3D Manufacturing Build Platform Alignment for Sub-Micron Precision
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Solution Overview
Problem
Existing 3D printers face challenges in accurately aligning the lower surface of the build surface to the build plane, particularly for producing 3D articles with feature size tolerances less than 10 microns, less than five microns, or less than one micron in size.
Innovation Solution
A 3D manufacturing system with a build platform mechanism that allows non-frictional rotation and frictional locking of the build surface to a datum surface, utilizing a tensioned transparent sheet and a spring-actuated rod system to ensure precise alignment and parallel orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment mechanisms are used, then device complexity is reduced, but manufacturing precision deteriorates (cannot achieve sub-micron tolerances)
Solution Approach 1:
The build surface is designed to dynamically transition between two states: free rotation mode during initial contact for self-alignment, and locked mode after alignment for precision maintenance. This dynamic behavior allows the system to achieve high precision without complex active control mechanisms during operation.
Solution Approach 2:
The build surface uses gravity and friction to automatically align itself with the datum surface through non-frictional rotation during contact. The system self-corrects alignment errors without requiring external actuators or complex control systems, achieving sub-micron precision through passive mechanical means.
2Stability of the object's composition
If frictional locking is used to maintain parallel orientation, then alignment stability is improved, but ease of operation deteriorates (difficulty in adjusting build surface position)
Solution Approach 1:
The system dynamically switches between friction-dominated locking mode (for stability) and reduced-friction rotation mode (for adjustment). The operator can easily adjust the build surface by overcoming static friction, and once aligned, the same friction provides stable locking without requiring additional fastening mechanisms.
Solution Approach 2:
The frictional interface automatically provides both alignment and locking functions without requiring separate adjustment mechanisms. The build surface self-locks in the aligned position through friction, eliminating the need for complex clamping or fastening systems while maintaining ease of repositioning.
3Measurement precision
If non-frictional rotation mechanism is used, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The system uses the inherent properties of friction and gravity to achieve self-alignment. When the build surface contacts the datum surface, it can freely rotate to find the correct parallel orientation, then automatically locks in place. This passive self-aligning mechanism achieves sub-micron precision without requiring active sensors, motors, or complex control systems.
Solution Approach 2:
The patent replaces complex active mechanical alignment systems (with motors, sensors, and controllers) with a passive mechanical system based on friction and gravity. The build surface naturally aligns itself through controlled frictional contact, eliminating the need for sophisticated mechanical alignment mechanisms.
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
Achieves precise alignment of the build surface to the datum surface, enabling the production of 3D articles with sub-micron feature size tolerances through controlled vertical movement and locking mechanisms.
Implementation Method 1
The spring is disposed within the lower section of the recess and is configured to exert a vertical force between the lower end of the rod and the base assembly
Implementation Method 2
The tapered section, by restraining the lower end of the rod, limits a vertical expansion of the spring
Implementation Method 3
The controller is configured to (1) operate the VMM to lower the elevator while monitoring the signal from the load sensor
Implementation Method 4
a vertical movement mechanism (VMM), an elevator coupled to the VMM
Data Source
Figure 1
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AI summary
A three-dimensional (3D) manufacturing system (2) is configured to fabricate a 3D article (4). The 3D manufacturing system includes a base (8), a resin vessel (10) supported by the base, a tension ring (32), a vertical movement mechanism (16), an elevator (18) coupled to the VMM, a build platform (20), a load sensor (26), and a controller (25). The resin vessel includes a transparent sheet (28) that is tensioned by the tension ring. An upper surface of the transparent sheet above the tension ring defines a datum surface (34). The build platform contains a mechanism and has a build surface. When the build surface is pressed against the datum surface, the mechanism allows the build surface to rotate about a horizontal axis so as to be flush with the datum surface. When the build surface is raised above the datum surface, the mechanism locks in a parallel orientation of the build surface with respect to the datum surface.