3D Printing VCSEL Array for Voxel-Level Material Control
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Solution Overview
Problem
Current additive manufacturing technologies face challenges in achieving precise control over material properties at the voxel level, leading to inconsistent results due to inefficient use of agent materials and scattering of electromagnetic energy, which limits the range of chemistries and properties that can be manipulated in three-dimensional printed objects.
Innovation Solution
The use of a vertical cavity surface emitting laser (VCSEL) array with multiple wavelengths and adjustable intensities and durations of electromagnetic energy application allows for precise manipulation of material properties at the voxel level, enabling the creation of complex patterns and designs with varying physical and visual characteristics by selecting specific wavelengths and energy profiles tailored to the substrate and agent materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional electromagnetic energy sources are used in additive manufacturing, then the equipment is simple and easy to operate, but the scattering of electromagnetic energy occurs and precise control over material properties at the voxel level is not achieved
Solution Approach 1:
The patent employs VCSELs that can operate at multiple discrete wavelengths (e.g., 850 nm, 980 nm, 1064 nm) and allows independent control of intensity and duration for each wavelength. This parameter control enables precise manipulation of material properties at the voxel level by selecting specific wavelength-intensity-duration combinations that target particular material responses, thereby achieving high manufacturing precision while minimizing energy waste through targeted applications.
Solution Approach 2:
The electromagnetic energy source is divided into multiple independent VCSEL elements, each capable of emitting at a specific wavelength. This segmentation allows the system to apply electromagnetic energy selectively to different voxels with different wavelength-intensity-duration parameters, preventing energy scattering and enabling precise voxel-level control. Each VCSEL acts as an independent energy delivery channel that can be activated only where and when needed.
2Adaptability or versatility
If agent materials are used extensively to achieve desired material properties, then the range of achievable properties increases, but the efficiency of agent material use decreases and costs increase
Solution Approach 1:
Instead of relying on extensive agent materials, the patent changes the parameters of electromagnetic energy (wavelength, intensity, duration) to achieve different material properties. By tuning these parameters, the system can induce desired changes in substrate materials and agent materials more efficiently, reducing the quantity of agent materials needed while expanding the range of achievable properties through precise energy control.
Solution Approach 2:
The patent applies electromagnetic energy with specific wavelength-intensity-duration parameters to specific voxels where agent materials are present or needed. This localized application ensures that agent materials are activated or modified only in the required regions, improving their utilization efficiency and reducing waste while still achieving diverse material properties through spatially selective processing.
3Manufacturing precision
If multiple wavelengths of electromagnetic energy are applied to achieve fine gradations of material change, then the manufacturing precision improves, but the device complexity increases
Solution Approach 1:
The patent uses an array of VCSELs where each element is responsible for a specific wavelength channel. This segmentation allows the system to deliver multiple wavelengths simultaneously to different voxels or to the same voxel in a controlled manner. The modular nature of the VCSEL array makes it easier to manage the complexity compared to using a single broadband source with complex filtering and modulation systems.
Solution Approach 2:
The VCSEL array is designed to provide multiple wavelengths from a single integrated system, making it a universal energy source that can handle diverse material processing requirements. Each VCSEL element can be independently controlled, allowing the same hardware platform to achieve fine gradations of material change across different wavelengths without requiring separate equipment for each wavelength, thus managing device complexity while maintaining high manufacturing 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 enables the production of three-dimensional objects with fine gradations of material change, abrupt changes, and complex patterns, expanding the range of achievable properties such as texture, rigidity, and reflectivity, while optimizing the effectiveness of agent materials and minimizing non-uniformity issues.
Implementation Method 1
applying electromagnetic energy of at least a first intensity and of at least a first wavelength to the at least one material for the voxel via at least a first vertical cavity surface emitting laser of a plurality of vertical cavity surface emitting lasers to alter at least one property of the at least one material for the voxel
Data Source
AI summary
In one example, a device for printing a three-dimensional object is described. The device may include at least one material application unit to deposit at least one material for a voxel of the three-dimensional object, a vertical cavity surface emitting laser array comprising a plurality of vertical cavity surface emitting lasers, the plurality of vertical cavity surface emitting lasers including a first vertical cavity surface emitting laser to operate at a first wavelength and a second vertical cavity surface emitting laser to operate at a second wavelength, and a processor to control a deposition of the at least one material for the voxel via the at least one material application unit and to control an application of electromagnetic energy via at least one of the plurality of vertical cavity surface emitting lasers to the voxel to alter at least one property of the at least one material.