Granted Patent B2

US 12,605,896 · App. 17/943,177 · Granted Apr 21, 2026

Inventor: Walter McAllister (Blacksburg, VA)

Assignee: Skyphos Industries Inc.

B29C64/286B01L3/502707B29C64/129B29C64/232B29C64/245B29C64/393B33Y10/00B33Y30/00B33Y50/02B33Y80/00B01L2200/12B01L2300/0654B29L2031/756

Abstract

Claims (43)

1 . A three-dimensional (“3D”) printing system comprising:

a resin for curing and creating layers for a layer-by-layer 3D printing process;

a light source projector comprising a light source, the light source including a wide-spectrum light source, a multi-LED array, or both, wherein the light source projector is attached to a gantry;

one or more bandpass filters located between the light source projector and the resin;

the gantry, which is moveable towards and away from the resin in a Z plane, and which is moveable in an X-Y plane for printing patterned layers; and

wherein moving the light source towards and away from the resin along with moving the light source in the X-Y plane is configured to print different pixel sizes at different areas within a single layer of the layer-by-layer 3D printing process, such that a layer of the layers for the layer-by-layer 3D printing process is printed having different pixel sizes at different areas within the same layer.

2 . The three-dimensional (“3D”) printing system of claim 1 , further comprising a linear activation mechanism for controlling the gantry, wherein the linear activation mechanism comprises at least one of a lead-screw, a stepper-motor, one or more linear rail, a linear rail, a nano-stage, or a single axis stage.

3 . A three-dimensional (“3D”) printing apparatus comprising:

a build deck allowing for loading and unloading of a printing surface for 3D printing of an object or device;

one or more clip located on a lateral side of the build deck, wherein the one or more clip has a bend providing a shelf for the printing surface, wherein the printing surface is secured in place between an upper surface of the one or more clip and a lower surface of the build deck, wherein the one or more clip has a thickness ranging from 0.15 mm to 0.5 mm;

one or more spring for at least one of spring-activated locating of the printing surface, allowing for a repeatable location of the printing surface, spring-activated leveling of the build deck, spring-activated locking of the printing surface and the build deck, or spring-activated removal of the object or the device being 3D printed without having to remove the build deck; and

one or more gantry located between an elevator and the build deck, wherein the one or more gantry has at least one axis of motion.

4 . The three-dimensional (“3D”) printing apparatus of claim 3 , wherein the 3D printing apparatus prints the object or the device within a range of resolution between 0.2 um and 50 um.

5 . A method of projector autofocus in three-dimensional printing providing for multiple pixel pitch and multiple mosaic layering, the method comprising:

providing a projector comprising a projector lens, wherein the projector is attached to one or more Z axis gantry;

automatically focusing of the projector lens for pixels between 0.1 um and 100 um;

providing at least one of a stepper motor or a servo motor that interfaces with the one or more Z axis gantry;

providing at least one of a bevel, a spur gears, set of screws, a hollow screw-set or a belt, or a linear activator, to activate the automatically focusing of the projector lens;

using a linear rail to adjust a zoom of the projector lens;

moving the projector as oriented relative to a vat window or a resin surface within a range between a first position wherein the projector lens is in contact with the bottom of the vat window or the resin surface and a second position 1 meter lower relative to the vat window or resin surface; and

allowing for adjusting a position of the projector lens during operation of a three-dimensional printing process.

6 . The method of claim 5 , further comprising providing a computer processing unit, wherein the computer processing unit controls the location of the projector as oriented relative to the vat window or the resin surface within the range from the first position to the second position.

7 . A shutter for a three-dimensional (“3D”) printing apparatus, the 3D printing apparatus comprising the shutter, at least one filter, and a light source;

wherein the shutter is located within the 3D printing apparatus, wherein the shutter is positionable between two or more positions, wherein the shutter is distance separated from the light source and operatively engaged with the at least one filter, and wherein the shutter is located between the light source and a polymerization vat;

wherein a first position of the two or more positions of the shutter applies a filter of the at least one filter to the light source;

wherein a second position of the two or more positions of the shutter applies a second filter of the at least one filter to the light source, or wherein the second position blocks the light source or allows light from the light source to freely pass; and

wherein the shutter uses a first shutter position for a first exposure and uses a second shutter position for a second exposure, wherein the second exposure can be at least one of, the same as the first exposure, different than the first exposure, or polymerize the same or similar pixels or voxels as the first exposure.

8 . A shutter for a three-dimensional (“3D”) printing apparatus comprising at least one filter and a light source from a projector;

wherein the shutter is located within the 3D printing apparatus, wherein the shutter has two or more positions, wherein the shutter is separate from the at least one filter and the light source, and wherein the shutter is positioned between the light source and a vat;

wherein a first position of the two or more positions applies a filter to the light source;

wherein a second position of the two or more positions applies a second filter to the light source, or wherein the second position blocks the light source or allows light from the light source to freely pass;

wherein the shutter uses a first shutter position for a first exposure and uses a second shutter position for a second exposure, wherein the second exposure can be one of the same as the first exposure, different than the first exposure, or polymerize the same or similar pixels or voxels as the first exposure; and

wherein a first position of the two or more positions apply a first filter during a first layer of 3D printing and a second position of the two or more positions applies a second filter during a second layer of 3D printing.

9 . The shutter for a three-dimensional (“3D”) printing apparatus of claim 7 , wherein two positions of the two or more positions use two different filters for a same layer.

10 . A shutter for a three-dimensional (“3D”) printing apparatus comprising at least one filter and a light source from a projector;

wherein the shutter is located within the 3D printing apparatus, wherein the shutter has two or more positions, wherein the shutter is separate from the at least one filter and the light source, and wherein the shutter is positioned between the light source and a vat;

wherein a first position of the two or more positions applies a filter to the light source;

wherein a second position of the two or more positions applies a second filter to the light source, or wherein the second position blocks the light source or allows light from the light source to freely pass;

wherein the shutter uses a first shutter position for a first exposure and uses a second shutter position for a second exposure, wherein the second exposure can be one of the same as the first exposure, different than the first exposure, or polymerize the same or similar pixels or voxels as the first exposure; and

wherein changing between the at least two or more positions causes a change in a surface roughness of an internal cavity of an object being 3D printed.

11 . The shutter for a three-dimensional (“3D”) printing apparatus of claim 7 , further comprising a computer processor having a computer-aided design (“CAD”) drawing setting, resin profile, or slicing setting, including a texture or roughness level, which selects the texture or roughness level and applies the texture or roughness level to internal surfaces of an object being 3D printed.

12 . The shutter for a three-dimensional (“3D”) printing apparatus of claim 7 , wherein the shutter is servo-controlled.

13 . The shutter for a three-dimensional (“3D”) printing apparatus of claim 7 , wherein the at least one filter comprises at least one of colored glass, a bandpass filter, or an optical filter.

Assignments (1)

Continuity (3)

References Cited (66)