Innovative Techniques for 3D Printing of Large Objects

A device for lithography-based additive manufacturing of three-dimensional structures on curved surfaces by rolling contact between the surface and a layer coated with photopolymer resin. The device has a light engine projecting patterned light onto the layer as it rolls. The layer feeding rate and light pulse rate synchronize to avoid motion blur. The rolling contact enables 3D printing on curved surfaces with a larger area than the light engine exposure field. It's useful for manufacturing cylindrical objects like bottles or tubes.

A building unit for large-format additive manufacturing with an inert gas system to allow high-quality prints at scale. The build unit has an energy beam system and an inertization system with supply and return manifolds. The supply manifold includes a downward flow manifold and a crossflow manifold to provide process gas flow through the irradiation chamber. The return manifold evacuates the gas. This prevents contaminants from the powder bed from contacting the energy beam components, allowing clean prints.

Wall-thickness additive manufacturing device for micro cast-rolling additive manufacturing of large-scale special-shaped pipes, such as those used in nuclear power plants. The device uses a crossed slide assembly and laser cladding assembly on a vertical wall to additively manufacture large irregular steel pipes. It enables near-net-shape manufacturing of complex-shaped pipes with variable wall thicknesses in a single step using laser cladding.

A method to create large-scale biological tissue containing regulated vascular structures for use in 3D cell culture and tissue engineering applications. The tissue is formed by printing a coaxial scaffold structure containing a thermosensitive material. After curing the outer scaffold material, the inner thermosensitive material is melted away to leave a hollow duct. A cell-laden hydrogel is then poured into the duct to create the tissue. The coaxial printing allows adjustable porosity of the duct walls. The thermosensitive material provides temporary support during hydrogel filling.

A method of secure and releasable attachment of a build sheet to a print bed in large-scale additive manufacturing without the need for adhesive. The method uses vacuum suction to hold the build sheet in place on the print bed. The print bed has a surface with a plurality of perforations. A vacuum source is connected to the perforations to apply suction through the holes. This pulls the build sheet down and holds it securely to the bed during printing. The vacuum can be released to remove the build sheet after printing easily.

Additive manufacturing of large parts using a linear laser beam increases efficiency and reduces costs compared to point laser beams. The method involves using a laser-generating unit that projects a linear light spot onto the material and drives the laser, platform, or material feed to move during manufacturing.

Large-format 3D printing uses separated components with tracking to increase print size beyond the printer's build volume. The method involves using a 3D printer made of movable components, each with a tracker. The trackers provide local coordinate systems, which a processing unit combines into a global coordinate system. Printing instructions are generated based on the global coordinates to print larger objects accurately. The tracking system also allows scanning a large object in sections and combining the scans.

A 3D printer with adjustable printing height to enable printing very tall objects without needing a large machine. The printer has a movable nozzle bracket and a movable platform to be elevated along the vertical axis. The nozzle bracket is driven by a motorized screw rod, and the platform by a separate motorized screw rod to adjust the distance between them independently. This allows extending the printing height range beyond the fixed vertical axis length. The nozzle bracket also has a 2D moving module to adjust the printing position.

Automatically printing 3D objects that are larger than the printing area of a 3D printer by automatically partitioning the object into pieces that will fit in the printer, generating connectors between the pieces, and then printing and assembling the partitioned pieces.

An extendable 3D printer that can print larger objects than the size of its base. The printer has a movable printing head that can slide along an extending mechanism. The printer can have interchangeable bases of different lengths. The extending mechanism and bases are controlled by a control unit based on the dimensions of the 3D model being printed.