High-Resolution 3D Part Production

Additive manufacturing system that combines extrusion and curing technologies to create high-resolution 3D printed objects using a single build material. The system has an extrusion printhead for depositing uncured material and a microheater printhead for curing specific areas. This allows using a lower-resolution extrusion printhead for faster deposition and then curing with the microheater to achieve high-resolution features. The curable build material can also be used as support material, reducing waste compared to separate support materials. The microheater curing improves strength and other properties compared to just extrusion.

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A method for printing 3D parts using metal jet printing that improves adhesion and part release properties. The technique involves printing the first layer at a higher standoff distance from the substrate, then lowering the standoff for subsequent layers. This initial higher standoff helps prevent bouncing or splashing of the first layer droplets. It also allows the metal to oxidize and form a better adhesive surface. Lowering the standoff for subsequent layers facilitates adhesion and prevents delamination. This allows the part to be easily released from the substrate without damage or excessive force.

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Reducing mixing and flowing of materials at boundaries in 3D printing to improve object fabrication precision. The technique involves depositing materials at different heights in successive printing passes to form discontinuous surfaces. By raising the first material higher than the second material, it solidifies before the second material is applied. This prevents mixing and flowing at the boundary when both materials are simultaneously in liquid state. A non-contact sensor is used to monitor the surface between passes.

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A five-axis multi-process integrated additive manufacturing system that allows simultaneous use of multiple 3D printing processes to create complex parts with improved efficiency and quality compared to traditional sequential processes. The system has a dual gantry frame that allows switching between different printing processes and materials mid-print. It also uses devices like positioning devices and laser scanners to ensure accuracy and stability during printing.

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Fast layered extrusion for additive manufacturing that enables high-speed 3D printing of complex objects by selectively blocking material flow through the print head to create layers with desired patterns. The print head has actuators along the width that can controllably block sections to prevent extrusion in certain areas. This allows printing an entire layer in a single pass by extruding across the full width initially, then blocking and unblocking sections to shape the layer. The print head and object move relative to each other to build the 3D object. The selective blocking enables fast, precise layer formation.

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Multi-material 3D printing using stereolithography without separate resin trays and cleaning steps between materials. The printer has a single build plate with a transparent window and a material dispenser. It deposits one material on the window, cures it, then the other material on top. Cleaning devices wipe the window and head between layers. This enables printing multiple materials in sequence on the same build plate without separating or cleaning between each material.

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A method for 3D printing metal objects that enhances accuracy and quality compared to previous methods. It involves building a frame and then an internal structure within the frame. The method includes measuring the base shape in the internal area before building the structure. It then calculates the deviation from the planned shape and makes welding corrections. This allows the internal structure to be built accurately even when the frame obstructs real-time measurement.

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3D printing method uses extrusion of partially-reacted thermoset materials to print objects with improved resolution and material properties compared to traditional thermoplastic 3D printing. The method involves extruding reactive components from a mixing chamber that partially react before deposition. The partially-reacted thermoset adheres to previously deposited layers and cures fully after printing. The extruded thermoset has properties that enable high-resolution printing and improved material performance, like flexibility, strength, and durability.

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Resin composition and production method for high-dimensional accuracy 3D-printed objects. The resin composition contains polysaccharide nanofibers dispersed in a thermoplastic resin. The nanofibers form a network structure when the resin melts, preventing shrinkage and shape distortion upon cooling. This provides dimensional accuracy in 3D-printed objects. The nanofiber content should be 1-70% by mass. The production method involves using the resin in selective laser sintering or fused deposition modeling to create 3D shapes.

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Three-dimensional printing with enhanced resolutions and cleaning capabilities. The 3D printing system uses a projector to project the appropriate energy onto forming materials in a reservoir tank to create a solid object. The projector can be customized to emit the required energy (e.g., UV light) for specific materials like resins, ceramics, metals, biologies, etc. The printer also has a cleaning method that coagulates debris in the tank using the projector and a removable bottom surface geometry.

