3D Printing Layer Exposure Control for Resin Shrinkage
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Solution Overview
Problem
Photocurable resin undergoes significant shrinkage during the curing process, leading to warpage and deformation in three-dimensional printed objects due to shrinkage stress, which existing methods fail to adequately address.
Innovation Solution
A photocuring-type three-dimensional printing method and device that divides the three-dimensional data model into layers, identifies exposed and internal areas, and performs exposure at intervals, using different exposure intensities and patterns to minimize shrinkage accumulation and tensile stress, including regional exposure techniques and support pillar formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large area of resin is cured together, then printing speed is improved, but shrinkage stress increases causing warpage and deformation
Solution Approach 1:
The patent divides the resin layer into multiple regions (first region and second region) with different exposure timing. The first region is exposed and cured before the second region, segmenting the curing process spatially to reduce cumulative shrinkage stress while maintaining overall printing efficiency.
Solution Approach 2:
The patent implements periodic exposure by alternating between exposing the first region and then the second region in sequential cycles. This periodic curing approach allows stress relaxation between regions while maintaining productivity through efficient regional exposure patterns.
2Loss of time
If exposure is performed on all areas simultaneously, then manufacturing time is reduced, but shrinkage accumulation causes deformation
Solution Approach 1:
The patent segments the exposure process into temporal sequences where the first region is exposed before the second region. This segmentation allows controlled shrinkage progression that prevents cumulative deformation while maintaining reasonable manufacturing time through efficient sequential processing.
Solution Approach 2:
The patent applies preliminary exposure to the first region before exposing the second region. This preliminary action allows the first region to cure and stabilize before the second region is exposed, preventing simultaneous shrinkage accumulation that would cause deformation.
3Productivity
If high exposure intensity is applied to all regions, then curing efficiency is improved, but shrinkage stress increases leading to warpage
Solution Approach 1:
The patent applies different exposure intensities to different regions: high intensity to the first region for efficient curing, and adjusted intensity to the second region. This local quality approach maintains overall curing efficiency while controlling shrinkage stress in specific areas to prevent warpage.
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
Significantly reduces warpage and deformation by controlling shrinkage and stress distribution, improving the accuracy and integrity of the printed objects.
Implementation Method 1
The photocuring method accumulates materials into certain form based on the principle that the photocurable resin can be cured by ultraviolet light
Data Source
AI summary
A photocuring-type three-dimensional printing method and device. The photocuring-type three-dimensional printing method comprises the following steps: obtaining a three-dimensional data model of a printing object; dividing the three-dimensional data model into a plurality of layers; identifying exposed areas and internal areas of various layers for at least a portion of the layers of the three-dimensional data model; performing exposure at each layer for the exposed areas of the various layers, and performing an exposure process at an interval of multiple layers for the internal areas of the various layers.