Precision Enhancement in 3D Printing

Fused deposition 3D printing method that improves accuracy and mechanical properties of printed parts, especially for irregular shapes. The method involves adaptive layer thickness and optimized internal structure. The layer thickness is adjusted based on the part's geometry to reduce step effect and minimize line width for upper/lower surfaces. The internal filling shape is customized to distribute stress evenly and prevent excessive local stress. This mitigates issues of excessive stress concentration and stress distribution differences in irregular shapes compared to uniform filling.

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Compensating 3D printed parts to more closely match the original CAD model due to deformations during printing. The method involves analyzing the original CAD model, identifying acute corners, and removing portions at those corners to create a compensated model. This compensated model is then printed using additive manufacturing. Due to the deformations that occur during printing, the final printed part will be more similar to the original CAD model than the compensated model.

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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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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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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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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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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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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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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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Improving the capability to modulate or control thermal conditions in additive manufacturing by application of in-process temperature measurement and application of forced convective cooling using jet devices. The cooling gas jets cool the metal during solidification to refine the grain structure and prevent columnar growth. This produces metal parts with finer, equiaxed grains and more consistent microstructure.

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Calibration method for a coating unit of an additive manufacturing device using a detection device. The calibration improves layer application and component quality in 3D printing by ensuring the coating unit elements properly spaced apart. The method involves moving the coating unit across the build area while a detection device measures the relative positions of the unit elements. The device detects position values with respect to a reference point. These values are used to determine if the unit elements are properly aligned. If not, they can be adjusted to ensure correct alignment before printing.

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A method of making 3D printed titanium orthopedic implants with customized porous structures that promote bone ingrowth for better fixation. The method involves creating a digital porous model by editing scanned images of artificial foams, optimizing the strut thickness and pore diameter, assembling the digital models into large blocks, and overlaying the blocks onto the implant substrate. The calibrated digital model is then 3D printed using technologies like Direct Metal Laser Sintering (DMLS).

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Multi-axis 3D printer and printing method that allows for high-precision printing of complex parts with variable cross-sections. The printer has a multi-axis motion platform connected to a material extrusion device. The control system extracts cross-sectional data from the 3D model and generates motion commands for the platform based on that data. This enables coordinated movement between the extruder and platform to print lines with adjustable widths and heights, avoiding issues like step errors and missing features. The variable cross-sections improve printing quality for complex shapes.

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Method to align the melting beam source in an additive manufacturing (AM) system to improve the quality of additively manufactured parts. The method involves building a test article using the AM system, measuring its dimensions, and adjusting the melting beam source alignment if they are not within tolerance compared to target specifications.

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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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An integrated robotic 3D printing system for automated manufacturing of high-performance continuous fiber reinforced parts. The system uses a robotic arm with a specialized nozzle assembly that can extrude composite materials made of continuous fiber reinforcement encased in a polymer matrix. The nozzle allows controlled deposition of the composite material while minimizing tension on the fiber. The robotic arm and print bed provide the necessary degrees of freedom for layer-by-layer additive manufacturing of complex parts with tailored fiber orientations. This enables automated production of high-strength fiber reinforced parts with optimized microstructure and performance compared to conventional 3D printing.

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Compensating for laser alignment errors in additive manufacturing machines to improve build quality and accuracy. The method involves measuring the differences in laser alignment between the calibration surface and the actual build surface, determining an offset that incorporates parallax errors based on the differences, and providing the offset to a calibration table to account for variations in powder bed position and flatness.

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A 3D printing system that uses multiple energy beams to improve the surface finish of 3D printed articles. The system has a printer with a motorized build plate, a powder coater, and multiple energy beam units. The beams scan over different regions of the build plate that overlap. This allows smoother transitions between beams compared to using a single beam. The overlapping regions reduce surface artifacts caused by switching beams. The system also offsets the layers slightly in the Y-axis to further smooth transitions.

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Improving the quality and reliability of additive manufacturing builds using techniques like laser powder bed fusion. It involves a recoater blade replacement system that replaces the recoater blade during the build process when it degrades. This allows continuous recoating of powder without issues like clumping as the blade wears, improving build quality and reducing failures. The recoater blade is replaced by a reel system while the build is in progress, preventing problems caused by blade wear.

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A nanomanufacturing method for producing 3D structures with precise control over composition and structure across six orders of magnitude in length scale. The key idea is to form product layers at the interface between a precursor layer and a support layer using directed self-assembly and 3D printing. The precursor layer is a liquid containing building block materials like nanocrystals that can assemble into a desired structure. Energy like light is applied to initiate the formation of a product layer from the precursor. The formed product layer is then separated from the remaining precursor to leave behind the printed structure. This process can be repeated to build up a complete 3D object.

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An improved method to produce titanium alloy powder optimized for 3D printing. The method involves gradually reducing gas atomization pressure and increasing feeding speed of the titanium alloy electrode while atomizing the metal. This hierarchical control reduces collision probability between droplets, improving surface quality, while maintaining fine powder yield.

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Calibration method for additive manufacturing systems. The method uses a removable calibration plate with laser-etched markings that can be imaged with an external camera. The plate has reference markings with known coordinates and test markings. The plate is initially imaged in a fixed camera setup to determine the reference marking locations. Then, when calibration is needed, it is placed in the additive manufacturing system and imaged again. By comparing the reference and test marking locations, aiming corrections can be calculated for the additive manufacturing system's laser.

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Additive manufacturing device and method for improving transparency of 3D printed objects. The device uses a light scattering member between the light source and the build surface to scatter the light and blur pixel boundaries. This reduces protrusions and depressions on the printed object surface, improving transparency and resolution compared to using unscattered light.

