Techniques for Improving Accuracy in 3D Printing High-Detail Objects

The method for manufacturing a resin-formed product with a leather grain is using 3D printing. It involves printing an intermediate product with a grain that serves as a base for the final leather grain. The key step is designing the intermediate grain by increasing the grain height in the input data by at least 120% of the printing layer height. This allows accurate reproduction of the leather grain in the final product.

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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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Powdered surface monitoring system for additive manufacturing to improve efficiency and quality of laser sintering 3D printing. The system uses a laser source and polarized imaging to monitor the surface of the powder bed during the printing process. The laser beam is directed onto the powder surface, and reflected light is analyzed using polarizers and detectors to obtain polarization images. By scanning the laser over the entire powder bed, the system constructs a complete 3D profile of the powder surface. This allows real-time powder level and density tracking during printing to optimize sintering parameters and reduce defects.

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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 entirely 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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Creating 3D tissue constructs to repair or replace tissue of a tissue cavity. The constructs are made using 3D printing techniques that inject biomaterials and cells into a support material. The printed constructs can be customized to match the target tissue cavity's size, shape, and topography. When the construct is implanted, the cells and biomaterials promote tissue growth to fill the cavity. This allows precise tissue engineering for tailored regeneration.

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Improving the manufacturing precision of objects using 3D printing and additive manufacturing devices. The method involves generating optimized control commands to improve the resolution and precision of manufactured objects. This is achieved using a geometric construction rule that describes the object as a series of line or area elements rather than using a volumetric CAD model. The construction rule parameters are used to drive the additive manufacturing device to solidify the building material layer at specific positions corresponding to the object elements. This allows precise control over the object details and dimensions during 3D printing to achieve higher resolution and accuracy than standard CAD models. The construction rule provides a more compact and detailed description of the object geometry compared to volumetric models, enabling optimized control commands for additive manufacturing.

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Determining locations for support structures in additive manufacturing build parts. The system examines the geometrical characteristics of each segment of a building part at a candidate position relative to the energy source. It determines support locations based on factors like the angle of incidence of each segment relative to the energy source. This allows precise determination of which segments require support to achieve good quality. Reducing unnecessary support can reduce the total amount of support material used in the build process.

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Calibrating an additive manufacturing system to improve fabrication accuracy. The calibration involves determining geometric relationships between the printhead, sensing system, and motion system.

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Improving productivity and precision of a stereolithography system for 3D printing of objects. The system uses a downward-facing support tray in the resin vessel to enable vertically stacked objects to be printed in a single batch. The objects are dental arches with couplings connecting arches. This arrangement allows multiple objects to be printed simultaneously, increasing productivity. The couplings are designed with break slots, allowing easy separation from the printed arches. This enables precise printing of the arches without damage when the supports are removed.

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High-resolution, high-speed jetting 3D printing of viscous materials using an intermediate substrate. The process involves printing viscous material onto an intermediate substrate before transferring it to the final substrate. This allows special coating and curing techniques on the intermediate substrate to optimize printing quality. The process can also involve multiple printing and inspection steps on the intermediate substrate to build up complex, multilayered structures.

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Device and method to precisely position core locating pins into additively manufactured molds with internal cores, to stabilize the cores for casting. The molds have angled holes leading to the core. The device is a set of tools where each tool has a pin cavity and standoff of unique length. The tool for each hole is selected, a pin is inserted to the cavity length, and the tool guides insertion to contact the mold surface. The angled hole and mold thickness precisely position the pin to engage and stabilize the core.

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Calibrating lag time in a 3D printer to accurately compensate for timing delays between instruction execution and physical movement during printing. The calibration involves forming a test pattern on the printer platform, capturing images of the pattern using an optical sensor, analyzing the pattern images to identify centerlines, and determining the lag time based on platform speed and centerline offsets.

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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 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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A loading system for 3D printers that reduces mounding and increases uniformity of powder layers. The system has a loading chamber positioned over the supply container. Powder is dispensed into the chamber and compacted to increase uniformity. The chamber floor is then lowered into the supply container, transferring the compacted powder. This loading process helps distribute the powder more evenly throughout the container compared to filling it directly.

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Method of producing gelatin-based scaffolds for tissue engineering. It involves depositing layers of gelatin powder and jetting an aqueous alcohol solution on each layer to dissolve and bind the powder particles together. The key steps are using gelatin powder with specific particle size range and jetting a solvent with low boiling point to dissolve the gelatin. This allows forming gelatin scaffolds with optimized biocompatibility and accuracy for regenerative medicine applications.

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A device and method for improving precision and surface quality of wire and arc deposition 3D printing. The method uses a camera to monitor the molten pool size and adjusts gas flow from both sides to control it. Increasing gas flow restrains the pool size and prevents collapse.

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An apparatus for cooling an LCD panel in a 3D printer to improve print quality. The cooling is achieved by installing a sealed case between the light source and LCD panel, with a cooling module that cools the air inside the case. This prevents the LCD panel from overheating and blackening during printing, which can degrade image quality.

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Manufacturing high precision 3D printed objects by directly measuring the base shape before weld deposition to enable feedback control of the robot arm, current, voltage, and filler metal supply. The system uses two measurement units: 1) a non-contact sensor on the torch that measures the base shape where the weld is deposited, and 2) monitoring the welding parameters like current and voltage. It selects the measurement (1 or 2) that is available at each location to control the weld process. This compensates for situations where obstacles block the base shape sensor.

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A low-cost method to manufacture 3D microelectrodes for applications like wearable electrochemical sensors. The method involves using a flexible mold to replicate the 3D shape of the electrode, allowing creation of high aspect ratio electrodes that are difficult to make using lithography. It uses a two-step molding process with a flexible material to replicate the electrode shape, then adding a conductive layer to form the final electrode. The flexible mold allows easy release of the shaped electrode.

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Real-time in-situ analysis of mechanical properties of an object being additively manufactured. The analysis is done using a nano-indenter to measure parameters like hardness and cameras to generate images of the object. This data is used to modify printing and environmental parameters in real-time to optimize the object properties. The goal is to avoid printing entire objects before discovering issues and improve consistency.

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