Large-size high-precision dual light source light curing forming control method

Abstract

The application discloses a large-size high-precision double-light-source light curing forming control method, and belongs to the technical field of light curing additive manufacturing. The method takes an SLA and DLP double-light-source system as a hardware basis, combines a dynamic partition engine, a sub-pixel level light field real-time calibration module, a high-resolution liquid surface interference monitoring unit and a multi-source error coupling compensation model, and is characterized in that: the SLA light source is responsible for high-precision scanning of contour and detail areas, and the DLP light source undertakes efficient exposure of large-area filling areas; by constructing a forming platform and a scraper feeding system suitable for large-size workpieces, the double-light-source forming area is dynamically divided based on model geometric characteristics, the double-light-source exposure path and timing are optimized in cooperation, accurate alignment of the double-light-source coordinate system and real-time correction of optical distortion are completed, and motion deviation and curing distortion are dynamically corrected based on liquid surface closed-loop feedback and error compensation. The method effectively improves the forming precision and efficiency of large-size workpieces, and is suitable for high-precision rapid light curing forming of large-size complex components.

Description

Technical Field

[0001] This invention relates to the field of photopolymer additive manufacturing technology, specifically to a high-precision dual-light source collaborative forming control method for large-sized workpieces. Background Technology

[0002] Photopolymer 3D printing encompasses two main technologies: SLA point scanning and DLP surface exposure. SLA offers high precision but suffers from low efficiency in large-scale forming, long scanning paths, and susceptibility to distortion due to heat accumulation. DLP offers high efficiency in surface exposure but lacks edge precision, and exhibits significant pixel aliasing and optical diffraction in large-scale applications. Existing dual-light source forming solutions are mostly static partitioning and simple parallel printing, failing to achieve dual-light source collaborative calibration, timing synchronization, and real-time compensation for multi-source errors. Furthermore, their control logic is closed, relying solely on the device's built-in program and lacking support for external path planning input and automatic control integration.

[0003] In large-size molding processes, problems such as resin level fluctuations, platform lifting errors, optical distortion, and interlayer cumulative deviations are coupled and superimposed, further reducing molding accuracy and stability. Meanwhile, traditional control systems lack standardized data interfaces, have inconsistent underlying hardware packaging, and separate printing logic and feedback control, making it impossible to achieve efficient access to external planning data and fully automated execution of the entire process. Therefore, there is an urgent need for a dual-light source photopolymerization molding control method that integrates external planning input and automatic control to solve the technical challenges of balancing efficiency and accuracy in large-size molding, insufficient control openness, and low automation. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and solve the contradiction between forming size and forming accuracy in large-size photopolymer 3D printing. It provides a large-size, high-precision dual-source photopolymer forming control method that combines external planning input with automatic control. Based on the completion of region segmentation and path planning, it achieves full-process automatic control of external planning data import, instruction parsing, hardware driving, real-time feedback and closed-loop correction through the coordinated operation of five major modules: printing interface, data management, low-level control encapsulation, printing logic and control algorithm, and control link. Ultimately, it achieves high-efficiency, high-precision and high-stability forming of large-size workpieces.

[0005] The objective of this invention is achieved through the following technical solution:

[0006] A method for controlling large-size, high-precision dual-light-source photopolymerization molding is presented. The system consists of five core modules: a printing interface module for user interaction and initial data import; a data management module for processing, storing, and optimizing external planning data; a low-level control encapsulation module for abstracting hardware operations and providing a unified device control interface; a printing logic and control algorithm module for integrating intelligent path planning and real-time parameter adjustment strategies; and a control link module for ensuring efficient coordination of data flow and commands between modules. Based on an SLA-DLP dual-light-source hardware system, this method integrates the advantages of SLA and DLP technologies, achieving deep integration of external planning data input and automatic device control throughout the entire process through dynamic light source switching and energy modulation. This deep integration not only optimizes the interlayer curing process and support structure generation but also corrects deviations in real time through a closed-loop feedback mechanism, thereby significantly improving the forming efficiency and accuracy of large-size photopolymerized workpieces.

