US 11014301

US Patent 11014301, titled "Multiple image projection system for additive manufacturing," was issued to Intrepid Automation Inc. on May 25, 2021. The application was filed on July 24, 2020, and lists Ben Wynne, Jamie Lynn Etcheson, Christopher Sean Tanner, Robert Lee Mueller, and Ivan Dejesus Chousal as the inventors. Intrepid Automation Inc. is both the original and current assignee.

The patent's abstract describes an additive manufacturing system and related methods. It features an image projection system with multiple projectors that cast a composite image onto a build area within a resin pool. This composite image is composed of several sub-images arranged in an array. The system's display subsystem can adjust the properties and alignment of each sub-image using a series of filters. These filters include: an irradiance mask for normalizing light intensity, a gamma adjustment mask to modify sub-image energy based on the resin's reactivity, a warp correction filter for geometric adjustments, and an edge blending bar for managing overlaps between sub-images.

A PTAB (Patent Trial and Appeal Board) case, IPR2025-01241, has been filed and is currently pending and instituted for this patent. Additionally, a US case (3:24-cv-02262) has been filed in the California Southern District Court, and the patent family has seen its first worldwide litigation. No specific dockets for US patent 11014301 in the CAFC for 2026 were found in the provided search results.

Here is a plain-language overview of the independent claims:

Independent Claim 1: Additive Manufacturing System
This claim describes an additive manufacturing system that has multiple image projectors. These projectors work together to project a single, larger "composite image" onto an area where a 3D object is being built in liquid resin. Each projector contributes a smaller "sub-image" to this composite. The system includes a control unit (display subsystem) that can fine-tune each sub-image, adjusting its characteristics and its exact position within the larger composite image. Importantly, where two sub-images meet, they intentionally overlap. To make these overlapping areas seamless and ensure proper curing of the resin, the system uses a set of digital filters for each sub-image. These filters perform four key functions:

1. Irradiance Mask: Ensures the light intensity across the projected sub-image is uniform.
2. Gamma Adjustment Mask: Modifies the sub-image's light energy based on how quickly the specific resin cures.
3. Warp Correction Filter: Corrects any geometric distortions or skew in the projected sub-image.
4. Edge Blending Bar: Smoothly fades the edges of overlapping sub-images to prevent visible seams or over/under-cured areas in the final printed part.

Independent Claim 7: Method for Additive Manufacturing
This claim describes a method for operating an additive manufacturing system, which involves the same type of hardware as in Claim 1 (multiple image projectors and a display subsystem). The method comprises the steps of:

1. Providing the System: Having an additive manufacturing system with an image projection system made up of several image projectors.
2. Projecting the Composite Image: Using the projection system, controlled by the display subsystem, to project a composite image onto the resin in the build area. This composite image is an array of sub-images, where each projector displays one sub-image, and adjacent sub-images intentionally overlap.
3. Adjusting and Aligning Sub-Images: Modifying the characteristics of each sub-image and ensuring their correct alignment within the composite image. This adjustment is performed using a similar set of filters as described in Claim 1: an irradiance mask for uniform intensity, a gamma adjustment mask based on resin reactivity, a warp correction filter for geometric accuracy, and an edge blending bar for seamless overlaps.