3D Printing Mirror Array Scanning for High-Resolution Curing
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Solution Overview
Problem
Current 3D printing systems face challenges in achieving high resolution and speed in imaging processes, 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 dispensing module, 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, allowing for selective imaging and redundancy to enhance resolution and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional imaging system is used in 3D printing, then the system is simpler and easier to operate, but the resolution and speed of imaging are insufficient
Solution Approach 1:
The imaging system is segmented into multiple independent components: a two-dimensional mirror array with individually controllable mirrors, a pulsed light source, and a scanning mechanism. Each mirror can be independently controlled to direct light to specific locations on the build plane, enabling high-resolution selective imaging while maintaining system modularity
Solution Approach 2:
The system employs dynamic scanning of the imaging module across the build plane in conjunction with pulsed illumination. The mirrors and light source operate in synchronization during scanning, allowing the system to achieve high resolution through temporal and spatial modulation rather than requiring a static, overly complex high-resolution imaging system
2Productivity
If the imaging system scans faster to improve productivity, then the printing speed increases, but the resolution and accuracy of material curing decrease
Solution Approach 1:
The system uses periodic pulsed illumination synchronized with the scanning motion. Pulses of light are emitted at specific intervals during the scan, with each pulse duration δT carefully controlled. This periodic action allows the imaging system to maintain high scanning speeds while ensuring sufficient energy delivery for precise material curing at each addressed location
Solution Approach 2:
The mirror array is pre-configured with ON/OFF states before each pulse is emitted. This preliminary configuration ensures that when the pulsed light reaches the build plane, the energy is delivered precisely to the intended locations without requiring slower, real-time adjustment during the pulse itself, thereby maintaining both speed and precision
3Reliability
If redundancy is increased by having multiple mirrors address the same point, then reliability improves and gray levels increase, but the device complexity and control difficulty increase
Solution Approach 1:
The controller pre-calculates and pre-configures the ON/OFF states of multiple mirrors that will address the same build plane location before the scan reaches that point. This preliminary assignment of mirror states simplifies real-time control during scanning, as the system only needs to execute pre-determined mirror configurations rather than making complex decisions during the scan
Solution Approach 2:
The redundant mirrors are activated in periodic sequences synchronized with the pulsed light source and scanning motion. Different mirrors address the same location at different times during the scan, with their collective contributions summed to achieve the desired gray level. This temporal separation of redundant mirror operations reduces control complexity compared to simultaneous activation
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 configuration enables high-resolution imaging with improved contrast ratio and the ability to form layers efficiently, reducing the impact of malfunctioning mirror elements and allowing for more gray levels, thus enhancing the overall printing process.
Implementation Method 1
a pulsed light source operable to generate a sequence of radiation pulses that illuminate the mirror array
Implementation Method 2
an imaging module that receives radiation from the pulsed light source and includes a two-dimensional mirror array defining N rows and M columns of mirrors
Implementation Method 3
Some of these three dimensional printing systems utilize the application of energy to selectively cure or fuse materials
Data Source
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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.