enable manufacturing of objects in an assembly line. For example, the system could use a secondary actuator to adjust the position and orientation of the containers, to allow energy sources to be associated with different curing volumes.

[0081] The secondary actuator can for example be selected from unmanned aerial vehicles, cranes / jibs, robotic arms, gantry systems, linear actuators, such as a moving belt, pneumatic actuators, hydraulic actuators, magnetic levitation systems, cable-driven parallel robots, screw-driven systems, telescopic masts, wheeled mobile robots, Stewart platforms, hexapod robots, and combinations thereof. This selection ensures flexible and precise positioning of the containers. For example, the system could use robotic arms for precise targeting and UAVs for general irradiation, ensuring optimal curing conditions. This flexibility enhances the efficiency and effectiveness of the curing process.

[0082] The curing volume can have any volume. In some examples, the curing volume has a larger volume, relative to conventional additive manufacturing methods, such as axial computed lithography / tomographic vat photopolymerization. For example, the one or more curing volumes could each have a volume of at least 1 Liter. This capacity allows for the manufacturing of large objects, enhancing the versatility and adaptability of the system. It can also enable the manufacturing of multiple objects in the same curing volume. However, in other examples, the curing volume could be at least 5 Liters, such as at least 10 Liters, or even at least 50 Liters, or 100 Liters. For example, the system could cure large objects such as automotive parts or aerospace components, ensuring consistent quality and even coverage.

[0083] The containers can be transparent to the wavelengths of energy used for curing. However, the material of the container can have a different refractive index compared to the curing volume and / or air, which can affect the irradiation process. For example, the system could use transparent containers to ensure that the energy sources can effectively cure the photosensitive material, reducing the risk of defects and improving the quality of the final product. At the same time, the refraction of the irradiation by the container, if present, could be taken into account using a ray-tracing approach. This means that the control system can calculate the exact path of the energy as it passes through different materials with varying refractive indices, ensuring that the energy is delivered precisely to the intended locations within the curing volume. By considering these refraction effects, the system can optimize the curing process, enhancing accuracy and ensuring uniform material properties throughout the three-dimensional object.

[0084] In a further aspect the present disclosure relates to the use of the system as disclosed herein, for manufacturing a three-dimensional object. The system may be arranged as disclosed elsewhere herein.

[0085] In yet a further aspect, the present disclosure relates to a method of manufacturing a three-dimensional object by additive manufacturing. The method can for example include positioning one or more energy sources around a curing volume, however this is not an essential part of the method. The method can comprise controlling the orientation and / or position of one or more energy sources via a control system, however this is not an essential part of the method. The method can comprise illuminating one or more curing volumes to cure one or more photosensitive materials, however this is not an essential part of the method.

[0086] This method ensures optimal curing conditions and enhances the quality of the final product. For example, the system could position multiple energy sources around the curing volume to ensure even coverage and consistent quality. This method enhances the efficiency and effectiveness of the curing process, making the system suitable for high-precision applications.

[0087] The orientation and position of each energy source can, in some examples, be controlled individually. For example, each energy source may be associated with a different actuator. This individual control enhances the quality and efficiency of the curing process, making the system suitable for high-precision applications.

[0088] The one or more energy source can for example be controlled by different actuators, or alternatively the one or more energy sources can be controlled by the same actuator. The actuator may be an actuator with six degrees of freedom. This level of control ensures comprehensive coverage of the curing volume, reducing the likelihood of defects. The method can comprise synchronizing the movements of the energy sources to achieve a uniform curing pattern within the curing volume. This synchronization ensures even coverage and consistent quality. For example, the system could synchronize the movements of multiple energy sources to cure different parts of an object simultaneously.

[0089] The method may be arranged such that the curing volume can be oriented / rotated and / or moved / displaced during the curing process. This may be made continuously, e.g. while being irradiated, or said adjustment of the orientation and position of the curing volumes may be carried out in a stepwise manner. For example, the curing volumes may be displaced while not being irradiated, and the curing volumes may be irradiated when the adjustment of the orientation and / or position of the curing volume(s) have, at least temporarily, ended.

