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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Additive manufacturing system and method for 3D printing using semi-crystalline polymers that prevents curling and delamination of the printed parts. The system uses electrophotography to selectively deposit semi-crystalline polymer layers. The layers are transferred to a cooled platen and fused using heat and pressure. Rapid cooling subcools the polymer to prevent crystallization. This allows using semi-crystalline materials for 3D printing without curling or delamination issues. The electrophotography technique allows precise layer development and transfer.

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Multi-material 3D printing using curing-on-demand printheads that enable accurate layer-by-layer deposition of multiple materials without contamination. The printheads have sections for coating, curing, cleaning, and optional post-curing. The coating section dispenses resin, the curing section exposes it to light, the cleaning section vacuum suctions off uncured resin, and the post-curing section further cures. This allows efficient cleaning and avoids mixing between materials. Multiple printheads register beneath the build platform to print the object layer by layer.

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A 3D printing method that reduces splashing and improves part precision by adjusting the droplet deposition height based on the pattern being printed. Droplets are deposited closer to the layer in the core of the pattern and farther from the layer in the edges. This prevents splashing and erosion in the core where density is high, while allowing splashing in the edges where density is lower. This allows printing at higher speeds without compromising part quality.

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3D printing method and platform to improve accuracy and surface finish of 3D printed objects, especially for parts with curved or inclined surfaces. The method involves using a special 3D printing assembly with a moving print head, arc sensors, and a water jet nozzle. The assembly allows the print head to precisely follow curved paths by adjusting its position and orientation. The water jet nozzle is used to apply the printing material to the curved surface instead of layering. The arc sensors detect the head position to avoid steps. This enables smooth printing of curved shapes without the typical layer lines. The platform has a moving support plate and cooling/heating systems to accommodate the moving print head.

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A 3D printing method that avoids inclined surfaces and improves the shape-forming resolution of the printed object. It involves generating control data for the printer that is deviated from the usual multi-pass printing approach when the printer has staggered nozzle columns. The deviation avoids nozzle overlap at the ends of each pass that causes inclined surfaces.

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3D printing of crystalline polymers with improved material properties and reduced printer wear compared to traditional methods. The process involves melting crystalline polymer in the print head, depositing layers, cooling rapidly to form amorphous regions, heat treating, and repeating. This avoids complete crystallization during printing, reduces stress accumulation, prevents deformation, and enables precise 3D printing of crystalline polymers without needing high temperatures. The cooled amorphous layers are bonded at lower temperatures than fully crystalline polymers. The cooled parts are then heat treated to relieve stress and prevent deformation.

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Additive manufacturing method for 3D printing high viscosity resins using a translating material support. The method involves applying thin layers of photopolymerizable material onto the moving support, exposing it to UV light to solidify, then scraping off excess material as the support moves back. This allows processing of thicker, more viscous resins by selectively feeding and removing material during translation instead of dipping or coating.

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Additive manufacturing method for 3D printing using a contactless printing process to reduce deformation of the printed layers. The method involves printing each layer above the previous layer instead of directly on top of it. This prevents shear stress on the extruded strands. The contactless printing is achieved by raising the print head to a distance above the substrate between layers. The layers are then cured separately after printing. This allows forming 3D objects without layer-to-layer adhesion issues. The contactless printing prevents deformation of the printed layers during subsequent printing steps. The method uses a reactive printable composition that can be cured separately after each layer.

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3D printer with improved accuracy for additive manufacturing by reducing shape error during printing. The printer has a printhead mounted on a carriage that moves along the X axis. The printhead orientation is perpendicular to the axis during printing. This orientation reduces errors in forming shapes like hemispheres by 15%. The printer also has features like a heated build plate and motorized Z axis movement.

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Efficient 3D printing method and system that allows faster and more accurate 3D printing of objects by using a compact 3D printer with a unique mechanism. The printer has a single arm that can move linearly and rotationally to cover a large print area. It has two printing tool supports, one for normal printing and one for mirror printing. The printer can switch between normal and mirror printing modes by folding the arm over the central support. This allows printing objects with features like overhangs that would otherwise require support structures. The printer also has a mechanism to accurately position the mirror tool support. The printer accesses the 3D object data, divides it into layers, and calculates offsets to account for the arm movement during printing.

