An additive manufacturing fusing module for use with an additive manufacturing base unit may include a housing, a reflector within the housing, a fusing unit within the housing, an electrical power connector connected to the heating device and having a terminal for releasable connection to a power source and a retainer coupled to the housing to releasably secure the housing to the additive manufacturing base unit.

An additive manufacturing fusing module for use with an additive manufacturing base unit may include a housing, a reflector within the housing, a fusing unit within the housing, an electrical power connector connected to the heating device and having a terminal for releasable connection to a power source and a retainer coupled to the housing to releasably secure the housing to the additive manufacturing base unit.

An additive manufacturing system, and associated methods, comprise an image projection system comprising a plurality of image projectors that project a composite image onto a build area within a resin pool. The composite image comprises a plurality of sub-images arranged in an array. The properties of each sub-image and the alignment of the position of each sub image within the composite image can be adjusted using a stack of filters comprising: 1) an irradiance mask that normalizes irradiance, 2) a gamma adjustment mask that adjusts sub-image energy based on a reactivity of the resin, 3) a warp correction filter that provides geometric correction, and 4) an edge blending bar at one or more sub-image edges.

An additive manufacturing system, and associated methods, comprise an image projection system comprising a plurality of image projectors that project a composite image onto a build area within a resin pool. The composite image comprises a plurality of sub-images arranged in an array. The properties of each sub-image and the alignment of the position of each sub image within the composite image can be adjusted using a stack of filters comprising: 1) an irradiance mask that normalizes irradiance, 2) a gamma adjustment mask that adjusts sub-image energy based on a reactivity of the resin, 3) a warp correction filter that provides geometric correction, and 4) an edge blending bar at one or more sub-image edges.

Methods and apparatus for the fabrication of solid three-dimensional objects from liquid polymerizable materials at high resolution. A material is coated on a film non-digitally, excess material is removed digitally, by laser, leaving an image of a layer to be printed, and the image is then engaged with existing portions of an object being fabricated and exposed to a non-digital heat source. Since the only part of the process that is digital is the material removal, and this part is done by laser, the speed of printing and the robustness of the manufacturing process is improved significantly over conventional additive or 3D fabrication techniques.

The present application relates to a linear light source using ultraviolet light emitting diodes (LEDs), and a photopolymer 3D printer comprising the linear light source. The linear light source may include a substrate distanced from a polymer case of the photopolymer 3D printer and an ultraviolet LED array in which a plurality of ultraviolet LEDs, which project ultraviolet rays toward the polymer case, are arranged on the substrate in multiple rows in the X-axis direction. The arrangement of the multiple columns in the Y-axis direction is at an oblique angle to the multiple rows.

A method and apparatus for forming a 3D article. According to the method, a composite filament material is formed from a UV curable material, a thermoset polymer material and at least one of filaments or fibers. After the composite is formed, the filament is dispensed to form the 3D article. Dispense is typically through a nozzle or other orifice that delivers the composite filament material as a bead of material. As the composite is dispensed, at least a portion of the composite material is exposed to UV radiation thereby curing a portion of the dispensed composite filament. The UV radiation is provided by a light source than can target discrete portions of the dispensed composite filament. For this purpose, the UV radiation source can be a light source integrated with the nozzle or a steered light source. As the composite filament is dispensed, UV radiation is directed onto the composite filament. If a steered light source is used, the composite filament is dispensed and light from the steered UV radiation source is directed to targeted regions of the composite filament, introducing cured zones or regions into the composite filament.

A method of making deflection members is disclosed. The deflection members are 3D objects that include cross-linkable polymers and are printed directly onto permeable materials utilizing at least two different printer settings.

A method of forming a three-dimensional object comprises the steps of forming a layer of a particulate composition, selectively depositing a liquid composition onto the layer of the particulate composition in accordance with computer data corresponding to the shape of at least a portion of a three-dimensional object, and repeating the steps a plurality of times to form a three-dimensional object. The particulate composition comprises a plurality of first particles that comprise a resin component comprising a first resin, the first resin comprising a first resin polymerizable group. Either or both of the particulate composition and the liquid composition comprise an initiator capable of initiating polymerization of at least the first resin. At least the first resin undergoes melting and polymerization in a plurality of the locations where the liquid composition has been selectively deposited.

A method of forming a three-dimensional object comprises the steps of forming a layer of a particulate composition, selectively depositing a liquid composition onto the layer of the particulate composition in accordance with computer data corresponding to the shape of at least a portion of a three-dimensional object, and repeating the steps a plurality of times to form a three-dimensional object. The particulate composition comprises a plurality of first particles that comprise a resin component comprising a first resin, the first resin comprising a first resin polymerizable group. Either or both of the particulate composition and the liquid composition comprise an initiator capable of initiating polymerization of at least the first resin. At least the first resin undergoes melting and polymerization in a plurality of the locations where the liquid composition has been selectively deposited.