[0090] For example, the system could rotate the curing volume to ensure that each part of the object receives the necessary energy exposure. This movement enhances the quality and efficiency of the curing process, making the system suitable for high-precision applications.

[0091] In one embodiment of the present disclosure, the energy sources are moved along one or more surfaces, also referred to as a trajectory surface herein, such as one or more curvilinear or curved surfaces. For example, each energy source may be associated with a different surface. Alternatively or additionally, the system may comprise one or more energy sources that are associated with one or more surfaces (i.e. to be translated along said surfaces), while the system further comprises one or more energy sources that can be moved independent of any predetermined surfaces. One example of a curved surface is a hemisphere. The curved or curvilinear surfaces are typically arranged around the curing volume, for example with its centre partially (i.e. along one axis or two axis) or completely overlapping with the centre of the curing volume. For example, the system could position the energy sources on a gantry system that moves the energy sources along a hemispherical path, ensuring even coverage and consistent quality.

[0092] The irradiation pattern of the energy sources can be dynamically adjusted based on real-time feedback from sensors monitoring the curing process. The dynamic adjustment is suitable for optimizing the curing conditions and can be used to enhance the quality of the final product. For example, the system could adjust the position and orientation of the energy sources based on real-time data, ensuring even coverage and consistent quality. This real-time feedback enhances the efficiency and effectiveness of the curing process, making the system suitable for high-precision applications.

[0093] The method can comprise a step of varying parameters of the energy sources. For example, the control system can be arranged to vary said parameters. For example, the intensity of the energy sources can be adjusted to provide more or less energy depending on the specific requirements of different regions within the curing volume. Further, the control system can be arranged to adjust one or more sequences of patterns of lights of the one or more energy sources.

[0094] Alternatively or additionally, the wavelength of the energy sources can be varied to match the absorption characteristics of different photosensitive materials used within the object. The focus point of the energy sources can also be adjusted to concentrate the energy on specific areas, enhancing the precision of the curing process. Moreover, the duration of energy exposure can be controlled to ensure that each section of the object receives the appropriate amount of energy over time.

[0095] The method can include the use of feedback mechanisms to continuously monitor and adjust the curing parameters. For example, the parameters of the energy sources mentioned elsewhere herein above can be optimized, as well as parameters of the actuators mentioned elsewhere herein, can be optimized continuously during the manufacturing process, for example by a feedback mechanism. For instance, optical sensors can capture real-time data on the curing process, and the control system can use this data to make immediate adjustments to the energy source parameters.

[0096] The method can further involve a step of synchronizing the movements of multiple energy sources to achieve a uniform curing pattern. This synchronization can be based on pre-determined sequences or real-time feedback, ensuring that the entire curing volume is uniformly exposed to the energy, resulting in a homogenous and high-quality final product.

[0097] The system can adjust the intensity and wavelength of the energy sources to ensure optimal curing conditions for different materials. This variation enhances the versatility and adaptability of the system, making it suitable for multi-material manufacturing.

[0098] The photosensitive material in the curing volume can be irradiated by energy sources, wherein each energy source or different energy sources are, emitting multiple wavelengths of energy. This can be used to cure different types of materials simultaneously. This capability allows the system to cater to the specific curing needs of different materials. For example, the system could use UV light to cure one material and infrared radiation to cure another, ensuring that each material is cured correctly.

[0099] The method can comprise using a control system to input and execute a predefined curing pattern based on a digital 3D model of the three-dimensional object. This can for example act to improve the precision and quality of the final product. For example, the system could generate precise instructions for curing each layer of the object, ensuring that the final product matches the digital model exactly.

[0100] The energy sources can be positioned using one or more actuators, for example selected from unmanned aerial vehicles, cranes / jibs, robotic arms, gantry systems, linear actuators, pneumatic actuators, hydraulic actuators, magnetic levitation systems, cable-driven parallel robots, screw-driven systems, telescopic masts, wheeled mobile robots, Stewart platforms, hexapod robots, and combinations thereof.