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Three-dimensional printer that improves the strength of printed objects by adding internal reinforcement between layers. The printer has multiple printing heads: a main head to extrude the first material for layers, a laser puncher to make connection holes extending between layers, and a secondary head to fill those holes with a second material. This creates internal reinforced structures that connect adjacent layers and improve overall object strength.

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A 3D printer using a visual display screen to selectively polymerize layers of resin and build 3D objects. The printer has a screen assembly with a display screen for providing patterned electromagnetic radiation to cure the resin. The screen assembly sits above the build platform. The display screen replaces traditional light sources like lasers or projectors. The screen exposure cures the resin layer by layer to create the 3D object. This allows using low-cost, high-resolution displays as the light source in 3D printing. The display screen is supported by a screen assembly above the build platform.

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Method for printing 3D products using a 3D printer that enables accurate and detailed 3D printing with materials like resins. The method involves spraying material layers onto a platform, curing the required areas using a light source, surrounding each layer with a frame, and dissolving the uncured areas. This prevents spreading of the gel-like material between layers. The printer has a print head with a nozzle and curing light, a piston container, and a mechanical arm to move the head. The container has a piston driven by a stepper motor to extrude material into the nozzle. The mechanical arm allows X/Y/Z movement.

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A method for 3D printing complex structures from shape memory and thermoresponsive polymers using fused filament fabrication. The key steps are: 1. Extrude the polymer at low speed (max 20 mm/s) through the printer nozzle to deposit thin layers. 2. Move the printer head back and forth between areas within the layer immediately after deposition. This prevents local melting of the polymer. 3. Use thermoplastic elastomers and shape memory polymers with thermoresponsive properties. These allow complex structures to be printed due to their shape recovery when heated. 4. The printed polymers can contain additives like dyes, pigments, fillers, etc. 5. The printed objects can have sections made from different thermoplastic elastomers and shape memory polymers. 6. The printed parts can be

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A 3D printing method and system that improves the strength of 3D printed objects by embedding reinforcement structures between the layers. The method involves using a laser to create connection holes extending between adjacent layers. A separate extruder fills these holes with a second material. This internal reinforcement prevents delamination between layers and improves vertical strength of the printed object.

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Method for 3D printing objects with improved speed and properties by selectively applying different material thicknesses in boundary vs core layers. The method involves using a primary printhead with a fixed material extrusion capacity to print the boundary layers around the object. For the core layers inside the object, a secondary self-propelled printhead with higher material extrusion capacity is used. This allows thicker core layers to be printed faster without sacrificing surface quality. After all boundary layers are printed, the core volume is filled with resin in a single operation. This separates the high-quality boundary layers from the lower-quality core layers, reducing print time without degrading surface finish.

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3D printing objects with smooth surfaces and improved mechanical properties by avoiding rough interfaces between the printed body and support materials. The method involves printing the body and support structures separately at different heights instead of layering them together. This prevents mixed droplets and rough interfaces that form when printing both materials simultaneously. After printing, the support structure is removed leaving a smoother, crack-free body surface.

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Generative manufacturing method for 3D printing that improves layer quality and reduces defects by performing local actions between the recoater and solidification device. The steps are: apply powder layer, solidify selected areas, then perform local actions like compaction or pre-solidification between the recoater and solidifier as they move across the build area. This improves powder properties before compaction/solidification.

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3D printer for creating objects using multiple types of photocurable resins without quality degradation from resin curing. The printer has parallel transport of light-transmissive films, resin application on the films, optical module to cure resin, and a build module to stack cured layers. This allows selective deposition of different resins on separate films, then laminating them without mixing. Features like blade adjustment, release force, rotation, washing, and feed control enable efficient multi-material 3D printing.

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3D printing method for manufacturing objects with better strength and without gaps between layers. The method involves dividing each layer into interlocking partial regions that engage and overlap at the edges. This creates a comb-like connection between adjacent regions. The regions are developed separately to form the layer. The overlapping regions have protrusions that interlock to prevent separation. This improves cohesion between adjacent regions and prevents gaps. The interlocking regions form the layer when developed together. The partial regions can have different patterns and dimensions layer by layer.

