US 12,263,646 B2
Devices, systems, and methods for multi-projector three dimensional printing
David Walker, Skokie, IL (US); Michael Flynn, Skokie, IL (US); and Jay Valdillez, Skokie, IL (US)
Assigned to Azul 3D, Inc., Skokie, IL (US)
Filed by AZUL 3D, INC., Skokie, IL (US)
Filed on Aug. 30, 2022, as Appl. No. 17/898,634.
Application 17/898,634 is a division of application No. 16/835,182, filed on Mar. 30, 2020, granted, now 11,472,119.
Claims priority of provisional application 62/826,361, filed on Mar. 29, 2019.
Prior Publication US 2022/0410491 A1, Dec. 29, 2022
Int. Cl. B29C 64/393 (2017.01); B29C 64/282 (2017.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 50/02 (2015.01)
CPC B29C 64/393 (2017.08) [B29C 64/282 (2017.08); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12)] 20 Claims
OG exemplary drawing
 
1. A method of performing additive manufacturing, the method comprising:
controlling emission of projected energy by an array of a plurality of patterning modules by a device controller that is remote to the patterning module array to initiate solidification of a polymerizable material, wherein each of the patterning modules within the array includes a micro-projector configured to project energy for performing energy patterning and a micro-computer comprising a microprocessor having data memory storage capabilities;
controlling positioning of each micro-projector relative to micro-projectors included in other patterning modules within the patterning module array using a multi-axis, micro-positioning system, wherein the micro-positioning system includes a plurality of actuators operated based on the corresponding micro-computer's use of positional data provided by the remote device controller for storage by the corresponding microprocessor; and
controlling patterned energy projection by each micro-projector relative to the micro-projectors included in other patterning modules within the patterning module array to solidify successive layers of polymerizable material based on the corresponding micro-computer's use of projection data provided by the remote device controller for storage by the corresponding microprocessor,
wherein controlling of the positioning and the projection of each micro-projector of the patterning module within the patterning module array is synchronized with the positioning and projection of other patterning modules within the patterning module array based on the corresponding micro-computer's use of synchronization data provided by the remote device controller for storage by the corresponding microprocessor of the patterning module.