[0101] For example, the system could use robotic arms for precise targeting and UAVs for general irradiation, ensuring optimal curing conditions. This flexibility enhances the efficiency and effectiveness of the curing process, making the system suitable for a wide range of applications. The method can comprise rotating and / or displacing the curing volume receptacle using one or more secondary actuators, for example one actuator per container or a single actuator for all containers. The secondary actuators can be selected from unmanned aerial vehicles, cranes / jibs, robotic arms, gantry systems, linear actuators, pneumatic actuators, hydraulic actuators, magnetic levitation systems, cable-driven parallel robots, screw-driven systems, telescopic masts, wheeled mobile robots, Stewart platforms, hexapod robots, and combinations thereof.

[0102] The system could use a secondary actuator to adjust the position and orientation of the curing volume, ensuring optimal curing conditions. This can be combined with one or more actuators adjusting the position and / or orientation of the one or more energy sources. The actuators and the secondary actuators may be active at the same time or at different time points. For example, the secondary actuators may be used to move the containers between different energy sources. During movement of the containers, the irradiation process could potentially be paused, e.g. until the container has been moved from a first curing position associated with one or more first energy sources to a second curing position, associated with one or more second energy source, and so on (e.g. third curing position, fourth curing position etc.). In this way different parts, or different materials of the object can be manufactured in serial, in a time-efficient manner.

[0103] The energy sources can for example be moved along a trajectory surface, such as a hemisphere. The trajectory surface may be arranged around the curing volume, in order to provide comprehensive energy coverage. The system could for example position the energy sources by a gantry system that moves the energy sources along a hemispherical path around the curing volume, ensuring that each part of the object can receive the necessary energy exposure. As such, the curing process can be paused and resumed without compromising the integrity of the partially cured object.

[0104] The method can include a step of monitoring the manufacturing process using one or more sensors. This monitoring ensures real-time optimization and control, enhancing the quality and efficiency of the curing process. For example, sensors could be used to monitor the curing process and provide data to the control system, which could then adjust the position and intensity of the energy sources accordingly. This real-time monitoring enhances the efficiency and reliability of the curing process, making the system suitable for high-precision applications. The method can include a step of compensating for external disturbances such as vibrations or airflow during the curing process. This compensation ensures optimal curing conditions and enhances the quality of the final product. For example, the system could adjust the position and intensity of the energy sources to compensate for vibrations or airflow, ensuring even coverage and consistent quality. For example, by a feedback mechanism as disclosed elsewhere herein.

[0105] The method can comprise a step of adjusting the position and / or orientation of the energy sources in response to the progress of the curing process. This real-time adjustment ensures consistent quality and efficiency. For example, the system could adjust the position and orientation of the energy sources based on real-time data, for example as obtained by one or more sensors, ensuring even coverage and consistent quality.

[0106] The method can comprise a step of converting digital models into curing instructions for the energy sources, for example by 3D model processing software, which can be integrated in the control system. For example, the software could generate precise instructions for curing of the object, ensuring that the final product matches the digital model exactly. In one example, the method comprises a step of providing, by the control system, the energy sources and / or the actuators, instructions to emit energy in specific patterns to cure the photosensitive material according to the 3D model of the object.

[0107] Detailed description of the drawings

[0108] The drawings are purely provided as examples of the present disclosure, and should not be taken as limiting to the present disclosure.

[0109] Fig. 1 illustrates an irradiation system according to an embodiment of the present disclosure, comprising multiple energy sources and actuators. Each energy source is associated with a unique actuator. The control system (not shown) can control the orientation and the three-dimensional position of each energy source individually via the actuators. This configuration allows for precise targeting of energy to specific areas within the curing volume. In one example, the energy sources can be configured to emit energy types selected from thermal, visible light, ultraviolet light, infrared radiation, electron beams, microwave radiation, acoustic energy, radiofrequency energy, magnetic fields, and / or X-rays. Each energy source may be independently controlled in three dimensions and oriented in three rotational degrees of freedom. The control system can optionally include software algorithms for managing the position and orientation of multiple energy sources simultaneously. Additionally, the control system may be integrated with 3D model processing software to convert digital models into curing instructions for the actuators and / or energy sources.

