Volumetric Additive Manufacturing With Object-Space Image Optimization

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Solution Overview

Problem

Multi-step additive manufacturing processes face challenges in connecting structures, transporting fresh printing material, and dealing with layering effects, which limit print speed and material properties, especially in volumetric additive manufacturing (VAM).

Innovation Solution

An algebraic object-space optimization algorithm for computing image sets in VAM that directly optimizes on the structure to be printed, allowing for improved reconstruction fidelity, simplicity, flexibility, and robust convergence, enabling new printing geometries and materials like Grayscale VAM.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multi-step printing processes are used to connect structures and transport material, then manufacturing capability is achieved, but print speed decreases and process complexity increases

Engineering Contradiction:

Improveprint speedVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the support structure requirement by using volumetric additive manufacturing. The system projects optical patterns directly into a 3D resin volume to polymerize structures without needing temporary supports, removing the multi-step process of adding and removing support material while maintaining manufacturing capability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent applies preliminary action by pre-calculating and pre-processing the optical projection patterns before printing. The system computes the complete set of 2D optical patterns that will integrate to form the desired 3D structure, allowing the actual printing process to proceed without intermediate material transport or support manipulation steps

Inventive Principle:

Principle #10Preliminary action

2Productivity

If fresh printing material is transported during printing, then material supply is maintained, but print speed is limited and material viscosity is constrained

Engineering Contradiction:

Improveprint speedVSAvoidmaterial viscosity range

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent replaces the mechanical material transport system with an optical field-based approach. Instead of physically moving resin through extrusion or deposition mechanisms, the system uses projected optical patterns to selectively polymerize resin in place, eliminating the need for continuous material transport and enabling the use of high-viscosity materials that would be difficult to pump or extrude

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If layer-by-layer printing is used to build structures, then manufacturing is achieved, but layering effects cause inhomogeneities in material properties

Engineering Contradiction:

Improvematerial property uniformityVSAvoidprinting process steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent transitions from 2D layer-by-layer printing to 3D volumetric printing by projecting optical patterns throughout the entire resin volume simultaneously. This dimensional change allows structures to be built in three dimensions at once rather than sequentially layer by layer, eliminating layering effects and achieving uniform material properties throughout the printed object

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Manufacturing precision

If algebraic object-space optimization algorithm is used, then reconstruction fidelity improves and convergence becomes robust, but computational complexity increases

Engineering Contradiction:

Improvereconstruction fidelityVSAvoidcomputational algorithm complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent implements self-service through the algebraic object-space optimization algorithm that automatically adjusts projection patterns based on real-time feedback from the printing process. The system monitors the polymerization state and autonomously computes corrective projections to maintain target fidelity, eliminating the need for manual intervention or complex external control systems

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The algorithm enhances print fidelity and versatility, enabling high-viscosity resins and complex structures without layering effects, allowing for new applications such as printing between flat slabs and arbitrary functionally graded materials.

Implementation Method 1

a series of 2D optical patterns is projected into a rotating volume of photosensitive liquid resin. Over the course of tens of seconds to a few minutes, the accumulated optical dose distribution polymerizes the material, resulting in an arbitrary 3D structure

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS12576595B2Systems and methods for improved volumetric additive manufacturing

Publication Date: 2026.03.17 THE REGENTS OF THE UNIVERSITY OF COLORADO

AI summary

Systems and methods for improved volumetric additive manufacturing (VAM) are described herein. In some aspects of the present disclosure, approaches to VAM image-computation are provided that algebraically optimizes directly on the structure to be printed, instead of on the set of external projection images. These approaches provide multiple advantages including improved reconstruction fidelity, simplicity, flexibility, and robust convergence to a desirable reconstruction, regardless of initial image-set guess.