3D Printing Illumination Pixel Alignment for Orthodontic Precision
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Solution Overview
Problem
The existing 3D printing process for orthodontic appliances lacks precision, leading to cumbersome reconstruction and increased costs due to limited precision and long printing durations, especially in manufacturing conventional orthodontic brackets without the need for reconstruction.
Innovation Solution
A method utilizing a 3D-printing device with adjustable illumination intensity and duration to align illumination pixels with the object's dimensions, allowing precise solidification of specific areas, reducing overlap and improving precision without the need for costly devices or lengthy printing times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional 3D printing processes are used for orthodontic appliances, then manufacturing can be performed with standard equipment, but precision is insufficient requiring cumbersome reconstruction and increasing costs
Solution Approach 1:
The patent changes the parameter of illumination pixel dimension to match the critical dimension of the orthodontic bracket (arch wire slot width). By setting illumination pixel dimensions between 10-80 μm to align with the bracket's critical features, the system achieves precise manufacturing without requiring complex design reconstructions, directly resolving the contradiction between precision and manufacturing ease
Solution Approach 2:
The patent performs preliminary alignment of the virtual model's dimensions with the illumination pixel grid before the printing process. This preliminary action ensures that critical features like arch wire slots are perfectly aligned with illumination pixels, eliminating the need for post-processing reconstructions and simplifying the manufacturing process while maintaining high precision
2Manufacturing precision
If higher precision is achieved through conventional methods, then manufacturing accuracy improves, but printing duration increases significantly
Solution Approach 1:
The patent segments the illumination process into discrete pixels that can be independently controlled. By dividing the illumination field into individual pixels with dimensions matching the object's critical features, the system can selectively illuminate only the necessary areas at full intensity, achieving high precision without requiring uniformly long printing times across the entire object
Solution Approach 2:
The patent implements dynamic adjustment of illumination parameters (intensity and duration) for different pixel regions. Critical dimensions receive targeted illumination with optimized parameters, while non-critical areas use reduced parameters, creating a dynamic printing process that maintains precision for important features while reducing overall printing time
3Manufacturing precision
If illumination parameters are optimized for precision, then dimensional accuracy improves, but control complexity increases
Solution Approach 1:
The patent creates a digital copy (virtual model) of the orthodontic bracket where the coordinate system is预先 aligned with the illumination pixel grid. This digital copying approach allows precise control of illumination parameters through software rather than complex hardware modifications, simplifying the control system while maintaining high dimensional precision
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 enhances the precision of 3D printing, enabling the production of orthodontic appliances with improved accuracy and reduced manufacturing time and costs, while maintaining the freedom to use various materials like ceramics, metals, and plastics.
Implementation Method 1
means for illumination to solidify a layer of non-solidified material provided by the supply device at least zonally to fabricate the object
Data Source
AI summary
A method for manufacturing an object, in particular an orthodontic appliance, by a 3D-printing device comprising a supply device for provision of a non-solidified material and means for illumination to solidify a layer of non-solidified material provided by the supply device at least zonally to fabricate the object, characterized by the following steps:a virtual model of the object to be printed is provided for the 3D-printing device,the supply device provides a layer of the non-solidified material,the means for illumination solidify the layer at least zonally, whereby the means for illumination comprises illumination pixels arranged in a grid, preferably with a dimension (between 10 μm and 80 μm, particularly preferred between 30 μm and 50 μm, wherein at least one dimension of the object represented by the virtual model is chosen to be aligned with the dimension of the illumination pixels.