Additive Manufacturing Device Using Programmable Radiation Module
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Solution Overview
Problem
Current stereolithographic additive manufacturing methods are slow due to the linear increase in printing time with object size and density, and DMD-based systems face limitations in scalability and resolution when printing large objects.
Innovation Solution
An additive manufacturing device employing a programmable radiation module with an array of individually addressable radiation emitting or transmitting elements, such as a liquid crystal display (LCD), which allows for layer-by-layer curing without magnification, enabling faster and more scalable production of three-dimensional structures by controlling the curing time independently of layer thickness and resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a scanning laser is used to polymerize material layer by layer, then manufacturing precision can be maintained, but productivity decreases linearly with object size and feature density
Solution Approach 1:
The patent replaces the mechanical scanning laser system with a digital micromirror device (DMD) projection system. Instead of physically moving a laser beam across the material, the DMD electronically directs UV light to polymerize entire regions simultaneously, eliminating the linear relationship between object size and printing time while maintaining precision through digital control of mirror orientations.
Solution Approach 2:
The invention transitions from one-dimensional sequential line scanning to two-dimensional parallel region projection. By projecting entire patterns of light across the material surface simultaneously rather than scanning line by line, the system achieves exponential speedup for larger objects and higher feature densities.
2Productivity
If a DMD-based projection system is used to increase printing speed, then productivity improves, but manufacturing precision deteriorates when printing large objects due to pixel stretching
Solution Approach 1:
The patent employs a dynamically adjustable projection system where the DMD can adaptively control light distribution. By varying the projection parameters and exposure timing, the system maintains consistent resolution across different object sizes without requiring physical enlargement of the DMD chip, thus preserving manufacturing precision while achieving high productivity.
3Adaptability or versatility
If the projected image area is enlarged to print large objects, then adaptability improves, but manufacturing precision and curing time deteriorate due to fixed pixel count
Solution Approach 1:
The invention changes the parameter of light intensity distribution dynamically. By adjusting the UV light source intensity and exposure duration based on the projected area size, the system compensates for the fixed pixel count limitation, maintaining consistent resolution across varying build sizes and improving adaptability without sacrificing manufacturing precision.
4Adaptability or versatility
If the projected image area is enlarged for large build sizes, then adaptability improves, but duration of action increases due to reduced photon intensity per unit area
Solution Approach 1:
The patent dynamically adjusts the UV light source intensity parameter in response to projected area changes. When printing larger objects, the system increases overall light output to compensate for the reduced photon density per unit area, thereby maintaining consistent curing times across different build sizes and improving adaptability without extending duration of action.
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 significantly increases printing speed and scalability, reducing the need for moving parts and lowering costs, while maintaining high resolution, and avoids the limitations of DLP projection systems by maintaining effective photon intensity across larger print sizes.
Implementation Method 1
a source of radiation and a means of directing that radiation in accordance with specific patterns onto a layer of polymerizable material. The radiation causes this material to polymerize
Data Source
AI summary
Disclosed is an additive manufacturing device, comprising: a vessel for containing a material which is polymerisable on exposure to radiation; a build platform having a build surface, the build platform being mounted or mountable for movement relative to the vessel; and a programmable radiation module comprising an array of individually addressable radiation emitting or transmitting elements, the array being configurable to produce radiation having a predetermined pattern by selective activation of elements of the array; wherein the programmable radiation module is positioned or positionable to irradiate uncured material adjacent the build surface, or adjacent a previously cured structure on the build surface, with the predetermined pattern without magnification. Also disclosed is an additive manufacturing method which employs the additive manufacturing device.