US 11,897,196 B2
Multiple image projection system and method for additive manufacturing
Ben Wynne, Escondido, CA (US); Jamie Lynn Etcheson, San Diego, CA (US); Christopher Sean Tanner, Idyllwild, CA (US); Robert Lee Mueller, San Diego, CA (US); and Ivan Dejesus Chousal, Chula Vista, CA (US)
Assigned to Intrepid Automation, San Diego, CA (US)
Filed by Intrepid Automation, San Diego, CA (US)
Filed on May 3, 2022, as Appl. No. 17/661,856.
Application 17/661,856 is a continuation of application No. 17/301,204, filed on Mar. 29, 2021, granted, now 11,338,511.
Application 17/301,204 is a continuation of application No. 16/938,298, filed on Jul. 24, 2020, granted, now 11,014,301, issued on May 25, 2021.
Application 16/938,298 is a continuation of application No. 16/370,337, filed on Mar. 29, 2019, granted, now 10,780,640, issued on Sep. 22, 2020.
Claims priority of provisional application 62/734,003, filed on Sep. 20, 2018.
Claims priority of provisional application 62/711,719, filed on Jul. 30, 2018.
Prior Publication US 2022/0258422 A1, Aug. 18, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. B29C 64/10 (2017.01); B29C 64/268 (2017.01); B33Y 30/00 (2015.01); B33Y 10/00 (2015.01); B29C 64/135 (2017.01); B29C 64/129 (2017.01); B29C 64/291 (2017.01)
CPC B29C 64/268 (2017.08) [B29C 64/129 (2017.08); B29C 64/135 (2017.08); B29C 64/291 (2017.08); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12)] 20 Claims
OG exemplary drawing
 
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.