A geometry model is defined of a part targeted for a manufacturing operation that includes an additive process followed by a subtractive process. Potential build orientations of the geometry model used in the additive processes are defined, as are one or more removal tools of the subtractive process. For each of the potential build orientations, supports that are used by the additive process at the orientation are determined. One of the build orientations is selected that minimizes portions of one of the supports that are inaccessible via at least one of the removal tools.

An additive manufacturing system has a light permeable base, a build carrier for holding a workpiece and a light source which is arranged to emit light through the light permeable base. The light permeable base and the build carrier are positionable relative to each other in a build dimension in which the workpiece is built up. The system further has a resin vat in which the light permeable base forms a wall portion thereof. The system further comprises a plurality of resin supplies for supplying different light hardenable resins in direct contact with each other in said vat. The system facilitates the rapid manufacturing of a dental restoration having a color gradation.

An additive manufacturing system has a light permeable base, a build carrier for holding a workpiece and a light source which is arranged to emit light through the light permeable base. The light permeable base and the build carrier are positionable relative to each other in a build dimension in which the workpiece is built up. The system further has a resin vat in which the light permeable base forms a wall portion thereof. The system further comprises a plurality of resin supplies for supplying different light hardenable resins in direct contact with each other in said vat. The system facilitates the rapid manufacturing of a dental restoration having a color gradation.

An additive manufacturing (AM) system includes a housing defining a chamber and a build platform disposed in a lower portion of the chamber. The AM system includes an upper gas inlet disposed in a side-wall and in an upper portion of the chamber and configured to supply an upper gas flow parallel to the build platform. The AM system includes a lower gas inlet in the lower portion of the chamber, wherein the lower gas inlet includes one or more pairs of dividing walls extending from the side-wall toward the build platform and configured to guide the lower gas flow at one or more flow angles with respect to the build platform. The AM system includes at least one gas delivery mechanisms to regulate flow characteristics of the upper and lower gas flows, and includes a gas outlet to discharge the upper and lower gas flows from the chamber.

An additive manufacturing (AM) system includes a housing defining a chamber and a build platform disposed in a lower portion of the chamber. The AM system includes an upper gas inlet disposed in a side-wall and in an upper portion of the chamber and configured to supply an upper gas flow parallel to the build platform. The AM system includes a lower gas inlet in the lower portion of the chamber, wherein the lower gas inlet includes one or more pairs of dividing walls extending from the side-wall toward the build platform and configured to guide the lower gas flow at one or more flow angles with respect to the build platform. The AM system includes at least one gas delivery mechanisms to regulate flow characteristics of the upper and lower gas flows, and includes a gas outlet to discharge the upper and lower gas flows from the chamber.

Methods and systems for 3D printing use a 3D printing device defined by a polar coordinate frame including an r-axis, a z-axis, and a rotational theta axis. The device includes a base, a rotatably attached printing stage is rotatably attached, a z-axis aligned pair of towers, an r-axis aligned rail slidably coupled to the towers, a print head slidably disposed on the rail, a printing tool coupling component (“master”) joined to the print head, and a rotatable tool carousel with bays housing printing tools, each including a printing tool body (“slave”). The slave may be coupled with and locked to or unlocked from the master to form a coupled tool assembly through a mechanical actuation assembly. With the coupled tool assembly, a printing tool is removable from a respective bay when the coupled tool assembly moves along the r-axis in a direction opposite from the rotatable tool carousel.

Methods and systems for 3D printing use a 3D printing device defined by a polar coordinate frame including an r-axis, a z-axis, and a rotational theta axis. The device includes a base, a rotatably attached printing stage is rotatably attached, a z-axis aligned pair of towers, an r-axis aligned rail slidably coupled to the towers, a print head slidably disposed on the rail, a printing tool coupling component (“master”) joined to the print head, and a rotatable tool carousel with bays housing printing tools, each including a printing tool body (“slave”). The slave may be coupled with and locked to or unlocked from the master to form a coupled tool assembly through a mechanical actuation assembly. With the coupled tool assembly, a printing tool is removable from a respective bay when the coupled tool assembly moves along the r-axis in a direction opposite from the rotatable tool carousel.

A three-dimensional object model is divided into slices that are targeted for an additive manufacturing process operable to deposit material at a variable deposition size ranging between minimum and maximum printable feature sizes. For each of the slices, a thinning algorithm is applied to contours of the slice to form a meso-skeleton. Topological features of the thinned slice are reduced over a number of passes such that a portion of the meso-skeleton is reduced to a single pixel wide line. Based on the number of passes, a slice-specific printable feature size within the range of the minimum and maximum printable feature sizes is determined. An adjusted slice is formed by sweeping the meso-skeleton with the slice-specific printable feature size. The adjusted slices are assembled into an object model which is used to create a manufactured object.

Four dimensional (4D) energy-field package assembly for projecting energy fields according to a 4D coordinate function. The 4D energy-field package assembly includes an energy-source system having energy sources capable of providing energy to energy locations, and energy waveguides for directing energy from the energy locations from one side of the energy waveguide to another side of the energy waveguide along energy propagation paths.

Four dimensional (4D) energy-field package assembly for projecting energy fields according to a 4D coordinate function. The 4D energy-field package assembly includes an energy-source system having energy sources capable of providing energy to energy locations, and energy waveguides for directing energy from the energy locations from one side of the energy waveguide to another side of the energy waveguide along energy propagation paths.