Sensors for three-dimensional printing systems and methods

Abstract

The present disclosure provides methods and systems for printing a three-dimensional (3D) object. The methods may comprise providing, adjacent to a build surface, a film comprising a polymeric precursor. A sensor may be used to determine a profile of the film. The profile may be indicative of a quality of the film. If the profile meets a quality threshold, at least a portion of the film may be exposed to light to initiate formation of a polymeric material from the polymeric precursor, thereby printing at least a portion of the 3D object.

1 .- 44 . (canceled) 
     
     
         45 . A system for printing a three-dimensional (3D) object, comprising:
 a build surface configured to retain a resin during printing of said 3D object;   a light unit configured to provide light;   an optical diffuser in optical communication with said light unit and said build surface, wherein said optical diffuser is configured to (i) receive said light, (ii) transform at least a portion of said light into diffused light, and (iii) transmit said diffused light towards said build surface; and   a controller operatively coupled to said light unit, wherein said controller is configured to direct said light unit to provide said light towards said optical diffuser, such that said at least said portion of said light is transformed by said optical diffuser into said diffused light and directed towards said build surface during said printing of said 3D object.   
     
     
         46 . The system of  claim 45 , further comprising a sensor in sensing communication with said build surface, wherein said controller is configured to direct said sensor to detect at least a portion of said diffused light for generating a sensing data that is indicative of (i) a quality of at least a portion of said resin or (ii) a quality of said build surface. 
     
     
         47 . The system of  claim 46 , wherein said controller is configured to generate said sensing data prior to using said at least said portion of said resin for printing at least a portion of said 3D object. 
     
     
         48 . The system of  claim 46 , wherein said controller is configured to generate said sensing data subsequent to using said resin for printing at least a portion of said 3D object, wherein said at least said portion of said resin comprises any excess of said resin remaining subsequent to said printing. 
     
     
         49 . The system of  claim 46 , wherein said sensing data is indicative of said quality of said build surface. 
     
     
         50 . The system of  claim 45 , wherein said optical diffuser is configured to spread an intensity profile of said at least said portion of said light, to provide said diffused light. 
     
     
         51 . The system of  claim 45 , wherein said light comprises a wavelength ranging between about 700 nanometers and about 1.5 micrometers. 
     
     
         52 . The system of  claim 45 , wherein said optical diffuser and said build surface are configured to move relative to one another. 
     
     
         53 . The system of  claim 45 , wherein said optical diffuser and said light unit are configured to move relative to one another. 
     
     
         54 . The system of  claim 45 , wherein said light unit is configured to provide an additional light towards said build surface, wherein said additional light is sufficient to cause formation of at least a portion of said resin into at least a portion of said 3D object. 
     
     
         55 . A method for printing a three-dimensional (3D) object, comprising:
 (a) providing:
 a build surface for retaining a resin; 
 a light unit that provides light; and 
 an optical diffuser in optical communication with said light unit and said build surface; 
   (b) directing said light from said light unit to said optical diffuser, which optical diffuser transforms at least a portion of said light into diffused light; and   (c) transmitting said diffused light from said optical diffuser towards said build surface during printing of said 3D object.   
     
     
         56 . The method of  claim 55 , further comprising using a sensor in sensing communication with said build surface to detect at least a portion of said diffused light for generating a sensing data, wherein said sensing data is indicative of (i) a quality of at least a portion of said resin or (ii) a quality of said build surface. 
     
     
         57 . The method of  claim 56 , comprising generating said sensing data prior to using said at least said portion of said resin for printing at least a portion of said 3D object. 
     
     
         58 . The method of  claim 56 , comprising generating said sensing data subsequent to using said resin for printing at least a portion of said 3D object, wherein said at least said portion of said resin comprises any excess of said resin remaining subsequent to said printing. 
     
     
         59 . The method of  claim 56 , wherein said sensing data is indicative of said quality of said build surface. 
     
     
         60 . The method of  claim 55 , wherein said optical diffuser is configured to spread an intensity profile of said at least said portion of said light, to provide said diffused light. 
     
     
         61 . The method of  claim 55 , wherein said light comprises a wavelength ranging between about 700 nanometers and about 1.5 micrometers. 
     
     
         62 . The method of  claim 55 , further comprising moving said optical diffuser and said build surface relative to one another. 
     
     
         63 . The method of  claim 55 , further comprising moving said optical diffuser and said light unit relative to one another. 
     
     
         64 . The method of  claim 55 , further comprising using said light unit to provide an additional light towards said build surface, wherein said additional light is sufficient to cause formation of at least a portion of said resin into at least a portion of said 3D object.