3D Printing Curing Beam Width Control for Vertical Wall Formation
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Solution Overview
Problem
Existing three-dimensional printing technologies face challenges in efficiently manipulating curing radiation to form complex shapes and structures, particularly when dealing with vertical walls and varying material compositions, leading to issues such as nozzle occlusion and inconsistent material deposition.
Innovation Solution
A system and method that employs a beam manipulator to adjust the angular width of curing radiation based on the three-dimensional shape of the stack and material composition, allowing for variable beam widths and multiple material formulations, and includes a reflective wall system to manage radiation direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed angular width beam is used for curing radiation, then the device complexity is reduced, but the manufacturing precision deteriorates due to inconsistent layer formation and inability to form complex shapes
Solution Approach 1:
The patent implements a dynamic beam width adjustment system where the angular width of the curing radiation beam is varied based on the detected geometry of previously formed layers. The beam manipulator changes the beam angular width in real-time during the printing process, allowing narrow beams for flat regions and wide beams for vertical walls, thereby achieving consistent layer formation across complex geometries without requiring overly complex manual intervention
Solution Approach 2:
The system changes the physical parameter of beam angular width dynamically during the curing process. By adjusting this parameter based on the three-dimensional shape of the stack, the system optimizes curing effectiveness for different geometries - using narrower angles for flat surfaces and wider angles for vertical walls, thus improving manufacturing precision without permanent device complexity
2Productivity
If the beam angular width is increased to cover vertical walls, then the productivity is improved, but the manufacturing precision deteriorates due to nozzle occlusion and inconsistent curing
Solution Approach 1:
The patent applies local quality by adjusting the beam angular width according to the local geometry being cured. Instead of using a uniform beam width across the entire build area, the system detects the local three-dimensional shape and tailors the beam angular width to match - narrow beams for flat regions where precision is critical, and wide beams for vertical walls where coverage and productivity are prioritized
Solution Approach 2:
The system dynamically adapts the beam angular width during the printing process based on real-time detection of layer geometry. This dynamic adjustment allows the system to optimize for both productivity and precision at different locations and times, rather than being constrained by a fixed beam width setting
3Manufacturing precision
If a narrow beam angular width is used, then the manufacturing precision is improved for flat surfaces, but the productivity deteriorates due to inability to efficiently cure vertical walls
Solution Approach 1:
The system implements local quality by matching the beam angular width to the local surface geometry - using narrow beams precisely where needed for flat surfaces to maintain curing accuracy, and automatically switching to wide beams when vertical walls are detected, thus optimizing both precision and productivity at different locations without compromise
4Adaptability or versatility
If the beam angular width is dynamically adjusted, then the adaptability is improved for complex shapes, but the device complexity increases due to beam manipulator and control system
Solution Approach 1:
The system employs self-service by using the detected geometry of previously formed layers to automatically determine the appropriate beam angular width for the current layer. The controller receives detection data, processes the three-dimensional shape information, and autonomously adjusts the beam manipulator settings without requiring external intervention or complex pre-programming, thus achieving high adaptability with manageable device complexity
Solution Approach 2:
The system implements feedback by continuously detecting the three-dimensional shape of the formed stack and using this information to adjust the beam angular width in subsequent layers. This closed-loop control enables the system to adapt to complex geometries automatically, with the feedback mechanism simplifying the overall control architecture compared to open-loop complex manipulation systems
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
Enhances the ability to create complex three-dimensional objects with precise material distribution and reduced nozzle occlusion, improving the formation of vertical features and composite materials.
Implementation Method 1
a curing system having an irradiation source emitting a beam of curing radiation
Data Source
AI summary
A system for additive manufacturing comprises an array of nozzles for dispensing a building material on a receiving surface; a curing system having an irradiation source emitting a beam of curing radiation, and a beam manipulator for manipulating an angular width of the beam on the building material. A computerized controller controls the array of nozzles to dispense the building material formulation to form a layer in a configured pattern corresponding to a slice of a three-dimensional object, and to control the beam manipulator to select an angular width of the beam based on a three-dimensional shape of a stack of previously formed layers.