Additive Manufacturing Stage Motion for Larger Resin Components
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Solution Overview
Problem
Existing additive manufacturing processes, such as tape casting, are limited in producing larger components due to the fixed nature of the radiant energy device and stage, restricting the size and complexity of the components that can be manufactured.
Innovation Solution
The implementation of a movable stage and radiant energy device relative to a transparent window, allowing simultaneous movement in the X-axis and Z-axis directions, enabling the production of larger components through multiple curing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the radiant energy device and stage are fixed in position, then the apparatus structure is simple, but the component size is limited to small dimensions
Solution Approach 1:
The patent implements movable stage and radiant energy device that can translate along the X-axis and rotate, transforming the fixed configuration into a dynamic one. This allows the build area to be expanded beyond the physical dimensions of the window by repositioning components to access different regions of the resin support sequentially.
Solution Approach 2:
The patent adds rotational degrees of freedom to the stage and radiant energy device, enabling movement not just in linear X-axis translation but also in angular orientation. This multi-dimensional movement capability allows access to larger build volumes and creates larger components through multiple curing steps.
2Adaptability or versatility
If the stage and resin support are separated, then larger components can be produced, but the manufacturing process becomes more complex
Solution Approach 1:
The stage is designed to be movable relative to the resin support, allowing dynamic separation and repositioning. This enables the stage to be moved to different positions along the X-axis and rotated to access different portions of the resin support, facilitating the production of larger components through multiple curing steps.
Solution Approach 2:
The patent implements a continuous manufacturing process where the stage moves sequentially to different positions and the radiant energy device cures resin in successive portions. This continuous action allows larger components to be produced without interrupting the manufacturing flow, maintaining efficiency while increasing component size capability.
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 configuration enhances the capability to produce larger and more diverse components while reducing the overall apparatus size, improving manufacturing flexibility and efficiency.
Implementation Method 1
a radiant energy device positioned on an opposite side of the resin support from the stage and operable to generate and project radiant energy in a patterned image through the window
Data Source
AI summary
An additive manufacturing apparatus includes a support plate defining a window and a resin support configured to support an uncured layer of resin. A stage is configured to hold one or more cured layers of the resin to form a component positioned opposite a support plate. A radiant energy device is positioned on an opposite side of the resin support from the stage and is operable to generate and project radiant energy in a patterned image through the window. The stage is configured to move simultaneously with the resin support from a first position to a second position in an X-axis direction.