[0110] Fig. 2 depicts an irradiation system with a plurality of energy sources, each associated with an actuator, according to an embodiment of the present disclosure. In this example, the actuators are unmanned aerial vehicles (UAVs). The energy sources are arranged to irradiate the curing volume. The irradiation system can position the energy sources along an irradiation surface. This arrangement allows for consistent energy distribution within the curing volume. The control system may synchronize the movement and orientation of multiple energy sources to achieve a desired curing pattern within the curing volume. The control system may include a feedback mechanism that continuously optimizes the build process based on real-time feedback from sensors monitoring the curing process. The sensors can include optical sensors, temperature sensors, pressure sensors, and / or chemical sensors. In another example, the energy sources may be positioned along curvilinear or curved surfaces, such as a hemisphere, to optimize the irradiation angle and distance. The control system can also dynamically adjust the focal point of the energy sources based on their position relative to the centre of the curing volume.

[0111] Fig. 3 is a flowchart outlining an example of a method for manufacturing a three- dimensional object by additive manufacturing, according to an embodiment of the present disclosure. The method comprises the following steps:

[0112] • Positioning one or more energy sources around a curing volume. This step may include using actuators such as UAVs, robotic arms, or gantry systems to position the energy sources.

[0113] • Controlling, by a control system in communication with at least one actuator, the orientation and the three-dimensional position of the energy sources. The control system may use algorithms to optimize the positioning and orientation of the energy sources.

[0114] Illuminating the curing volume with the energy sources to cure a photosensitive material. The illumination step can involve varying the intensity, wavelength, and / or pattern of the energy sources based on the material properties and desired curing profile.

[0115] Additionally, the flowchart includes an optional step of providing feedback by a feedback mechanism to adjust and improve the irradiation process. The feedback mechanism can include real-time data collection from sensors and use this data to adjust energy source parameters. The method may also include synchronizing the movements of the energy sources to achieve a uniform curing pattern within the curing volume. Another optional step can involve rotating and / or displacing the curing volume during the curing process to ensure even coverage. The control system may communicate wirelessly with the actuators to dynamically adjust their positions and orientations. The method may further include integrating the control system with 3D model processing software to convert digital models into curing instructions for the energy sources.

[0116] Items

[0117] 1 . A system for manufacturing a three-dimensional object, the system comprising:

[0118] • an irradiation system comprising one or more energy sources; and

[0119] • a control system arranged to control the orientation and the three- dimensional position of the energy sources, by at least one actuator.

[0120] 2. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the control system is arranged to control the orientation and the three-dimensional position of each energy source individually.

[0121] 3. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the irradiation system comprises a plurality of energy sources and wherein the control system comprises a plurality of actuators with each energy source associated with a different actuator.

[0122] 4. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the system is adapted such that the orientation and the three-dimensional position of each energy source can be adjusted by a different actuator. 5. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the control system is configured to control each energy source with at least four degrees of freedom, comprising three translational degrees of freedom and at least one rotational degree of freedom.

[0123] 6. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the control system is arranged to control the at least one energy source with six degrees of freedom, comprising three translational and three rotational degrees of freedom.

[0124] 7. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the control system is arranged to control the one or more energy sources such that said one or more energy sources are displaced along a hemisphere surrounding the curing volume.

[0125] 8. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the control system is arranged to control the one or more energy sources according to a sequence of positions and / or orientations, wherein said sequence of positions and / or orientations may be predetermined and / or determined based on a feedback mechanism.

[0126] 9. The system for manufacturing a three-dimensional object according to item 8, wherein the control system is arranged to generate the sequence of positions and / or orientations based on an optimization.

[0127] 10. The system for manufacturing a three-dimensional object according to item 9, wherein the optimization is arranged to optimize the sequence to minimize the manufacturing time of the three-dimensional object and / or displacements of the one or more energy sources.

