# US 11,440,257 B2 · Three-dimensional printing apparatus using DLP projector with laser scanner

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 11,440,257 B2
- Document ID: US11440257B2
- Status: Granted
- Kind: B2
- Application number: 16/497,621
- Filed: 2017-04-14
- Published: 2021-04-15
- Granted: 2022-09-13
- Earliest claimed: 2017-04-06
- Assignees: Hyvision System Inc.
- Applicants: Hyvision System Inc.
- Inventors: Doo Won Choi; Jun Seok Seo
- Web page: https://patentgrep.com/patent/US11440257B2

## CPC

- B29C 64/268: using laser beams; using electron beams [EB]
- B23K 26/0006: {taking account of the properties of the material involved (B23K26/32, B23K26/40 take precedence)}
- B23K 26/032: {using optical means}
- B23K 26/046: Automatically focusing the laser beam
- B23K 26/0821: {using multifaceted mirrors, e.g. polygonal mirror}
- B23K 26/0869: {Devices involving movement of the laser head in at least one axial direction}
- B23K 26/342: Build-up welding
- B29C 64/129: characterised by the energy source therefor, e.g. by global irradiation combined with a mask
- B29C 64/135: the energy source being concentrated, e.g. scanning lasers or focused light sources
- B29C 64/20: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C 64/393: for controlling or regulating additive manufacturing processes
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- G01B 11/24: for measuring contours or curvatures
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- B23K 26/082: Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
- B23K 26/083: {Devices involving movement of the workpiece in at least one axial direction}
- B23K 2103/42: {Plastics other than composite materials}
- B29C 64/277: using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
- B29C 64/282: of the same type, e.g. using different energy levels
- B29C 64/286: Optical filters, e.g. masks
- Y02P 10/25: Process efficiency
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- G01B: MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

The present invention relates to a three-dimensional printing apparatus using a digital light processing (DLP) projector with a laser scanner, the apparatus comprising: a resin storage unit storing a photocurable resin; a DLP projector unit projecting light to the resin storage unit; a molding stage unit provided to be capable of being lifted and lowered in a vertical direction from a bottom of the resin storage unit; a laser scanner unit performing scanning of light for the resin storage unit; a scanner transfer unit allowing the laser scanner unit to move in an x-axis direction; an image processing unit dividing one sectional image of a sculpture into a core portion and a shell portion; and a controller receiving data on the core portion and the shell portion from the image processing unit, controlling the DLP projector, the laser scanner unit, the scanner transfer unit, and the molding stage unit.

## Claims

### Claim 1

A three-dimensional printing apparatus using a digital light processing (DLP) projector with a laser scanner, the apparatus comprising:
a resin storage unit storing a photocurable resin;
a DLP projector unit disposed above the resin storage unit and projecting light corresponding to a core portion of an axial cross section of a sculpture to the resin storage unit;
a molding stage unit provided to be capable of being lifted and lowered in a vertical direction from a bottom of the resin storage unit, wherein the sculpture is formed on an upper side portion thereof;
a laser scanner unit disposed above the resin storage unit and performing scanning of light corresponding to a shell portion of the axial cross section of the sculpture for the resin storage unit in a y-axis direction;
a scanner transfer unit supporting and transporting the laser scanner unit, thereby allowing the laser scanner unit to move in an x-axis direction;
an image processing unit dividing one sectional image of the sculpture into the core portion and the shell portion; and
a controller receiving data on the core portion from the image processing unit, thereby outputting the data on the core portion to the DLP projector unit, receiving data on the shell portion from the image processing unit, on the basis of the data on the shell portion input thereto, controlling the laser scanner unit and the scanner transfer unit, and lifting and lowering the molding stage unit on the basis of data of the sculpture,
wherein the image processing unit sets an overlap portion so that the shell portion and the core portion are slightly overlapped at an interface thereof, and
wherein the data on the shell portion is obtained by adding the shell portion and the overlap portion, and the data on the core portion is obtained by adding the core portion and the overlap portion.

### Claim 2 (depends on 1)

The three-dimensional printing apparatus of claim 1, wherein the laser scanner unit is a galvano mirror scanner.

### Claim 3 (depends on 1)

The three-dimensional printing apparatus of claim 1, wherein the laser scanner unit is a polygon mirror scanner.

### Claim 4 (depends on 1)

The three-dimensional printing apparatus of claim 1, wherein the laser scanner unit is a micro-electro-mechanical systems (MEMS) mirror scanner.

### Claim 5 (depends on 1)

The three-dimensional printing apparatus of claim 1, wherein the DLP projector unit includes,
a high output UV LED radiating light;
a mirror reflecting the light radiated from the high output UV LED;
a lens projecting the light reflected from the mirror toward the upper portion of the resin storage unit; and
a projector housing accommodating the high output UV LED, the mirror, and the lens.

### Claim 6 (depends on 1)

The three-dimensional printing apparatus of claim 1, wherein the image processing unit adjusts a size of the core portion to include an area overlapping the shell portion by a predetermined thickness along an outline of the core portion.