[0007] This method specifically includes the following steps:

[0008] Step S1: Import external planning documents, configure process parameters, and initialize the printing task through the printing interface;

[0009] Step S2: The data management module parses, verifies, converts, and stores the external planning data in layers to generate standardized control instructions;

[0010] Step S3: The underlying control encapsulation module encapsulates hardware operations such as motion control, light source control, scraper control, and data acquisition into unified input / output functions;

[0011] Step S4: The printing logic and control algorithm module reads standardized instructions, calls the underlying encapsulated functions in sequence, and drives the dual light source system and motion mechanism to perform printing actions;

[0012] Step S5: Insert a pause at the critical node of instruction execution, call the acquisition function to obtain real-time status data, and send it to the feedback control loop;

[0013] Step S6: Based on the collected data, complete the error calculation and parameter correction, resume command execution, and realize layer-by-layer closed-loop control;

[0014] Step S7: Repeat the layer printing process until the entire large workpiece is formed.

[0015] In step S1, the external planning file is imported through the printing interface. The file that meets the format requirements is selected and loaded from the local storage device or network location. Then, the process parameters are configured, including adjusting key options such as printing speed, temperature setting, material type and layer thickness. Finally, the printing task is initialized to ensure that the equipment is ready and the printing process is started, laying the foundation for subsequent operations.

[0016] In step S2, the data management module is responsible for the full lifecycle processing of external planning data and equipment operation data, ensuring the legality of instructions, the security of timing, and the reliability of data. The data management module reads information such as region segmentation results, scanning paths, projection sequences, exposure parameters, motion timing, and layer thickness settings; checks path integrity, coordinate rationality, parameter range, timing conflicts, and format errors; stores instructions according to the printing layer index, supporting breakpoint resume printing and anomaly recovery; and converts external planning data into unified control instructions that the equipment can recognize and execute.

[0017] In step S3, the underlying control encapsulation module, as the core hub for system hardware interaction, abstracts and integrates key hardware operations such as motion control, light source control, scraper control, and data acquisition, encapsulating them into a standardized unified input / output function interface. This module effectively isolates the direct dependency between upper-layer applications and underlying hardware, significantly reducing system integration complexity and enhancing code maintainability and scalability by providing a simple and consistent calling method. Precise control and status acquisition of each hardware unit can be achieved simply by calling a unified function, thereby improving the overall system reliability and development efficiency.

[0018] In step S4, the printing logic and control algorithm module is responsible for reading standardized instructions from the upper-level control system or preset programs. These instructions define the specific parameters and processes of the printing task. Internally, the module calls underlying encapsulated functions step-by-step according to precise timing logic. These functions encapsulate direct operation interfaces for the hardware devices. By driving the dual-light source system, the module adjusts the light intensity and exposure time, while coordinating the precise displacement of the motion mechanism to execute complex printing actions, ensuring that each layer of material is accurately deposited or cured. The entire process achieves automated control, improving printing efficiency and product quality.

[0019] In step S5, a pause is inserted at a critical node in instruction execution to ensure system stability. Then, a dedicated acquisition function is called to obtain real-time status data, including the current system operating parameters. Next, the acquired data is sent to the feedback control loop for analysis and adjustment of subsequent instruction execution, thereby achieving a more precise and adaptive control process.

[0020] In step S6, firstly, based on the real-time data collected by the system, accurate error calculation and parameter correction are performed; then, the normal execution of the command is restored according to the corrected parameters to ensure operational continuity; finally, through a layer-by-layer feedback and adjustment mechanism, efficient closed-loop control is achieved, thereby improving the stability and accuracy of the overall system.

[0021] In step S7, when manufacturing large-sized workpieces, the system continuously executes the layer printing process in a loop. Each layer is precisely deposited and cured based on the digital model. The workpiece structure is gradually built by layering the layers until all layer printing tasks are successfully completed, ensuring that the geometry and mechanical properties of the entire workpiece are fully formed and meet the final specifications.

[0022] The beneficial effects of this invention are as follows:

[0023] It breaks through the inherent paradox between scale and precision in traditional single-light source technology, and achieves dual assurance of size and precision through the complementary advantages of dual light sources.

[0024] It achieves deep integration of external planning input and automatic control, opens up standardized interfaces, supports access to external path planning software, and improves the versatility and scalability of equipment.

[0025] The dual-light source equipment is highly adaptable and can meet the molding requirements of various resins and mixed materials such as photocurable ceramic resins prepared based on them.