[0128] 11. The system according to any one of items 9-10, wherein the optimization is a optimization for deriving a solution to a traveling salesman problem, such as an exact algorithm, a heuristic algorithm, or a metaheuristic algorithm.

[0129] 12. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the control system is adapted to communicate wirelessly with the one or more actuators. 13. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the control system is capable of synchronizing the movement and orientation of multiple energy sources to achieve a desired curing pattern within the curing volume.

[0130] 14. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the position of the one or more energy sources are given by an azimuthal angle and an elevational angle; and / or wherein the orientation of the one or more energy sources are given by Euler angles or quaternions.

[0131] 15. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the control system is integrated with a 3D model processing software to convert digital models into curing instructions, such as for the actuators and / or the energy sources.

[0132] 16. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the system is arranged for manufacturing multiple three-dimensional objects in parallel or in series.

[0133] 17. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the control system includes a feedback mechanism for adjusting the manufacturing process.

[0134] 18. The system for manufacturing a three-dimensional object according to item 17, wherein the control system comprises one or more sensors, such as optical sensors, temperature sensors, pressure sensors, and / or chemical sensors, for obtaining manufacturing data.

[0135] 19. The system for manufacturing a three-dimensional object according to item 18, wherein the control system is arranged to adjust the manufacturing process based on the manufacturing data.

[0136] 20. The system for manufacturing a three-dimensional object according to any one of items 17-19, wherein the manufacturing process is adjusted by adjusting the sequence of positions and / or orientations according to any one of items 8-11 . The system for manufacturing a three-dimensional object according to any one of items 17-20, wherein the feedback mechanism is a closed-loop feedback mechanism. The system for manufacturing a three-dimensional object according to any one of items 17-21 , wherein the feedback mechanism is arranged to adjust the energy intensities, dosages, orientations and / or positioning based on the manufacturing data, such as by real-time monitoring of the curing process. The system for manufacturing a three-dimensional object according to any one of items 17-22, wherein the control system can dynamically adjust the position and orientation of the energy sources based on the progress of the curing process. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the one or more energy sources are configured to emit thermal energy, visible light, ultraviolet light, infrared radiation, electron beams, microwave radiation, acoustic energy, radiofrequency energy, magnetic fields, and / or X-rays. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the one or more energy sources are adapted to irradiate one or more curing volumes accommodated by one or more containers. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the irradiation system comprises a plurality of energy sources. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the irradiation system comprises a single energy source, such as consists of a single energy source. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein each individual energy source can be moved individually in three dimensions and / or individually oriented in three rotational degrees of freedom. 29. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the control system is arranged to control, such as the orientation and the three-dimensional position of, the one or more energy sources with respect to the curing volume.

[0137] 30. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the energy source is arranged to irradiate the curing volume with a single point-source of energy, such as a single pixel of energy.

[0138] 31. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the energy source is arranged to irradiate the curing volume with a plurality of pixels of energy, such as wherein the energy source can irradiate the curing volume with a pattern of energy.

[0139] 32. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the at least one energy source is arranged to irradiate the curing volume with a plurality of wavelengths of energy.

[0140] 33. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the system comprises a plurality of energy source, and wherein at least two energy sources are arranged to irradiate the curing volume with different wavelengths of energy.

[0141] 34. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the irradiation system comprises one or more energy sources selected from the group consisting of: projection units, laser energy sources, LEDs (energy-emitting diodes), OLEDs (organic energyemitting diodes), DLP (digital energy processing) projectors, LCD (liquid crystal display) projectors, VCSELs (vertical-cavity surface-emitting lasers), xenon arc lamps, metal-halide lamps, halogen lamps, fiber optic energy sources, microoptoelectromechanical systems, such as digital micromirror devices, and / or combinations thereof.

[0142] 35. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the energy sources are capable of emitting energy in the UV, the visible, and / or the infrared spectrum. 36. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the irradiation of the energy sources are controlled by the control system and / or the actuators.

