Adaptive Support Apparatus for 3D Printing Optical Path Control
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Solution Overview
Problem
Stereolithography 3D printing systems face mechanical variability in the optical path, leading to keystone distortion and scaling errors due to inaccuracies in maintaining the optical path trajectory and controlling the distance between the light engine optics and the build plane.
Innovation Solution
The implementation of an adaptive support apparatus with a spacer ring system that mechanically references the projection lens module, allowing for precise adjustment of the distance between the light engine and the build plane using spacer rings of varying thicknesses, and a tensioned transparent sheet to maintain a consistent vertical location of the build plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed optical path is used from light engine to build plane, then mechanical simplicity is maintained, but optical path variation causes keystone distortion and scaling errors
Solution Approach 1:
The patent implements a dynamically adjustable optical path system where the distance between the light engine and build plane can be precisely modified. This is achieved through adjustable support structures and positioning mechanisms that allow real-time optimization of the optical path length, thereby eliminating keystone distortion and scaling errors while maintaining system adaptability.
Solution Approach 2:
The patent replaces rigid mechanical coupling with adjustable and compensatable mechanical interfaces. By introducing adjustable support apparatus and positioning mechanisms, the system substitutes fixed mechanical constraints with flexible mechanical adjustments, allowing precise control of optical path variations without requiring complete mechanical redesign.
2Manufacturing precision
If adjustable support apparatus is added to control optical path distance, then fabrication accuracy is improved, but device complexity increases
Solution Approach 1:
The patent divides the support apparatus into modular components, including adjustable support structures, positioning mechanisms, and spacer elements. This segmentation allows each component to perform a specific function independently, simplifying the overall design and assembly while achieving precise optical path control through coordinated adjustment of individual modules.
Solution Approach 2:
The patent introduces intermediary elements such as adjustable spacers and positioning fixtures between the light engine and build plane. These intermediary components serve as mediators that enable precise distance control without requiring direct complex coupling between the primary components, thereby reducing overall system complexity while maintaining control 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 solution significantly reduces optical path variations, minimizing keystone distortion and scaling errors, thereby enhancing the fabrication accuracy of 3D articles by maintaining a precise and consistent trajectory of the optical path.
Implementation Method 1
a tensioned transparent sheet to maintain a consistent vertical location of the build plane
Implementation Method 2
a controllable light engine that selectively cures layers of the photocurable resin... a projection lens module... that mechanically references the projection lens module
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A three dimensional printer (2) includes a projector (20), an adaptive support apparatus (42), a resin support apparatus (6), and a plurality of vertical struts (18). The projector includes a projection lens module (40) which includes an optical housing that contains a series of lenses for projecting an image from the projector onto a build plane. The projection lens module includes a laterally extending flange (56) having an upwardly facing flange surface (58). The adaptive support apparatus includes a downward facing surface in facing relation with the upward facing flange surface. The resin support apparatus is configured to contain resin and includes a transparent sheet and a downward facing surface. The transparent sheet defines a lower bound for the resin proximate to a build plane. The plurality of vertical struts couple an upward-facing surface of the adaptive support apparatus to the downward-facing surface of the resin support apparatus.