Scalable and fast three dimensional printing system

Abstract

A three dimensional printing system includes a light engine having a spatial light modulator for curing individual layers of a photocure resin to form a three dimensional article of manufacture. The light engine is configured to: (1) receive a slice image that defines an array of energy values for curing a layer, (2) process the slice image to define an image frame compatible with the spatial light modulator, (3) receive an on signal, (4) activate the first light source in response to the on signal; (5) repeatedly send the first defined image frame to the first spatial light modulator during a defined cure time for the single layer of resin; (6) receive an off signal; (7) deactivate the first light source in response to the off signal; and (8) repeat steps (1) - (7) until the three dimensional article of manufacture is formed.

1 - 20 . (canceled) 
     
     
         21 . A three dimensional printing system including:
 a vessel configured to contain photocure resin;   a plurality of light engines individually including a light source and a spatial light modulator;   a control system including a controller, the control system configured to operate portions of the three dimensional printing system to form a three dimensional article from a sequence of selectively hardened layers of the photocure resin according to the following control system steps for an individual one of the sequence of selectively hardened layers:
 receiving an incoming slice energy data array; 
 processing the incoming slice energy data array to provide an image frame for individual ones of the plurality of light engines, the processing including:
 correcting the data array including one or more of correcting distortions and de-warping; 
 calibrating the data array including one or more of compensation for one or more of a light source and an optical path length; 
 scaling the data array including for the image frame; and 
 stitching the data array to allow defining a composite build plane; 
 
 for individual ones of the plurality of light engines, activating the light source; 
 for individual ones of the plurality of light engines, sending the image frame to the spatial light modulator; and 
 for individual ones of the plurality of light engines, deactivating the light source. 
   
     
     
         22 . The three dimensional printing system of  claim 21  wherein the plurality of light engines define a corresponding plurality of build fields that individually include a non-overlapping field portion and an overlapping field portion, the non-overlapping portion is unique to one light engine and the overlapping field portion is shared by two or more light engines, the plurality of build fields form a composite build field. 
     
     
         23 . The three dimensional printing system of  claim 22  wherein the plurality of light engines include four light engines, including an area of the composite build field over which the four light engines overlap. 
     
     
         24 . The three dimensional printing system of  claim 21  wherein the plurality of light engines are individually coupled to an image scaler that performs the processing the incoming slice energy data array to provide the image frame. 
     
     
         25 . The three dimensional printing system of  claim 24  wherein a light engine of the plurality of light engines includes a formatter that converts the image frame from pixel energy values from pixel energy values to a format compatible with the spatial light modulator. 
     
     
         26 . The three dimensional printing system of  claim 21  wherein the controller performs the processing the incoming slice energy data array to provide the image frame before the image frame is sent to individual ones of the plurality of light engines. 
     
     
         27 . The three dimensional printing system of  claim 26  wherein the light engine includes a formatter that converts the image frame from pixel energy values to a format compatible with the spatial light modulator. 
     
     
         28 . The three dimensional printing system of  claim 21  wherein sending the image frame includes repeatedly sending a plurality of the same image frame to the spatial light modulator. 
     
     
         29 . The three dimensional printing system of  claim 21  wherein the control system includes a master system processor associated with a master light engine that delivers signals to a subsidiary light engine. 
     
     
         30 . The three dimensional printing system of  claim 21  wherein the control system includes a master system processor associated with a master light engine that delivers signals to a plurality of subsidiary light engines. 
     
     
         31 . A three dimensional printing system including:
 a vessel configured to contain photocure resin;   a plurality of light engines configured to selectively and simultaneously illuminate a composite build plane and individually corresponding to one of a plurality of build fields that collectively form the composite build plane, the plurality of light engines individually including:
 a light source module including a light source driver and a light source; and 
 a digital mirror device module including a digital mirror device; 
   a control system including a controller, the control system configured to operate portions of the three dimensional printing system to form a three dimensional article from a sequence of selectively hardened layers of the photocure resin according to the following control system steps for an individual one of the sequence of selectively hardened layers:
 receiving an incoming slice energy data array; 
 processing the incoming slice energy data array to provide an image frame for the individual light engines, processing the incoming slice energy data array including:
 correcting the data array including one or more of correcting distortions and de-warping; 
 calibrating the data array including compensation for one or more of a light source and an optical path length; 
 scaling the data array for the image frame; and 
 stitching the data array to allow the formation of a composite build frame from overlapping build fields; 
 operating the light source driver to activate the light source to generate unprocessed light emitted from the light source that is directed to the digital mirror device; 
 for individual ones of the plurality of light engines, sending the image frame to the digital mirror device, the digital mirror device responds by processing the light received from the light source and reflecting processed light one of the overlapping build fields; and 
 operating the light source driver to deactivate the light source. 
 
   
     
     
         32 . The three dimensional printing system of  claim 31  wherein the build fields individually include a non-overlapping field portion that is unique to one of the plurality of light engines and an overlapping field portion that is shared by at least two of the plurality of light engines. 
     
     
         33 . The three dimensional printing system of  claim 32  wherein the plurality of light engines include four light engines, including an area of the composite build field over which the four light engines overlap. 
     
     
         34 . The three dimensional printing system of  claim 31  wherein the plurality of light engines individually include an image scaler that performs the processing the incoming slice energy data array to provide the image frame. 
     
     
         35 . The three dimensional printing system of  claim 34  wherein a light engine of the plurality of light engines includes a digital mirror device formatter that converts the image frame from pixel energy values to a sequence of bit planes. 
     
     
         36 . The three dimensional printing system of  claim 36  wherein the controller performs the processing the incoming slice energy data array to provide the image frame before the image frame is sent to individual ones of the plurality of light engines. 
     
     
         37 . The three dimensional printing system of  claim 36  wherein the light engine includes a digital mirror device formatter that converts the image frame from pixel energy values to a sequence of bit planes. 
     
     
         38 . The three dimensional printing system of  claim 31  wherein sending the image frame includes repeatedly sending a plurality of the same image frame to the spatial light modulator. 
     
     
         39 . The three dimensional printing system of  claim 31  wherein the control system includes a master system processor associated with a master light engine that delivers signals to a subsidiary light engine. 
     
     
         40 . The three dimensional printing system of  claim 31  wherein the control system includes a master system processor associated with a master light engine that delivers signals to a plurality of subsidiary light engines.