[0143] 37. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the at least one actuator is selected from the group consisting of: unmanned aerial vehicles (UAV), such as quadcopters, cranes / jibs, robotic arms, gantry systems, linear actuators, pneumatic actuators, hydraulic actuators, magnetic levitation systems, cable-driven parallel robots, screw-driven systems, telescopic masts, wheeled mobile robots, Stewart platforms, and / or hexapod robots or a combination thereof.

[0144] 38. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the actuators can be remotely controlled by the control system, such as by a wireless communication system.

[0145] 39. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the actuators displaced and / or orient the one or more energy sources.

[0146] 40. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the at least one actuator is configured to dynamically adjust a focal point of the energy source, such as based on the position of the energy source with respect to the centre of the curing volume.

[0147] 41. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the system comprises one or more containers for accommodating one or more curing volumes, such as wherein each container accommodates a different curing volume.

[0148] 42. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the control system is arranged to control the position and / or orientation of the one or more containers.

[0149] 43. The system for manufacturing a three-dimensional object according to item 42, wherein the control system is arranged to control the position and / or orientation of the one or more container by a secondary actuator. 44. The system for manufacturing a three-dimensional object according to item 43, wherein the secondary actuator is selected from the group including: unmanned aerial vehicles (UAV), such as quadcopters, cranes / jibs, robotic arms, gantry systems, linear actuators, pneumatic actuators, hydraulic actuators, magnetic levitation systems, cable-driven parallel robots, screw-driven systems, telescopic masts, wheeled mobile robots, Stewart platforms, and / or hexapod robots or a combination thereof.

[0150] 45. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the curing volume has a volume of at least 1 litre.

[0151] 46. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the irradiation system is suitable and / or configured to illuminate the curing volume with the one or more energy sources to cure a photosensitive material, typically located in the curing volume.

[0152] 47. The system for manufacturing a three-dimensional object according to any one of the preceding items, wherein the one or more containers are transparent to the wavelengths of energy used for curing.

[0153] 48. Use of the system for manufacturing a three-dimensional object according to any one of the preceding items, for manufacturing a three-dimensional object.

[0154] 49. A method of manufacturing a three-dimensional object by additive manufacturing, the method comprising:

[0155] • positioning one or more energy sources around a curing volume;

[0156] • controlling, by a control system in communication with at least one actuator, the orientation and the three-dimensional position of one or more energy sources;

[0157] • illuminating the curing volume with the one or more energy sources to cure a photosensitive material.

[0158] 50. The method according to item 49, wherein the orientation and position of each energy source is controlled individually. 51. The method according to items 49-50, wherein the control system is configured to control each energy source with at least four degrees of freedom, comprising three translational degrees of freedom and at least one rotational degree of freedom, by at least one actuator.

[0159] 52. The method according to any one of the preceding items, wherein the control system is arranged to control the at least one energy source with six degrees of freedom, comprising three translational and three rotational degrees of freedom, such as by the actuators.

[0160] 53. The method according to any one of items 49-52, wherein each energy source is controlled by a different actuator with at least four degrees of freedom.

[0161] 54. The method according to item 52 wherein each energy source is controlled by a different actuator with six degrees of freedom.

[0162] 55. The method according to any one of items 49-53, comprising synchronizing the movements of the energy sources to achieve a uniform curing pattern within the curing volume.

[0163] 56. The method according to any one of items 49-55, wherein the curing volume is rotated and / or displaced.

[0164] 57. The method according to any one of items 49-56, wherein the one or more energy sources are moved along a hemisphere around the curing volume.

[0165] 58. The method according to any one of items 49-57, wherein the irradiation pattern of the energy sources is dynamically adjusted based on real-time feedback from sensors monitoring the curing process.

[0166] 59. The method according to any one of items 49-58, comprising varying the intensity and wavelength of the energy sources to optimize the curing process for different regions of the three-dimensional object.

