# US 11,897,196 B2 · Multiple image projection system and method for additive manufacturing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,897,196 B2 - Document ID: US11897196B2 - Status: Granted - Kind: B2 - Application number: 17/661,856 - Filed: 2022-05-03 - Published: 2022-08-18 - Granted: 2024-02-13 - Earliest claimed: 2018-07-30 - Assignees: Intrepid Automation - Applicants: Intrepid Automation - Inventors: Ben Wynne; Jamie Lynn Etcheson; Christopher Sean Tanner; Robert Lee Mueller; Ivan Dejesus Chousal - Web page: https://patentgrep.com/patent/US11897196B2 ## CPC - B29C 64/268: using laser beams; using electron beams [EB] - 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 64/277: using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] - B29C 64/291: for operating globally, e.g. together with selectively applied activators or inhibitors - 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 - Y02P 30/20: using bio-feedstock - 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) - 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 - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract 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 set 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, and 3) a warp correction filter that provides geometric correction. ## Claims ### Claim 1 A method comprising: controlling an image projection system of an additive manufacturing system using an image display subsystem, wherein the image projection system comprises a plurality of image projectors; projecting a composite image onto a build area within a resin pool of the additive manufacturing system using the image projection system, wherein the composite image comprises a plurality of sub-images arranged in an array, and wherein the projecting the composite image comprises projecting each sub-image onto a portion of the build area using one of the plurality of image projectors; and adjusting properties and aligning a position of each sub-image in the array using a set of filters comprising: an irradiance mask that normalizes irradiance; a gamma adjustment mask that adjusts sub-image energy based on a reactivity of resin in the resin pool; and a warp correction filter that provides geometric correction. ### Claim 2 (depends on 1) The method of claim 1, wherein the image display subsystem controls the image projection system and each of the image projectors using digital light processing. ### Claim 3 (depends on 1) The method of claim 1, wherein the irradiance mask additionally adjusts the sub-image energy across the build area to compensate for non-uniformities in optics of the plurality of image projectors. ### Claim 4 (depends on 1) The method of claim 1, wherein the gamma adjustment mask comprises a logarithmic relationship between a cure depth of the resin and the sub-image energy per unit area in the build area. ### Claim 5 (depends on 1) The method of claim 1, wherein the resin is selected from acrylates, epoxies, methacrylates, urethanes, silicone, vinyls, and combinations thereof. ### Claim 6 (depends on 1) The method of claim 1, wherein two or more adjacent sub-images in the array overlap, and wherein the set of filters further comprises an edge blending bar. ### Claim 7 (depends on 6) The method of claim 6, wherein the edge blending bar comprises a blending distance and a function selected from linear, sigmoid and geometric. ### Claim 8 (depends on 6) The method of claim 6, wherein the edge blending bar adjusts one or more sub-image edges based on at least one layer boundary location within an object being manufactured. ### Claim 9 (depends on 1) The method of claim 1, further comprising a system controller that synchronizes exposure control of the plurality of image projectors with each other. ### Claim 10 (depends on 1) The method of claim 1, wherein the adjusting properties and aligning the position of each sub-image in the array further comprises applying the irradiance mask to each sub-image such that the composite image has a uniform irradiance range across the composite image. ### Claim 11 (depends on 1) The method of claim 1, wherein the adjusting properties and aligning the position of each sub-image in the array further comprises applying the irradiance mask to each sub-image to normalize irradiance non-uniformities within the image projection system arising from a projector-based spatial energy non-uniformity. ### Claim 12 An additive manufacturing system, comprising: an image projection system comprising a plurality of image projectors that project a composite image onto a build area within a resin pool, wherein each of the image projectors projects a sub-image onto a portion of the build area, wherein the composite image comprises a plurality of sub-images arranged in an array; a display subsystem, wherein the display subsystem controls the image projection system and each of the image projectors to adjust properties and alignment of a position of each sub-image in the array; and a set of filters configured to adjust the properties of each sub-image in the array, the set of filters comprising: an irradiance mask that normalizes irradiance; a gamma adjustment mask that adjusts sub-image energy based on a reactivity of resin in the resin pool; a warp correction filter that provides geometric correction. ### Claim 13 (depends on 12) The additive manufacturing system of claim 12, wherein the irradiance mask additionally adjusts the sub-image energy across the build area to compensate for non- uniformities in optics of the plurality of image projectors. ### Claim 14 (depends on 12) The additive manufacturing system of claim 12, wherein the gamma adjustment mask is configured to adjust the sub-image energy by mapping a plurality of pixel intensity levels to an addressable range of reactivity for curing the resin, thereby reducing aliasing artifacts of curved or smooth surfaces, and wherein the plurality of pixel intensity levels comprises levels from 0 to 255. ### Claim 15 (depends on 12) The additive manufacturing system of claim 12, wherein the gamma adjustment mask further comprises a transfer function that maps an operating energy range of a printed layer to a control system operating range, wherein the control system operating range is a quantized set of values. ### Claim 16 (depends on 12) The additive manufacturing system of claim 12, wherein the gamma adjustment mask comprises a logarithmic relationship between a cure depth of the resin and the sub-image energy per unit area in the build area. ### Claim 17 (depends on 12) The additive manufacturing system of claim 12, further comprising the resin pool, wherein the resin of the resin pool is selected from a group consisting of acrylates, epoxies, methacrylates, urethanes, silicone, vinyls, and combinations thereof. ### Claim 18 (depends on 12) The additive manufacturing system of claim 12, wherein the warp correction filter corrects skew in projected images that are caused by variation in alignment within the build area. ### Claim 19 (depends on 12) The additive manufacturing system of claim 12, wherein the warp correction filter corrects skew in projected images that are caused by variation in projector optics. ### Claim 20 (depends on 12) The additive manufacturing system of claim 12, wherein two or more adjacent sub-images in the array overlap, wherein the set of filters further comprises an edge blending bar, and wherein the edge blending bar comprises a blending distance and a function selected from a group consisting of linear, sigmoid and geometric.