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Method for 3D printing multi-material objects with customizable material distributions. It involves generating area-specific print data for each layer based on user-defined area information, randomly generating print data within each area, and testing the randomness of the generated data. The area-specific print data is used to selectively deposit different materials in each layer, allowing customized material distribution. The randomness testing ensures smooth material transitions between areas. The data processor, print head, and process controller communicate to implement the printing. The method allows printing objects with arbitrary material compositions in each layer.

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A method for 3D printing complex structures with smooth surfaces and easy removal of support material. The method involves using two separate print materials, one for the final structure and one for support. The structure material is printed first, followed by selective deposition of support material where needed. After printing, the entire structure is cured. The support material is then dissolved or washed away to leave the final structure. This allows precise control over the structure and surface by using the optimal material for each part, and enables complete removal of the support.

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A very fast 3D printing technique for creating metal parts with high surface finish and uniform density. The technique involves a print head with alternating energy sources and material supplying apertures that move horizontally back and forth to build layers. When the head moves horizontally, the apertures supply liquid material and the sources cure it. Then the head moves up a layer. The back and forth motion allows continuous printing without layer-by-layer lifts. The technique can also move horizontally for larger objects.

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3D printing method using electrostatic printing techniques to improve dimensional accuracy and part-to-part repeatability in additive manufacturing. The method involves applying a leveling powder on top of partially built 3D parts, then mechanically removing the excess powder to create a flat surface. This leveled powder layer is fused with the build and support materials and becomes part of the final structure. By mechanically planing the leveling powder, it compensates for non-uniformities in the individual layers and ensures a consistent, flat final part.

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3D printing using electrostatic printing processes to improve accuracy and part repeatability. The method involves leveling each printed layer to ensure uniform thickness and prevent errors accumulating in multi-layer 3D prints. After transferring the build and support materials to the intermediate transfer belt (ITB), an angled blade removes excess material to flatten and level the layer before fusing. This prevents voids, misregistration, and non-uniformity issues that can arise from uneven layers during additive printing.

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3D printing system that allows integrating different types of materials like photopolymers and thermoplastics in a single 3D object to improve strength and durability. The system has multiple inkjet print heads, an extruder, UV curing source, and a moving build platform. It prints using photopolymer droplets extending above a base, then extrudes thermoplastic into the volume below. The UV cures the photopolymer and forms a surface over the thermoplastic. This composite structure combines the benefits of photopolymer properties like surface finish and resolution with the durability and lower cost of thermoplastics.

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Three-dimensional (3D) printing using electrostatic transfer to overcome the challenges of traditional 3D printing methods like fused deposition modeling (FDM) for printing complex shapes with thin layers. The electrostatic transfer involves sequentially transferring the print material and support material from belts onto the build platform using electrostatic charging and transfer stations. Solvent stations make the print material sticky without affecting the support material. This allows separating and removing the support material after printing. The electrostatic transfer allows thin layers without peeling force issues and controlled temperature transfer.

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A stereolithography 3D printer that improves speed, accuracy, and material properties of printed objects compared to conventional stereolithography printers. The printer uses a moving platform, moving UV light source, and immersion of the printed object between layers to overcome limitations of static printers. The moving components allow features like object immersion between layers, surrounding the object with fluid, and adjusting UV exposure to avoid shadows and meniscus effects. This enables faster printing, better object properties, and more complex geometries compared to static printers.

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A 3D printing method and printer that enables creating stronger and smoother 3D printed objects. The method involves filling a 3D object with fiber-reinforced plastic in the inner layers, followed by filling the outer layers with a liquid thermosetting resin. The resin is then cured to solidify. This allows the fiber-reinforced plastic to provide strength and voids for resin penetration, while the outer resin layer provides a smooth finish. The printer has separate printheads for the fiber-reinforced plastic and resin.

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Hybrid 3D printer with integrated CNC machining capability for producing high quality plastic parts with improved productivity and surface finish compared to traditional 3D printing. The hybrid printer has a 3D printing module using FDM (fused deposition modeling) technology for rapid prototyping, and an integrated CNC machining module for finishing and surface machining. This allows printing the initial structure of the part using FDM, followed by CNC machining to finish and refine the surface. The CNC module has a rotating worktable to enable machining of all sides of the part. The hybrid printer provides a single device solution for producing plastic parts with better quality and productivity compared to separate 3D printers and CNC machines.

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