[0167] 60. The method according to any one of items 49-59, wherein the photosensitive material in the curing volume is irradiated with energy sources emitting multiple wavelengths to cure different types of materials simultaneously. The method according to any one of items 49-60, comprising using a control system to input and execute a pre-defined curing pattern based on a digital 3D model of the three-dimensional object. The method according to any one of items 49-61 , wherein the energy sources are positioned using actuators selected from the group is selected from the group including: unmanned aerial vehicles (UAV), such as quadcopters, cranes / jibs, robotic arms, gantry systems, linear actuators, pneumatic actuators, hydraulic actuators, magnetic levitation systems, cable-driven parallel robots, screw-driven systems, telescopic masts, wheeled mobile robots, Stewart platforms, and / or hexapod robots or a combination thereof. The method according to any one of items 49-62, comprising rotating and / or displacing the curing volume receptacle using a secondary actuator. The method according to any one of items 49-63, wherein the energy sources are moved along a hemisphere around the curing volume to provide comprehensive energy coverage. The method according to any one of items 49-64, comprising monitoring the manufacturing process using one or more sensors. The method according to any one of items 49-65, wherein the curing process is paused and resumed without compromising the integrity of the partially cured object. The method according to any one of items 49-66, comprising compensating for external disturbances such as vibrations or airflow during the curing process. The method according to any one of items 49-67, wherein the position and orientation of the energy sources are adjusted in response to the progress of the curing process. The method according to any one of items 49-68, comprising integrating the control system with 3D model processing software to convert digital models into curing instructions for the energy sources. The method according to any one of items 49-69, wherein the energy sources are programmed to emit energy in specific patterns to cure the photosensitive material according to the 3D model of the object. A control system for additive manufacturing, the control system comprises a memory having instructions that, when executed, carries out the method of any of the items 49-70.

Claims

Claims1. A system for manufacturing a three-dimensional object, such as from a curing volume, the system comprising:• an irradiation system comprising one or more energy sources; and• a control system arranged to control orientation and position in three spatial dimensions of the energy sources, by at least one actuator.

2. The system for manufacturing a three-dimensional object according to claim 1, wherein the control system is configured to control each energy source with at least four degrees of freedom, comprising three translational degrees of freedom and at least one rotational degree of freedom.

3. The system for manufacturing a three-dimensional object according to claim 2, wherein the control system is arranged to control the at least one energy source with six degrees of freedom, comprising three translational and three rotational degrees of freedom.

4. The system for manufacturing a three-dimensional object according any one of the preceding claims, wherein the irradiation system comprises a plurality of energy sources and wherein each energy source is associated with a different actuator configured for independent movement.

5. The system for manufacturing a three-dimensional object according to any one of the preceding claims, wherein the control system is arranged to control the orientation and the three-dimensional position of each energy source individually.

6. The system for manufacturing a three-dimensional object according to any one of the preceding claims, wherein the control system is arranged to control the one or more energy sources, such that said one or more energy sources are displaced along a hemispherical trajectory surrounding the curing volume.

7. The system for manufacturing a three-dimensional object according to any one of the preceding claims, wherein the actuators can be remotely controlled by the control system, such as by a wireless communication system.

8. The system for manufacturing a three-dimensional object according to any one of the preceding claims, wherein the position of the one or more energy sources is defined by an azimuthal angle and an elevational angle, and / or wherein the orientation of one or more energy sources is defined by Euler angles or quaternions.

9. The system for manufacturing a three-dimensional object according to any one of the preceding claims, wherein the control system is arranged to control the one or more energy sources according to a sequence of positions and / or orientations, wherein said sequence of positions and / or orientations may be predetermined and / or determined based on a feedback mechanism.

10. The system for manufacturing a three-dimensional object according to claim 9, wherein the control system is arranged to continuously optimize the sequence of positions and / or orientation based on the feedback mechanism, such that the total movement of the one or more energy sources for manufacturing the three- dimensional object is minimized.

11. The system for manufacturing a three-dimensional object according to claim 10, wherein the optimization is an optimization for deriving a solution to a traveling salesman problem.

12. The system for manufacturing a three-dimensional object according to any one of claims 10-11, wherein the control system comprises one or more sensors, such as optical sensors, temperature sensors, pressure sensors, and / or chemical sensors, for obtaining manufacturing data for use in the feedback mechanism.

