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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Multi-material 3D printing system with gradual drying and curing to increase speed, reduce shrinkage and distortion compared to traditional inkjet 3D printing. The system has separate material deposition, drying, and curing stations. It uses a delivery system to move the printed layers through multiple extraction units that gradually remove solvent. This allows faster drying compared to all-in-one solvent evaporation. The printed layers are then transferred to curing stations for final curing before being stacked.

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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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A 3D printing material for dental applications that allows the fast production of accurate dental models. The material contains specific monomers and initiators that reduce polymerization shrinkage and deformation after printing. The key components are monofunctional acrylate monomers with an electronegativity difference of less than 1.0 between adjacent atoms and initiators with absorption bands of 350-450nm. The material may also include low-shrinkage polyfunctional methacrylates, non-dendritic polymers, fillers, and colorants.

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Accelerating high-resolution 4D thermal simulation for additive manufacturing using machine learning to bridge the resolution gap between affordable simulation resolution and actual print resolution. The technique leverages deep learning models trained on low-resolution simulation output and geometrical data to infer high-resolution thermal images in 4D (x, y, z, time). This allows for generating detailed thermal simulations near print resolution to guide additive manufacturing processes.

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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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3D printing with multiple fluids improves print quality and prevents printed object degradation. The approach uses a kit of fluids, including a fusing agent, antioxidant formulation, coloring agent, and detailing agent. The antioxidant formulation protects the polymer build material from thermal degradation during printing. Applying the antioxidant along with fusing agents selectively pattern the layers. This prevents degradation when the build material is exposed to high temperatures during fusing. The coloring and detailing agents provide additional customization options.

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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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Reducing distortion in 3D printed parts by alternating the direction of printing layers. Instead of always printing layers with the extruder moving in the same direction, the direction is alternated between clockwise and counterclockwise. This eliminates warping and distortion as the material cools, as opposed to parts printed with consistent layer orientation. The technique involves manually modifying the layer paths to achieve the alternating printing direction.

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A compact heater on a 3D printer dries filament before printing to improve the quality of 3D-printed objects. The heater is positioned between the filament source and the printer head. It has heating elements to warm the filament and moisture collectors to absorb any moisture. This dehumidifies the filament before it is extruded.

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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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Fabricating inorganic 3D nanostructures using 3D printing techniques with resolution below 200nm. A nanocomposite ink containing functionalized silica nanoparticles is used. Two-photon polymerization is performed to form the 3D structures, followed by pyrolysis and sintering to convert the polymerized ink into pure silica nanostructures. The crystallinity of the structures can be controlled by adjusting the sintering temperature.

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