History repeats itself: how 3D Systems tries to take down another startup in a legal battle, the same way DuPont wanted to kill them 36 years ago
The Atomic Layers: S8E22 (00228)
Atomic Layer of the Day:
Most of you probably don't know Ben Wynne. But let me put it this way — from what I've gathered, those who do know him are serious people in the AM industry. Really — the most renowned names in the field. I've also had the chance to meet him. I'm not claiming that this makes me as serious as the rest, but I can say it means a lot to me.
Ben Wynne is the man who created the Figure 4 for 3D Systems — the company's most significant original technology since Chuck Hull invented stereolithography. Before that, he worked for HP for over a decade. If I could tell you about the things I know — about the projects Ben created in the past that never got commercialized — you'd fall off the chairs you're sitting on.
Because back in 2010–2012, Ben created things that the world went crazy about in 2021 (when someone else developed them.)
Ben Wynne is one of the most significant engineers in the history of AM, but only those who've achieved a lot themselves know him (again — I'm not talking about myself! I'm just lucky).
In 2016, Ben joined 3D Systems because the then-CEO Vyomesh Joshi, whom he knew from working at HP, brought him in. Ben spent a little over a year there, creating the aforementioned Figure 4, and left because he didn't particularly like it there (at least that's what he claims).
In 2017, he founded Intrepid Automation with the idea of creating something much bigger than Figure 4. For the next seven years, he worked on this. The result was a photopolymer system that was even faster and more efficient than Figure 4, and additionally, it was large-format.
Ben became a legend among American CEOs of the largest AM companies. As I mentioned, some really big names visited him. Until one day, a man named X visited him, seeking a job. Like Ben, he had also previously worked at 3D Systems.
The two talked, looked at some things, and then... X went back to work at 3D Systems, reportedly because they offered him a raise.
And from that point on, the story got really sour…
AND NOW, ATTENTION!
Everything you read below involves mutual accusations that are currently the subject of ongoing lawsuits.
What I write comes from legal documents. These are not my opinions, and I am not trying to take sides. Yes, Ben Wynne has achieved a lot in the field of 3D printer design, and a few big names respect and value him highly. In a conversation I had with him a few months ago, I also got the impression that he is a nice person, and I was genuinely impressed by his accomplishments.
But the validity of the allegations will be decided in court. I am just describing them...
The formal dispute began with 3D Systems accusing Intrepid of allegedly misappropriating trade secrets related to their 3D printing technology. In other words, 3D Systems claimed that the work Wynne was doing at Intrepid involved their intellectual property.
In response, at the beginning of December 2024, Intrepid filed a countersuit against 3D Systems for patent infringement. The case was filed in the United States District Court for the Southern District of California.
In the lawsuit, Intrepid Automation claimed that 3D Systems took steps to hinder Intrepid's market entry and seize its "groundbreaking technology." According to the complaint, 3D Systems gained access to Intrepid's confidential information through a former employee - X - who violated a non-disclosure agreement under the pretense of applying for a job at Intrepid.
3D Systems allegedly used this information to develop its own 3D printing system, the PSLA 270, which Intrepid claims is a direct copy of its technology.
Yes, that's right — the PSLA 270, proudly presented at the Formnext 2024 trade show as 3D Systems' biggest new product.
Intrepid owns two patents: US Patent No. 11,014,301 ("Multiple Image Projection System for Additive Manufacturing") and US Patent No. 11,338,511 ("Multiple Image Projection Method for Additive Manufacturing").
Both patents cover systems and methods for 3D printing using multiple projectors that project images onto the work area to create material layers.
This technology differs from traditional stereolithography methods, which use a laser to cure resin layer by layer. The Intrepid system, known as "Range" (or internally as "Valkyrie"), uses six DLP projectors that project images onto a large work area, enabling faster and more precise printing compared to traditional laser systems.
Intrepid claimed that 3D Systems willfully infringed its patents by developing and marketing the PSLA 270 system, which uses the multi-projection technology described in Intrepid's patents.
According to the complaint, 3D Systems had knowledge of Intrepid's patents as early as 2020 and even used them as a "roadmap" to develop its system. Intrepid also alleges that 3D Systems deliberately concealed the development of the PSLA 270 during previous legal proceedings concerning alleged trade secret misappropriation.