[0026] It improves the forming efficiency of single-layer large-format forming, with high single-layer forming efficiency, significantly shortens the overall manufacturing cycle in large-size formed parts, and takes into account both micro-structural details and macro-dimensional accuracy. Attached Figure Description

[0027] The present invention will now be described in further detail with reference to the accompanying drawings and specific implementation methods.

[0028] Figure 1 It is a large-size, high-precision dual-light source photopolymerization molding control method and process;

[0029] Figure 2 This is a schematic diagram of the overall process of the feedback control mechanism. Detailed Implementation

[0030] The present invention will now be described in further detail with reference to the accompanying drawings.

[0031] like Figures 1 to 2 As shown below, the steps and functions of a large-size, high-precision dual-light source photopolymerization molding control method will be explained in detail.

[0032] Step S1: As Figure 1As shown in the process diagram, firstly, in the printing interface, the user needs to import external planning files. These files are usually from local storage or network sharing and contain 3D model data and layer slicing information of the object to be printed. Next, based on the characteristics of the selected material, such as PLA, ABS, or resin, and the required printing accuracy, the user gradually configures core process parameters such as printing speed, nozzle temperature, heated bed temperature, material diameter, and flow rate. In addition, advanced settings such as layer height, infill density, support structure, and cooling fan speed can be adjusted to optimize printing results and prevent defects. After all parameter settings are completed, the process is started by initializing the print job. The system will automatically perform steps such as printer self-check, platform leveling, preheating, and material preloading to ensure that the equipment is ready before starting the formal printing job.

[0033] Step S2: The data management module is responsible for handling the entire data lifecycle, covering all stages such as data generation, storage, processing, transmission, and destruction, to ensure the legality of instructions, the security of timing, and the reliability of data. This module first reads the planning information and performs multi-level error checks, including syntax verification, logic auditing, and consistency checks, to identify and correct potential problems. Next, it securely stores the instructions in persistent media, supporting breakpoint resumption, allowing execution to resume from a precise breakpoint after system interruption. It also integrates an exception recovery mechanism, handling unexpected failures through log recording and state backup. Finally, the data management module converts the processed instructions into unified control instructions executable by the device, ensuring compatibility with hardware devices, standardized interfaces, and efficient execution, thereby improving the overall system stability and maintainability.

[0034] Step S3: The underlying control encapsulation module, as the core of hardware interaction, abstracts and integrates key operations such as motion control and light, mapping these diverse hardware functions into standardized, unified input / output interfaces. This module hides the specific implementation details of the underlying hardware, encapsulating them into concise calling methods, effectively isolating the direct dependency between upper-layer applications and the underlying hardware, reducing system coupling. This design provides a concise and consistent calling method, such as using unified function names and parameter structures to control different hardware units, significantly reducing system integration complexity and supporting modular development. Simultaneously, its configurability and interface standardization enhance code maintainability and scalability. When hardware is replaced or upgraded, only the internal logic of the encapsulation module needs adjustment, without modifying the upper-layer application, facilitating long-term maintenance. Through unified function calls, the module achieves precise control and real-time status acquisition of hardware units. Combined with error handling and data verification mechanisms, it ensures accurate and reliable operation, thereby improving overall system stability. Furthermore, standardized interfaces simplify testing, debugging, and collaboration processes, accelerating development iterations and significantly improving development efficiency and project deliverability.

[0035] Step S4: The printing logic and control algorithm module reads upper-level instructions from the computer-aided design system or user interface, parses and defines printing parameters and processes, including key settings such as printing speed, layer height, material type, and curing conditions. Based on predetermined timing logic and event triggering conditions, the module dynamically calls underlying encapsulated functions. These functions encapsulate hardware operation interfaces such as motor drive, light source control, sensor data reading, and communication protocol processing. It drives a dual-light source system, with one light source used for material pre-curing to enhance adhesion, and the other for main curing to ensure structural strength, while precisely adjusting light intensity and exposure time. The module also coordinates the displacement of the X, Y, and Z axis motion platforms, synchronously executing printing actions and adjusting in real time through a closed-loop feedback mechanism to ensure accurate deposition or layered curing of photosensitive materials or other printing materials. The entire process is fully automated, requiring no manual intervention from initialization to completion. Optimized algorithms reduce errors and waste, significantly improving printing efficiency and finished product quality.

