A method of printing one or more three-dimensional objects comprises: providing a volume of a photopolymerizable liquid in a closed container including an entry port and an exit port, the entry port and the exit port being connected by a channel therebetween, the container including at least one printing zone comprising at least an optically transparent window to facilitate irradiating excitation light at a first wavelength into a printing zone through the at least an optically transparent window, wherein the photopolymerizable liquid displays non-Newtonian rheological behavior such that the object formed in the photopolymerizable liquid within the printing zone remains at a fixed position or is minimally displaced in the unpolymerized photopolymerizable liquid during formation, directing the excitation light through the at least an optically transparent window into the printing zone to selectively photopolymerize the photopolymerizable liquid in the printing zone without support structures to form a printed object, wherein the printed object remains at a fixed position or is minimally displaced in the unpolymerized photopolymerizable liquid during formation, and applying pressure to the contents of the closed container and/or pumping additional photopolymerizable liquid into the closed container through the entry port to at least transport the printed object out of the printing zone toward the exit port, thereby discharging at least a portion of contents of the closed container out of the closed container through the exit port. Systems for printing one or more three-dimensional objects are also disclosed.

A method for manufacturing an object, in particular an orthodontic appliance, by a 3D-printing device comprising a supply device for provision of a non-solidified material and means for illumination to solidify a layer of non-solidified material provided by the supply device at least zonally to fabricate the object, characterized by the following steps: a virtual model of the object to be printed is provided for the 3D-printing device, the supply device provides a layer of the non-solidified material, the means for illumination solidify the layer at least zonally, whereby the means for illumination comprises illumination pixels arranged in a grid, preferably with a dimension (between 10 μm and 80 μm, particularly preferred between 30 μm and 50 μm, wherein at least one dimension of the object represented by the virtual model is chosen to be aligned with the dimension of the illumination pixels.

A method for manufacturing an object, in particular an orthodontic appliance, by a 3D-printing device comprising a supply device for provision of a non-solidified material and means for illumination to solidify a layer of non-solidified material provided by the supply device at least zonally to fabricate the object, characterized by the following steps: a virtual model of the object to be printed is provided for the 3D-printing device, the supply device provides a layer of the non-solidified material, the means for illumination solidify the layer at least zonally, whereby the means for illumination comprises illumination pixels arranged in a grid, preferably with a dimension (between 10 μm and 80 μm, particularly preferred between 30 μm and 50 μm, wherein at least one dimension of the object represented by the virtual model is chosen to be aligned with the dimension of the illumination pixels.

A method of fabricating a three-dimensional (3D) object includes atomizing a pre-polymer composition into an aerosol jet stream. The pre-polymer composition includes an epoxy precursor and a photoacid generator. The method further includes depositing the aerosol jet stream onto a substrate to form a first layer of dielectric ink and curing the first layer of dielectric ink using ultraviolet (UV) light. The method further includes depositing the aerosol jet stream onto the first layer of dielectric ink to form a second layer of dielectric ink. The first layer of dielectric ink and the second layer of dielectric ink overlap by at least 50%.

A method of fabricating a three-dimensional (3D) object includes atomizing a pre-polymer composition into an aerosol jet stream. The pre-polymer composition includes an epoxy precursor and a photoacid generator. The method further includes depositing the aerosol jet stream onto a substrate to form a first layer of dielectric ink and curing the first layer of dielectric ink using ultraviolet (UV) light. The method further includes depositing the aerosol jet stream onto the first layer of dielectric ink to form a second layer of dielectric ink. The first layer of dielectric ink and the second layer of dielectric ink overlap by at least 50%.

Systems, apparatuses, and methods are described for 3D printing using a stationary build platform. Resin (e.g., a photopolymer) may be dosed into a vat in volumes required to create one layer at a time. An image projector may cure the top-most layer of the resin in the vat to create one layer at a time to fabricate a three-dimensional (3D) object from the bottom up, right side up, and/or layer-by-layer over the build plate.

Systems, apparatuses, and methods are described for 3D printing using a stationary build platform. Resin (e.g., a photopolymer) may be dosed into a vat in volumes required to create one layer at a time. An image projector may cure the top-most layer of the resin in the vat to create one layer at a time to fabricate a three-dimensional (3D) object from the bottom up, right side up, and/or layer-by-layer over the build plate.

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 UV curing light 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.

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 UV curing light 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.

A method of manufacturing a component includes additively manufacturing (AM) a plurality of interior layers of the component and AM at least one anti-bump, squeak, rattle (BSR) layer of the component such that the at least one anti-BSR layer reduces BSR acoustic noise compared to the plurality of interior layers. The at least one anti-BSR layer can be a plurality of anti-BSR layers and the plurality of anti-BSR layers includes a BSR property that is different than a corresponding BSR property of the plurality of interior layers.