System and method for additive manufacturing
Inventors
Assignees
Publication Number
US-12319004-B2
Publication Date
2025-06-03
Expiration Date
2041-08-24
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Abstract
A system for additive manufacturing includes a multi-material vat that includes a plurality of resins. The system also includes a robotic arm that provides at least six degrees of freedom of motion, where the robotic arm moves with the six degrees of freedom to draw resin out of the multi-material vat to form an object. The system further comprises a processor operatively coupled to the robotic arm and configured to control movement of the robotic arm in the six degrees of freedom.
Core Innovation
The invention describes a system for additive manufacturing that combines a multi-material vat containing multiple resins, a robotic arm with at least six degrees of freedom (DOF), and a processor configured to control the arm and execute a dynamic conformal slicing (DCS) algorithm. The robotic arm operates with six DOF to draw resin from the vat and form objects, enabling the construction of complex geometries and structures with multiple material regions. The processor coordinates the motion and slicing operations needed to create the object from digital designs stored in memory.
The core problem addressed is the limitation of traditional three-dimensional (3D) printing systems that use unidirectional, planar-layer approaches constrained to 1-DOF or 3-DOF Cartesian motion. These limitations hinder the fabrication of complex geometries, multi-material integration, and customized structures such as conformal biomedical devices. The described system overcomes these barriers by introducing full 6-DOF manipulation of individual build layers, motorized stage control for resin selection, solvent rinsing to prevent material contamination, and continuous or modular strategies to enhance manufacturability and material efficiency.
The invention further introduces the DCS algorithm, which discretizes 3D surface models into a series of slicing layers with minimized cross-sectional area by varying the surface normal angles. Each layer can be individually represented, transformed, and approximated (for example, as an ellipse parameterized by dimensions along principal axes and in-plane rotation), and the DCS process enables conformal mapping and customized builds. The modular and curvilinear approach described facilitates the realization of objects such as multi-material soft robotic actuators and patient-specific vascular scaffolds, providing new possibilities for additive manufacturing technologies.
Claims Coverage
The patent contains three independent claims outlining novel features in system structure and method for additive manufacturing, as well as specific algorithmic approaches for slicing and object formation.
Additive manufacturing system with multi-material vat and six-degree-of-freedom robotic arm
The system comprises: - A multi-material vat containing a plurality of resins. - A robotic arm that provides at least six degrees of freedom of motion, used to draw resin from the vat to form objects. - A processor operatively coupled to the robotic arm, configured to control its movement in six degrees of freedom. - The processor executes a dynamic conformal slicing (DCS) algorithm to form a conformal map of a surface model of the object. - The processor uses the DCS algorithm to discretize the surface model into slicing layers, minimizing the cross-section area of each slicing layer by varying angles of surface normal.
Method for additive manufacturing using six-degree-of-freedom robotic arm and dynamic conformal slicing algorithm
The method includes: - Storing a design of an object to be printed in memory. - Controlling, by a processor, the position of a multi-material vat containing a plurality of resins. - Controlling a robotic arm with at least six degrees of freedom to move and draw resin to form the object. - Executing a dynamic conformal slicing (DCS) algorithm by the processor to form a conformal map of a surface model of the object. - Using the DCS algorithm to discretize the surface model into slicing layers and minimize the cross-section area of each by adjusting the surface normal angle.
Additive manufacturing system with conformation vector-based slicing layer approximation
The system includes: - A multi-material vat with multiple resins. - A six-degree-of-freedom robotic arm that draws resin from the vat to form objects. - A processor configured to control the robotic arm and execute a DCS algorithm. - The DCS algorithm is further configured to approximate each slicing layer as a shape represented by a conformation vector (e.g., comprising dimensions along two principal axes and in-plane rotation).
The main claim coverage is directed to systems and methods enabling six-degree-of-freedom additive manufacturing from multiple resins via a robotic arm, utilizing dynamic conformal slicing algorithms that optimize the slicing process and support advanced geometric and material customization.
Stated Advantages
Allows construction of complex geometries and structures that are difficult or impossible with traditional unidirectional 3D printing processes.
Enables support-free fabrication, particularly for downfacing features, by locally pivoting the printing direction and utilizing curvilinear printing paths.
Facilitates efficient and high-quality multi-material integration within single objects, reducing time and contamination compared to conventional methods.
Enables on-the-fly digital transformation and customization of printed parts, supporting conformal geometry fabrication such as custom-fitted biomedical devices.
Improves manufacturing flexibility, efficiency, and quality by leveraging full six degrees of freedom in robotic arm movement and advanced slicing algorithms.
Reduces or eliminates the need for complex mathematical manipulations to alter and re-slice digital models during customizations or modular builds.
Documented Applications
Direct fabrication of customized biomedical devices, such as vascular scaffolds conforming to patient-specific anatomy.
Multi-axis, multi-material 3D printing of soft robotic actuators, including soft pneumatic gripping devices.
Manufacture of functional devices including energy storage, electronics, microfluidics, robotic manipulators, and prototypes for aircraft and automobiles.
Application in continuous and modular fabrication of structures with intricate freeform geometries that require sequential or heterogeneous material integration.
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