[0036] Step S5: As Figure 2 As shown in the overall control process of the feedback loop, at critical execution points, the system inserts a brief pause to ensure system stability and avoid fluctuations or errors caused by continuous operation. Subsequently, a dedicated acquisition function is called, responsible for acquiring real-time system status data, including key operating parameters such as temperature, speed, and load. This acquired data is immediately sent to the feedback control loop, where the control algorithm analyzes the data, identifies deviations or anomalies, and makes real-time corrections based on preset adjustment strategies. Through this series of steps, the system achieves precise and adaptive control, dynamically responding to environmental changes and improving overall performance and reliability.

[0037] Step S6: First, based on the real-time data collected by the system, perform accurate error calculation and parameter correction; then, restore the normal execution of the command according to the corrected parameters to ensure operational continuity; finally, through a layer-by-layer feedback and adjustment mechanism, achieve efficient closed-loop control, thereby improving the stability and accuracy of the overall system.

[0038] Step S7: When manufacturing large-sized workpieces, the system will continuously execute the layer printing process in a loop. Each layer is precisely deposited and cured according to the digital model. The workpiece structure is gradually built by layering the layers until all layer printing tasks are successfully completed, ensuring that the geometry and mechanical properties of the entire workpiece are fully formed and meet the final specifications.

Claims

1. A method for controlling large-size, high-precision dual-light-source photopolymerization molding, characterized in that: It is suitable for the field of large-format photopolymer additive manufacturing. It uses a dual-light source hardware system of SLA and DLP as the execution carrier and consists of five major modules that work together: printing interface, data management, low-level control encapsulation, printing logic and control algorithm, and control link. S1: Import external planning documents, configure process parameters, and initialize printing tasks through the printing interface; S2: The data management module parses, verifies, converts, and stores external planning data in layers, generating standardized control instructions; S3: The underlying control encapsulation module encapsulates motion, light source, scraper, and acquisition hardware operations into unified input / output functions; S4: The printing logic and control algorithm module reads instructions and calls the underlying encapsulated functions in sequence to drive the hardware to execute printing actions; S5: Insert a pause at a critical node in instruction execution, call the acquisition function to obtain real-time status data and send it to the feedback loop; S6: Based on real-time data, error calculation and parameter correction are completed, and instruction execution is resumed to achieve layer-by-layer closed-loop control; S7: Repeat the layered printing process until the large workpiece is fully formed; In step S1, the printing interface supports loading external planning files from local and network locations, configuring printing speed, temperature, material type, layer thickness process parameters, and completing device status self-check and printing task startup, providing a unified entry point for human-computer interaction and task initialization. In step S2, the data management module can read the region segmentation results, scanning path, projection sequence, exposure parameters, motion timing, and layer thickness setting data, complete the verification of path integrity, coordinate rationality, parameter range, timing conflict, and format legality, and store instructions by layer index to support breakpoint resume printing; In step S3, the underlying control encapsulation module abstracts motion control, light source control, scraper control, and data acquisition hardware operations into standardized input and output functions, isolating the upper-layer application from the underlying hardware dependency. In steps S4-S6, the printing logic and control algorithm module calls the underlying functions in sequence to drive the dual light source and motion mechanism. It pauses at key instruction nodes and collects real-time data. After error calculation and parameter correction, it resumes execution to achieve layer-by-layer closed-loop feedback control.

2. The method according to claim 1, characterized in that: The printing interface features visualized printing progress, device status monitoring, alarm information prompts, log recording, and resume printing functionality. It also supports start, pause, continue, stop, and emergency stop control commands.

3. The method according to claim 2, characterized in that: The data management module converts external planning data into unified control commands that can be recognized and executed by the equipment, enabling standardized integration between external planning data and the equipment control system.

4. The method according to claim 3, characterized in that: The underlying encapsulated functions include Z-axis motion, platform displacement, optomechanical movement, SLA laser control, DLP projection control, scraper material spreading, air pressure regulation, liquid level monitoring, displacement reading, and temperature and light intensity acquisition functions.

5. The method according to claim 1, characterized in that: The control link module is responsible for data flow and command transmission between modules. It supports multiple types of communication interfaces, ensures low-latency and high-reliability command transmission, and collaboratively realizes dynamic switching of dual light sources, energy modulation, and fully automated forming of the entire process.

Images