3D Printing Image Scrolling for Large Area High Resolution
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Solution Overview
Problem
Existing 3D printing technologies using electronic light projectors are limited by the native pixel size, restricting the building area and resolution, especially for larger areas, as they rely on static image exposure, which cannot efficiently accommodate varying object sizes without compromising resolution or increasing building time.
Innovation Solution
Implementing an image scrolling technique where the light projector moves relative to the material, allowing for continuous exposure of a seamless image strip, enabling increased building area and resolution without altering hardware, by using subpixelation and optical multiplexing to dynamically adjust resolution and building speed through software control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the image size is increased to cover a larger building area, then the building area is improved, but the resolution deteriorates due to increased pixel size
Solution Approach 1:
The patent divides the building area into multiple sequential image strips that are exposed one after another. Each strip contains multiple images that are stitched together to form a continuous seamless image strip. This segmentation allows the system to cover a large building area while maintaining high resolution in each individual strip, as the resolution is determined by the projector's native pixel size rather than the total area.
Solution Approach 2:
The patent introduces dynamic motion between the projector and the material during exposure. The projector moves relative to the material along the x-axis while continuously exposing image strips. This dynamic approach replaces the static image exposure method, allowing the system to cover an effectively infinite building area by simply extending the duration of the scanning process without compromising resolution.
2Area of stationary object
If the pixel size is increased to cover a larger building area, then the building area is improved, but the resolution deteriorates
Solution Approach 1:
The patent segments the total building area into multiple sequential image strips, each containing multiple images. By dividing the exposure into these segments, the system can cover a large area while each segment maintains the projector's native high resolution. The segmentation prevents the need to increase pixel size by spreading the total area coverage across time and multiple sequential exposures.
Solution Approach 2:
The patent adds the time dimension to the exposure process by introducing continuous motion along the x-axis. Instead of capturing the entire building area in a single static image, the system exposes multiple images sequentially over time, creating a seamless image strip through temporal integration. This dimensional transformation allows area expansion without sacrificing resolution.
3Manufacturing precision
If a static image is used for exposure, then the resolution is maintained, but the building area is limited by the image size
Solution Approach 1:
The patent transforms the static image exposure method into a dynamic scanning process. The projector moves continuously relative to the material along the x-axis during exposure, creating a seamless image strip by sequentially exposing multiple images. This dynamic approach removes the building area limitation inherent in static images, as the area can be extended simply by continuing the scanning process, while resolution is maintained through the projector's native pixel size.
Solution Approach 2:
The patent implements continuous exposure during the scanning process, where the projector continuously exposes the material as it moves. This continuous action creates a seamless image strip without gaps or interruptions, allowing the building area to be extended indefinitely by simply continuing the continuous exposure process, while maintaining consistent resolution throughout.
4Area of stationary object
If the building area is increased using flash and step mode, then the building area is improved, but the building time increases
Solution Approach 1:
The patent replaces the discontinuous flash and step mode with a continuous exposure process. The projector moves continuously relative to the material while exposing the entire image strip in one uninterrupted sequence, rather than exposing multiple separate images with positioning movements in between. This continuity eliminates the time-consuming step movements and positioning operations, significantly reducing the total building time while covering the same large area.
Solution Approach 2:
The patent introduces dynamic continuous motion during exposure, where the projector and material move relative to each other in a coordinated manner throughout the entire exposure process. This dynamic approach allows the system to cover large areas in a single continuous operation, eliminating the need for repeated positioning and exposure cycles required by static flash and step mode, thereby reducing building time.
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 method allows for an effectively infinite building area, high resolution, and adjustable building speed, enabling the creation of multiple small or large 3D objects with increased efficiency, as the pixel size remains small and exposure time is maintained, even at higher resolutions, without requiring hardware changes.
Implementation Method 1
Method for exposing a photo polymerizable material for solidification of material layer by layer to build a 3D object
Data Source
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AI summary
A method for exposing a photo polymerizable material (405) for solidification of material layer by layer to build a 3D object comprises the following steps dividing the image (303) to be exposed into a number of sub images (304, 305, 306, 307) with an internal distance (302) of at least one pixel, and exposing the sub images (304, 305, 306, 307) sequentially onto the photo polymerizable material (405) by means of a light projector (402).