3D Printing Actuator Oscillation for High-Viscosity Resin Flow
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Solution Overview
Problem
The existing 3D printing systems face issues with reduced printing speed due to resin voids and slower resin flow rates, particularly when printing larger parts or high-strength polymers, which are exacerbated by high viscosity resins.
Innovation Solution
Incorporation of a deformable actuator, such as a piezoelectric stack, connected to the build plate or tank to facilitate resin flow by oscillating and inducing shear stress, thereby maintaining resin supply during the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a high viscosity resin is used to print high strength polymer, then the strength of the printed object is improved, but the resin flow rate decreases resulting in slower printing speed
Solution Approach 1:
The patent applies mechanical vibration through an actuator that oscillates the build plate or tank at specific frequencies. This vibration induces shear stress in the resin, reducing its effective viscosity and enhancing flow rate. The actuator operates at frequencies and amplitudes optimized to prevent resin void formation while maintaining the resin's high strength properties, thus resolving the contradiction between strength and printing speed
2Productivity
If the build plate is raised to print the next layer, then the printing process continues, but a resin void is left between the build plate and transparent window reducing resin supply and printing speed
Solution Approach 1:
The patent implements preliminary action by activating the actuator before and during the build plate raising process. The actuator creates vibrations that pre-condition the resin to flow more readily into the space created by the rising build plate. This anticipatory vibration ensures resin supply is maintained throughout the layer transition, preventing void formation and maintaining printing speed
3Adaptability or versatility
If larger parts are printed with larger cross-sectional areas, then the printing capability is improved, but the resin supply requirement increases resulting in slower printing speed due to increased time to fill resin void
Solution Approach 1:
The patent uses mechanical vibration from the actuator to enhance resin flow throughout the entire tank volume. The vibration creates shear stress that reduces resin viscosity and promotes uniform flow distribution across large cross-sectional areas. This ensures that even when printing larger parts, resin is supplied efficiently to all areas simultaneously, maintaining printing speed while preserving the ability to print large components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The actuator enhances resin flow, preventing resin voids and ensuring sufficient resin is available for each layer, thereby increasing printing speed and quality.
Implementation Method 1
A deformable actuator, such as a piezoelectric stack, connected to the build plate or tank to facilitate resin flow by oscillating and inducing shear stress
Data Source
AI summary
A three-dimensional printing system includes a tank containing a liquid photopolymer resin. An arm is configured to be movable relative to the tank. A rigid base is connected to the arm. A light source is configured to emit light to the tank to form an object on the rigid base. An actuator is connected to at least one of the build plate and the tank. The actuator is configured to deform when power is supplied to the actuator.