3D Over-Printing With Multi-Directional UV Photocuring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D over-printing methods face challenges in photocuring opaque or highly absorbent light-curable materials due to shadow areas caused by complex shapes or projection directions, limiting their application on existing structures.
Innovation Solution
A 3D over-printing device and method utilizing a projector and mirror structure to project UV light in multiple directions, allowing simultaneous photocuring of light-curable materials on existing structures by dividing and reflecting images through mirrors, enabling shadow-free over-printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If UV light is projected from above the resin surface (top-down method), then the resin surface can be directly photocured, but shadow areas occur depending on the shape of the existing structure, making it impossible to print properly
Solution Approach 1:
The patent divides the UV light projection into multiple independent projector units, with each projector responsible for a specific directional coverage. This segmentation allows each projector to illuminate specific areas without creating shadows from complex structures, as each segment can independently cover its designated zone.
Solution Approach 2:
The patent transitions from a single vertical projection direction to a multi-directional projection system. By arranging projectors at different positions and orientations, the system achieves illumination from multiple dimensions simultaneously, eliminating shadow areas that would occur with single-direction top-down projection.
2Manufacturing precision
If multiple projectors are used to project UV light images simultaneously in several directions, then shadow areas can be reduced, but the device complexity and cost increase
Solution Approach 1:
The patent designs each projector unit to serve multiple functional purposes: they project UV light images, can be positioned at various orientations, and collectively cover the entire resin surface. This multi-functionality reduces the need for specialized components and simplifies the overall system architecture while achieving comprehensive illumination.
Solution Approach 2:
The patent combines multiple projector units into a unified system that operates as a single integrated whole. The projectors are coordinated to work simultaneously, with their outputs merged to create complete coverage. This merging approach maintains the benefits of multi-directional projection while reducing the complexity of managing separate systems.
3Reliability
If opaque or highly absorbent light-curable materials are used, then the resin can provide adequate light absorption for curing, but UV light cannot penetrate into the resin, preventing over-printing on existing structures
Solution Approach 1:
The patent segments the UV light projection into multiple directional beams that simultaneously reach the resin surface from different angles. This segmentation allows light to reach the surface effectively without requiring deep penetration, enabling over-printing on existing structures while maintaining adequate light absorption for curing.
Solution Approach 2:
The patent changes the illumination approach from single-direction vertical projection to multi-directional projection. By projecting UV light from multiple angles simultaneously, the system ensures that light reaches the resin surface effectively without requiring penetration through the material, thus enabling over-printing on existing structures with opaque or highly absorbent materials.
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
Enables easy over-printing of 3D shapes on existing structures with opaque or highly absorbent materials by preventing shadow areas and reducing system complexity and cost, while maintaining efficient photocuring.
Implementation Method 1
a projector and a mirror structure, and configured to photocure an area to be cured on a surface of the light-curable material by projecting UV light in several directions simultaneously
Implementation Method 2
an optical part including a projector and a mirror structure, and configured to photocure an area to be cured on a surface of the light-curable material by projecting UV light in several directions simultaneously from above the surface of the light-curable material
Data Source
AI summary
Proposed is a 3D over-printing device for over-printing a 3D shape on an existing structure, the device including: a vat containing a light-curable material; a driving part configured to fix the existing structure and move the existing structure vertically, layer by layer, within the vat; and an optical part comprising a projector and a mirror structure, and configured to photocure an area to be cured on a surface of the light-curable material by projecting UV light in several directions simultaneously from above the surface of the light-curable material toward the surface of the light-curable material that is upward exposed and in contact with the existing structure.