US 11338511

Here's a concise summary of US Patent 11338511:

US Patent 11338511: Multiple image projection method for additive manufacturing

• Title: Multiple image projection method for additive manufacturing
• Assignee: Intrepid Automation Inc
• Inventors: Ben Wynne, Jamie Lynn Etcheson, Christopher Sean Tanner, Robert Lee Mueller, Ivan Dejesus Chousal
• Filing Date: 2021-03-29
• Issue Date: 2022-05-24
• Abstract: An additive manufacturing system and related methods utilize an image projection system with multiple image projectors. This system projects a composite image, made of several sub-images arranged in an array, onto a build area within a resin pool. To improve the quality of the printed object, the properties and alignment of each sub-image are adjusted using a stack of digital filters. These filters include an irradiance mask for uniform light distribution, a gamma adjustment mask to match resin reactivity, a warp correction filter for geometric accuracy, and an edge blending bar to seamlessly combine overlapping sub-images.

Plain-Language Overview of Independent Claims:

• Independent Claim 1 (Method): This claim describes a method for additive manufacturing. It involves providing a system with multiple projectors that project a composite image (made of several sub-images in an array) onto a resin pool's build area. Adjacent sub-images in this array are designed to overlap. The method then adjusts the properties and alignment of each sub-image using a specific set of four filters: one for normalizing light intensity (irradiance mask), one for adjusting light energy based on how the resin reacts (gamma adjustment mask), one for correcting any geometric distortions (warp correction filter), and one for smoothly blending the edges where sub-images overlap (edge blending bar).

• Independent Claim 11 (System): This claim describes an additive manufacturing system. The system includes an image projection system with multiple projectors that cast a composite image, composed of sub-images in an array, onto a build area within a resin pool. Each projector creates one sub-image. The system also has a display subsystem that controls the projectors to adjust the sub-image properties and their alignment within the composite image. A key feature is that adjacent sub-images overlap, and each sub-image is modified using a stack of four filters: an irradiance mask for normalization, a gamma adjustment mask for resin reactivity, a warp correction filter for geometric corrections, and an edge blending bar for overlapping edges.

• Independent Claim 15 (Method with Moving Projectors): This claim outlines an additive manufacturing method that, similar to Claim 1, uses a system with multiple projectors and a display subsystem. However, a distinguishing feature is that the array of image projectors is actively moved relative to the build area. The method then proceeds to project a composite image (of overlapping sub-images) onto the resin pool, with each sub-image coming from one projector. The properties and alignment of these sub-images are adjusted using the same four types of filters as in Claim 1: irradiance mask, gamma adjustment mask, warp correction filter, and an edge blending bar.

USPTO and CAFC Search Results:

USPTO Search (as of 2026-05-20):
A search for patent 11338511 on the USPTO Public Patent Search website confirms the patent details provided above, including the title, inventors, current assignee (Intrepid Automation Inc), filing date, and issue date. The patent is listed as "Active". The Google Patents page linked in the prompt also confirms the active status and anticipated expiration date of 2039-03-29.

CAFC 2026 Dockets Search (as of 2026-05-20):
A search of the provided patent text and external knowledge (Google Patents) indicates ongoing litigation related to US11338511:

• PTAB case IPR2025-01242 was filed and is listed as "Pending - Instituted".
• A US case was filed in California Southern District Court (case number 3:24-cv-02262).
• There is also a note of First worldwide family litigation filed.

These litigation activities indicate that the patent is currently involved in legal proceedings.