13. The system for manufacturing a three-dimensional object according to any one of claims 10-12, wherein the feedback mechanism is a closed-loop feedback mechanism.

14. The system for manufacturing a three-dimensional object according to any one of claims 10-13, wherein the control system is arranged to adjust the orientation and / or position of the one or more energy sources based on the progress of the curing process.

15. The system for manufacturing a three-dimensional object according to any one of claims 10-14, wherein the feedback mechanism is arranged to adjust the energy intensities, dosages, orientations and / or positioning, based on the manufacturing data, obtained by real-time monitoring of the curing volume.

16. The system for manufacturing a three-dimensional object according to any one of the preceding claims, wherein the control system is communicatively coupled with a three-dimensional model processing software configured to convert a digital model of a three-dimensional object into curing instructions for the actuators and / or the energy sources.

17. The system for manufacturing a three-dimensional object according to any one of the preceding claims, wherein the at least one actuator is selected from the group consisting of: unmanned aerial vehicles (UAV), such as quadcopters, cranes / jibs, robotic arms, gantry systems, linear actuators, pneumatic actuators, hydraulic actuators, magnetic levitation systems, cable-driven parallel robots, screw-driven systems, telescopic masts, wheeled mobile robots, Stewart platforms, and / or hexapod robots or a combination thereof.

18. The system for manufacturing a three-dimensional object according to any one of the preceding claims, wherein the at least one actuator is configured to dynamically adjust a focal point of the energy source, such as based on the position of the energy source with respect to the centre of the curing volume.

19. The system for manufacturing a three-dimensional object according to any one of the preceding claims, wherein the one or more energy sources are configured to emit thermal energy, visible light, ultraviolet light, infrared radiation, electron beams, microwave radiation, acoustic energy, radiofrequency, energy, magnetic fields, and / or X-rays.

20. The system for manufacturing a three-dimensional object according to any one of the preceding claims, wherein the control system is arranged to control the position and / or orientation of one or more containers, for accommodating the curing volume, by a secondary actuator.

21. A method of manufacturing a three-dimensional object by additive manufacturing, the method comprising:positioning one or more energy sources around a curing volume;• controlling, by a control system in communication with at least one actuator, the orientation and the three-dimensional position of one or more energy sources;• illuminating the curing volume with the one or more energy sources to cure a photosensitive material.

22. The method according to claim 21 , wherein the control system is configured to control each energy source with at least four degrees of freedom, comprising three translational degrees of freedom and at least one rotational degree of freedom.

23. The method according to any one of the claims 21-22, wherein the control system is arranged to control the at least one energy source with six degrees of freedom, comprising three translational and three rotational degrees of freedom.

24. The method according to any one of the claims 21-23, comprising:- displacing the one or more energy sources along a hemisphere surrounding the curing volume.

25. The method according to any one of the claims 21-24, comprising defining the position and / or the orientation of each energy source using azimuthal and elevational angles and / or Euler angles or quaternions.

26. The method according to any of the claims 21-25, comprising integrating the control system with a three-dimensional model processing software configured to convert a digital model into curing instructions for the actuators and / or energy sources.

27. The method according to any of the claims 21-26, comprising adjusting the orientation and / or the position of the one or more energy sources based on real-time feedback regarding the progress of the curing process.

28. The method according to claim 27, wherein:- the feedback is provided by one or more sensors selected from the group comprising optical sensors, temperature sensors, pressure sensors, and chemical sensors.

29. The method according to any one of the claims 21-28, wherein the feedback mechanism is configured to adjust parameters, such as energy intensities, dosages, orientations, and / or positions of the one or more energy sources.

30. The method according to any one of the claims 21-29, wherein the one or more energy sources are configured to emit thermal energy, visible light, ultraviolet light, infrared radiation, electron beams, microwave radiation, acoustic energy, radiofrequency, energy, magnetic fields, and / or X-rays.

31. A control system for additive manufacturing, the control system comprises a memory having instructions that, when executed, carries out the method of any of the claims 21-30.

Images