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3D printing method using a fixed-head printer with multiple nozzles in a row to improve speed and efficiency by optimizing extrusion patterns. The method involves changing the head's movement direction mid-layer while maintaining the same angle relative to the build platform. This allows wider or narrower swaths of material to be deposited in different directions, leveraging the fixed-head setup. By switching directions mid-layer, the multiple nozzles can be used more effectively compared to just using them all in one direction. This allows wider or narrower lines to be printed as needed, without needing a rotating head or extra nozzles. The method is controlled by a computer to automate the mid-layer direction change based on the 3D model.

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Micro-nano 3D printing device with multi-nozzle jet deposition driven by the electric field of a single flat plate electrode for high-resolution, stable, and efficient micro-nano 3D printing. It uses multiple non-conductive nozzles without connecting them to high voltage, which avoids electric field crosstalk. The flat plate electrode generates an electric field to propel neutral droplets from each nozzle.

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High speed, high resolution 3D printing of viscous materials using a multistep process that separates the printing, curing, and transfer steps. The process involves printing the viscous material onto an intermediate substrate, curing it, and then transferring the cured layer to a final substrate. This allows higher resolution printing without limitations of a single material. The intermediate substrate provides a precise gap for printing. Imaging and processing steps can be done between printing and curing.

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A method and 3D printing system for manufacturing physical objects with customizable surface quality. The method allows selecting the resolution of the 3D printing process for each object being printed. This is done by dynamically changing the optical resolution during printing using techniques like switching light engines, adjusting optics, or zooming lenses. The resolution can also be adjusted by displacing the cured layer relative to the light source. This flexibility lets objects with different surface quality requirements be printed simultaneously or sequentially using the same 3D printer.

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3D printing system using inkjet printers that improves speed and material versatility compared to conventional inkjet 3D printers. The system removes a significant portion of the liquid carrier from printed layers using a pressure differential to form dry layers. This allows faster printing compared to evaporation alone. The dry layers are then transferred to the build station. The inkjet printers can use specialized inks with high-performance materials like ceramics, metals, and organics. The system coordinates multiple printer modules with transfer devices for customization.

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3D printing that achieves higher resolution by selectively curing regions of a resin using cumulative light exposure along a specific path. The method involves moving a light modulator and delivering light in steps smaller than a pixel width so curing energy accumulates in overlapped regions. This allows precise control of resin curing to achieve subpixel-level resolution.

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Three-dimensional printing system using rotating trays and inkjet print heads for improved efficiency and speed compared to traditional 3D printing methods. The system has a rotating tray and multiple inkjet print heads that can reciprocate radially. The heads dispense build material in layers as the tray rotates. The head movements and tray rotation speed are synchronized to prevent errors. This allows printing objects with complex geometries and features that can't be achieved with fixed print beds. The system also has features like staggered dispensing, preheating, radiation sources, and automated object placement to further optimize printing.

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A 3D printing system and method that enables producing high performance plastic parts with high strength and durability. The system uses a modified stereolithography process with oxygen reduction and controlled oxygen gradients in the resin chamber and below the build plate. This allows curing of the resin layers with reduced oxygen levels to create parts with improved mechanical properties compared to conventionally cured stereolithography parts. The system has a resin vessel with a transparent bottom, a build tray, movement mechanism, light engine, gas handling system, and controller. It reduces and controls oxygen levels in the resin chamber and below the build plate during curing to enhance the strength and durability of the printed parts.

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A resin-enhanced fused deposition modeling 3D printing system that improves the strength and layer adhesion of 3D printed parts. The system uses a rotating ring with a fixed seat and bearing to move the resin nozzle relative to the print nozzle. This allows the resin to be selectively applied between layers to improve bonding. A resin transfer tray below the rotating ring collects and distributes the resin. The rotating ring also has a gear mesh with the motor shaft to synchronize motion. The rotating ring design allows controlled resin dispensing between printed layers.

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3D printing method using a bottom-up printing technique that eliminates the need for support structures and reduces the risk of damage during printing. The method involves filling a gap between the build platform and a reference surface with uncured resin, curing it to form a patterned layer, and repeating for subsequent layers. The object and support structures are separated by intersecting cross-sections with cured resin and support features. The object layers are thinner than the support layers. This allows printing without internal supports and reduces the need for external supports compared to top-down printing.

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