Three-dimensional printing system with integrated scan module calibration

The method of claim 1 wherein the reflective feature includes an array of reflective features having generally known locations corresponding to the build plane, the method includes correlating operation of the scan module with build plane locations.

The method of claim 1 wherein the reflective feature is formed upon an upper surface of the transparent plate, during operation of the laser module and the scan module light reflects from the transparent feature to the sensor without passing through the transparent plate.

The method of claim 3 wherein analyzing the signal includes a measurement of the trajectory of the light beam during scanning.

The method of claim 1 wherein the reflective feature is disposed upon a lower surface of the transparent plate, during operation of the laser module and the scan module light passes through the transparent plate, is reflected by the reflective feature, and then passes a second time through the transparent plate.

The method of claim 5 wherein analyzing the signal includes a measurement of the power level of the light during scanning.

The method of claim 1 wherein the reflective feature is a dot having an axial dimension, the light beam impinging on the transparent plate with an impinging diameter that is at least ten times the axial dimension of the dot.

The method of claim 1 wherein the 3D printing system includes a resin vessel configured to contain photocurable resin and a motorized build platform, the method including operating the laser module, the scan module, and the motorized build platform to manufacture the 3D article.

The method of claim 8 wherein during operation of the laser module, the scan module, and the motorized build platform to manufacture the 3D article the transparent plate provides a dual function of blocking vapors to protect the scan module and to provide the reflective feature for analyzing the signal.

The method of claim 8 further including estimating a power level attenuation effect of a resin film that has accumulated on a lower side of the transparent plate based upon the power level of the light beam received by the sensor.

The method of claim 10 further comprising adjusting an energy level delivered by the laser module in response to estimating the power level attenuation effect of the resin film.

The method of claim 10 further comprising sending an alert or message to a user interface when the power level attenuation reaches a threshold level.

The method of claim 13 wherein the reflective feature is formed upon an upper surface of the transparent plate, during operation of the laser module and the scan module light reflects from the transparent feature to the sensor without passing through the transparent plate.

The method of claim 14 wherein analyzing the signal includes aligning the scan module to the build plane.

The method of claim 13 wherein the reflective feature is disposed upon a lower surface of the transparent plate, during operation of the laser module and the scan module light passes through the transparent plate, is reflected by the reflective feature, and then passes a second time through the transparent plate.

The method of claim 16 wherein analyzing the signal includes estimating an attenuation of light passing through the transparent plate and to the build plane.

The method of claim 17 further comprising adjusting an energy level delivered by the laser module in response to estimating the attenuation.

The method of claim 17 further comprising sending an alert or message to a user interface when an estimated attenuation exceeds a predetermined threshold.

The method of claim 13 wherein analyzing the signal includes both of (1) aligning scan module to the build plane and (2) estimating an attenuation of light passing through the transparent plate and to the build plane.