3D Print Mirror Array Scanning for High-Resolution Imaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current three-dimensional printing systems face challenges in achieving high resolution and speed in the imaging process, particularly in selectively curing or fusing materials using energy sources like lasers.
Innovation Solution
A three-dimensional printing system incorporating a motorized build platform, a pulsed light source, an imaging module with a two-dimensional mirror array, and a controller that scans the imaging module over a build plane, using a sequence of radiation pulses to selectively image and harden layers of build material, with redundancy in mirror elements to enhance resolution and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a laser imaging system is used to selectively cure or fuse materials in 3D printing, then the manufacturing capability is enabled, but the resolution and speed of the imaging system are insufficient
Solution Approach 1:
The imaging system is segmented into multiple independent laser sources arranged in an array, with each laser source corresponding to a specific region or pixel on the build plane. This allows parallel imaging of multiple regions simultaneously, thereby increasing imaging speed while maintaining high resolution through the coordinated operation of individual laser elements
Solution Approach 2:
The system employs pulsed laser operation where laser sources are activated in periodic sequences rather than continuous operation. By controlling the timing and duration of laser pulses, the system achieves high-resolution selective curing while the periodic nature allows for rapid scanning and repeated imaging cycles, thus improving both resolution and speed
2Reliability
If a single mirror element is used in the imaging system, then the device complexity is reduced, but the reliability decreases due to malfunction risk
Solution Approach 1:
The mirror system is organized as an array where each mirror element serves a specific local function in the imaging path. This segmentation allows individual mirrors to be optimized for their specific positions and functions, and more importantly, enables the system to tolerate failures in individual local elements while maintaining overall system reliability through redundancy and error correction capabilities
Solution Approach 2:
The system incorporates redundant mirror elements and error correction algorithms that prepare in advance for potential mirror malfunctions. By having backup mirror elements and pre-programmed correction routines, the system can compensate for failed mirrors without complete system failure, thereby enhancing reliability while the modular array structure keeps the added complexity manageable
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
This approach allows for improved resolution and reduced impact of malfunctioning mirror elements, enabling faster and more precise imaging, thereby enhancing the manufacturing capability of three-dimensional articles.
Implementation Method 1
The imaging module receives radiation from the pulsed light source and includes a two-dimensional mirror array defining N rows and M columns of mirrors
Implementation Method 2
The controller is configured to operate the pulsed light source to generate a sequence of radiation pulses that illuminate the mirror array. The radiation pulses individually having a time duration of δT. The radiation pulses are emitted at a frequency of ν=1/T
Implementation Method 3
The movement mechanism imparts motion between the imaging module and the build platform in one or two lateral directions. The controller is configured to operate the movement mechanism to scan the imaging module along an X-axis over the build plane
Data Source
AI summary
A three-dimensional printing system for fabricating a three-dimensional article includes a motorized build platform, a dispensing module, a pulsed light source, an imaging module, a movement mechanism, and a controller. The imaging module receives radiation from the pulsed light source and includes a two-dimensional mirror array. The movement mechanism imparts lateral motion between the imaging module and the build platform. The controller is configured to operate the motorized build platform and the dispensing module to form a layer of build material at a build plane, operate the movement mechanism to laterally scan the imaging module over the build plane, operate the pulsed light source to generate a sequence of radiation pulses that illuminate the mirror array, and operate the mirror array to selectively image the build material.