3D Printing System with Dynamic Optical Resolution Switching
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Solution Overview
Problem
Current 3D printing systems are limited by fixed optical resolutions, which restrict their versatility in manufacturing objects with varying surface quality requirements, leading to increased complexity, space requirements, and inefficiencies in production processes.
Innovation Solution
A method that allows selection of multiple optical resolutions within a single 3D printing system, enabling the use of different hardenable materials and adjusting light exposure parameters to achieve desired surface qualities, thereby optimizing the manufacturing process for various products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single 3D printing system uses fixed optical resolution, then the system structure is simple, but the adaptability to different surface quality requirements is poor
Solution Approach 1:
The patent implements dynamic optical resolution switching by enabling the light source to alternate between different resolution modes (first optical resolution and second optical resolution) based on the surface quality requirements of different objects. This dynamic adjustment allows a single system to adapt to varying production needs without requiring multiple fixed-resolution systems, thereby improving versatility while maintaining relatively simple system architecture.
Solution Approach 2:
The patent makes the 3D printing system universal by equipping it with the capability to perform multiple optical resolution functions using the same hardware platform. The system can selectively apply high optical resolution for objects requiring fine surface quality and low optical resolution for objects with less stringent requirements, enabling one system to serve multiple production scenarios and eliminating the need for multiple specialized systems.
2Adaptability or versatility
If multiple 3D printing systems with different optical resolutions are used, then the adaptability to different surface quality requirements is improved, but the device complexity and space requirements increase
Solution Approach 1:
The patent merges the functions of multiple separate 3D printing systems (each with fixed optical resolutions) into a single unified system. By integrating the capability to switch between different optical resolutions within one system, the patent consolidates what would have required multiple physical machines into one, thereby reducing space requirements while maintaining the adaptability to produce objects with different surface quality specifications.
3Adaptability or versatility
If multiple 3D printing systems with different optical resolutions are used, then the adaptability to different surface quality requirements is improved, but the device complexity increases
Solution Approach 1:
The patent implements dynamic optical resolution switching by enabling the light source to alternate between different resolution modes (first optical resolution and second optical resolution) based on the surface quality requirements of different objects. This dynamic adjustment allows a single system to adapt to varying production needs without requiring multiple fixed-resolution systems, thereby improving versatility while maintaining relatively simple system architecture.
4Manufacturing precision
If high optical resolution is used for all objects, then the surface quality of manufactured objects is improved, but the productivity decreases due to longer manufacturing time
Solution Approach 1:
The patent applies local quality by matching the optical resolution to the specific surface quality requirements of each object being manufactured. Instead of universally applying high optical resolution to all objects, the system selectively uses high resolution only when necessary (for objects requiring fine surface quality) and low resolution for objects with less stringent requirements. This localized approach to quality control ensures that manufacturing time is not unnecessarily extended while still achieving the required surface quality for each specific product.
Solution Approach 2:
The patent changes the optical resolution parameter dynamically based on the production requirements. By adjusting the optical resolution parameter (switching between first and second optical resolutions) according to the specific needs of different objects, the system optimizes the balance between surface quality and manufacturing efficiency, avoiding the productivity loss that would result from consistently using high optical resolution for all production tasks.
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 enables flexible and efficient manufacturing of objects with diverse surface qualities using a single 3D printing system, reducing complexity and space requirements while improving production efficiency and adaptability.
Implementation Method 1
selectively hardening a layer of the hardenable material by irradiating light having the at least one or at least two selected optical resolutions provided by at least one light engine provided within the 3D printing system onto a focal plane within the hardenable material to form a layer of hardened material
Data Source
AI summary
A 3D printing system (10) for manufacturing at least one physical object comprises at least one reservoir (12) for receiving hardenable material; at least one light engine (22) configured to irradiate light onto a focal plane within the reservoir of the hardenable material to form a layer of hardened material; at least one build platform (18) for carrying the physical object to be manufactured; and a controller configured to select at least one or at least two optical resolutions from two or more optical resolutions available in the 3D printing system for irradiating the hardenable material based on a predetermined surface quality of the physical object to be manufactured.