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Automated evaluation of the quality of 3D printed parts during the printing process that enables optimizing printing parameters in real-time to improve the density and reduce defects. The method involves: acquiring 3D surface data of the printed object, calculating 3D surface texture parameters from the 3D data, and evaluating object quality using the parameters. Parameters like autocorrelation length, hill/dale areas/volumes, and void volumes are calculated and correlated to density. By monitoring

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An improved 3D printer system that uses a heated auger screw to deliver powder material to the build platform. The auger screw is heated to pre-heat the powder as it is moved from the storage unit to the build platform. This improves the performance of the 3D printer by allowing the powder to be pre-heated before printing, preventing cooling and solidification issues that can occur when cold powder is exposed to the high temperature energy source that fuses the printed layers.

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Performing in-process non-destructive testing of 3D printed objects to verify print accuracy and quality. The testing involves analyzing sensor data obtained during printing to confirm that print parameters were met. By comparing pre- and post-layer sensor measurements, the system can detect defects, verify filament placement, and check infill density and shell thickness. Differential analysis of sensor data between prints can reveal deviations from known good parts and build models to predict print accuracy.

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3D printing with multiple fluids to improve print quality and prevent degradation of printed objects. 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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3D printing system that uses UV light to rapidly cure the binder and evaporate the solvent in each layer of a 3D printed object made from metal powder. This allows precise control over curing and solvent removal to improve accuracy and mechanical properties.

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Micro-nano 3D printing device with multi-nozzles jet deposition driven by electric field of 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. This avoids electric field crosstalk. The flat plate electrode generates an electric field to propel neutral droplets from each nozzle.

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A 3D printer with selectable modes that allow the user to customize the printer's performance for different applications. The printer has multiple predetermined modes that define acceptable ranges of output tolerances for properties like color and mechanical characteristics. The user can select a mode that matches the requirements of a specific print job, and the printer will modulate its internal operations and alter the output properties to meet the defined tolerances for that mode.

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Improving resolution and reducing stair-stepping errors in additive manufacturing using pixel-based stereolithography. The method uses a rotating projector to align pixel edges with layer edges, reducing errors where pixels protrude past intended borders. The projector is rotated at each layer to orient the pixel grid to match the layer shape. This reduces stair-stepping errors caused by fixed pixel grids that don't align exactly with layer edges.

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A 3D printer that can accurately print sharp corners and features by moving the printhead and platform at a constant velocity when forming the feature. This avoids the deceleration and acceleration that would occur when changing direction at the feature edges.

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Detecting 3D printer errors and calibration issues by analyzing printed objects. The method involves obtaining measurement data of a 3D printed object. Processing the data to identify printing anomalies, errors, and calibration issues. Then generating instructions to adjust the 3D printer to address those issues.

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Three-dimensional shaping device with improved accuracy and reliability for additive manufacturing. It uses a weight measuring unit to monitor material deposition from the extruder. The control system compares the measured weight to the expected weight to verify the correct amount was extruded. If needed, it adjusts the extruder to ensure accurate material deposition for each layer of the 3D print. This prevents issues like gaps or overextrusion. The weight measurement can be done in the build area or on a separate table.

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Liquid fabrication composition optimized for binder jet 3D printing of metal objects with high accuracy and strength. The liquid has specific properties that reduce oozing and increase dischargeability when applied to a powder bed. It has a high powder contact angle (>50 degrees) to prevent spreading. The ratio of surface tension times cosine of the contact angle to viscosity (γcosθ/η) is limited to 1.5 m/s.

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An improved powder-layer 3D printing process that enables fine powders to be used while improving powder deposition uniformity and reducing powder pluming. The improvements involve using specialized recoaters, supply hoppers, and dust collection systems. The recoaters use ultrasonic vibrations to pelletize the powder during dispensing, reducing pluming. The hoppers use vibration to discharge powder uniformly. The dust collection systems capture airborne particles.

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Calibrating 3D printer nozzles for accurate additive manufacturing when print heads are swapped mid-print. The calibration process uses an inductive sensor to locate the nozzle tip center. This data, along with factory measurements of the nozzle inner diameter center, enables compensation of toolpaths to account for variations in nozzle geometry.

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Three-dimensional shaping device to improve temperature control for accurate shaping of 3D printed objects. The device uses temperature sensors to measure the temperature of the material during shaping. It then adjusts the temperature of subsequent layers based on the actual measured temperature of the previous layer. This compensates for variations in heat dissipation and material properties between layers. The device also measures temperature at an inner region of each layer to avoid cooling effects at the outer edge.

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Creating better multi-material, large size additive manufactured parts with high quality, speed, accuracy and cost efficiency. It involves combining multiple additive manufacturing processes to optimize different properties in different parts of a larger object. The idea is to use different additive manufacturing processes to construct portions of the object that are optimized for their specific requirements. These portions are then attached together to form the final multi-material object.

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A method to detect deviations in material properties of 3D printed parts without damaging them, and using the detected deviations to optimize the printing process. The method involves adding a unique structure inside the part where the material properties can be controlled. Ultrasound scanning is then used to detect any deviations in the unique structure's properties compared to the target properties. These deviations provide an indication of overall property deviations in the rest of the part. The detection results are fed back to the 3D printing process to optimize it.

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Real-time inspection system for detecting surface imperfections on parts during additive manufacturing. The system uses uniform chromatic illumination and imaging to highlight imperfections that would otherwise be camouflaged. One or more illumination sources produce uniform monochromatic light that can't match the part color. Feedback cameras analyze the reflected light to detect imperfections. The illumination sources are adjusted to homogenize the reflected light except for imperfections. If the target area looks uniform, imperfections are hidden.

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