Intrepid has requested the court to:
Confirm that patents 11,014,301 and 11,338,511 are valid and enforceable.
Recognize that 3D Systems infringed on these patents, both directly and indirectly.
Determine that the infringement was willful.
Award damages for patent infringement, including treble damages for willful infringement.
Issue preliminary and permanent injunctions preventing the sale of products that infringe on Intrepid's patents (i.e., the PSLA 270).
Award customary legal costs incurred in connection with this case.
Last Thursday saw the first partial ruling in the case. So far, the court has ruled that some of 3D Systems' allegations do not meet the legal requirements for identifying trade secrets; however, it determined that further issues will require a full trial and court proceedings.
Now, why am I even writing about this?
Because from a historical perspective, this is the second time 3D Systems has attempted to break the career of another young company in precisely the same way that, at the dawn of its own history, another major corporation tried to break its career.
I genuinely wonder if the people involved in this lawsuit are even aware of what I'm writing below.
On March 11, 1986, the U.S. Patent Office granted Charles Hull patent No. US4575330A for stereolithography, the first additive manufacturing technology. Shortly after receiving the patent, Hull and Raymond Freed co-founded 3D Systems Inc., the world's first company dedicated to manufacturing 3D printers.
In 1987, 3D Systems launched the first commercial 3D printer, the SLA-1, marking the beginning of the 3D printing industry.
However, soon after, Hull and 3D Systems faced a significant challenge from the chemical giant DuPont.
In September 1988, DuPont filed a request with the U.S. Patent Office for a reexamination of Hull’s patent, arguing that his invention was based on prior research, particularly the work of Kodama and other scientists.
Seven months later, in 1989, the Patent Office informed 3D Systems that it was rejecting all claims in Hull's patent. At the same time, DuPont announced the launch of its own 3D printing technology, the Somos 1000 Solid Imaging System, which closely resembled the stereolithography process developed by 3D Systems.
By the end of 1989, the Patent Office ultimately reversed its decision after 3D Systems presented strong evidence supporting Hull’s patent claims. The rest is history…
24 years later, on November 20, 2012, 3D Systems sued a newly debuted startup — Formlabs — for allegedly infringing its stereolithography patents. After two years, the dispute ended in a settlement. Today, Formlabs is one of 3D Systems' key competitors in the field of SLA.
And last year, 36 years after the DuPont case and 12 years after the Formlabs case, 3D Systems is once again trying to crush Intrepid.
As I wrote above, I don't know who is right in this dispute. The court will ultimately decide who is at fault. So far, the only thing the court has determined is that a full trial must take place.
But history clearly shows who benefits from these disputes in the end...
That's why people should read my history books! Then they'd know! Didn't I tell you yesterday that history keeps repeating itself? Sigh...
Atomic Layer from the Past:
03-22-2018: Massivit 3D introduced the 1500 3D printer.
‘2013 in AM’ - brand new history book! GET IT NOW!
News & Gossip:
Japanese firm Sodick Co., Ltd. has acquired a majority stake in Italy’s Prima Additive, a leading metal 3D printer manufacturer. This move deepens their collaboration, combining Sodick’s precision machining expertise with Prima’s advanced laser technologies. Prima Additive’s Italian headquarters and management will remain unchanged.
Shutterstock introduces a generative AI service for automated 3D model creation, powered by NVIDIA Edify. The tool offers text-to-3D and image-to-3D capabilities, using a neural network trained on Shutterstock’s licensed content. This ensures copyright compliance, setting it apart from other AI platforms. Users can test the service for free, with downloads available in GLB and USDZ formats.
While this is really cool and somewhat sweet product… Tinymaker introduced a portable resin 3D printer, standing just 16 cm tall, designed for small spaces and on-the-go use. Featuring LCD-based stereolithography, it offers a 30.6 × 40.8 × 60 mm build volume and 0.05 mm layer height. Priced at €110, it’s crowdfunded on Indiegogo, with delivery expected by June 2025. A compact wash-and-cure station and carry bag are also available.