Aligning Pixelated Light Engines in 3D Printing
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Solution Overview
Problem
Current stereolithography systems using spatial light modulators are limited by the pixel count, making it difficult to produce larger and higher resolution three-dimensional articles with multiple light engines effectively aligned for accurate and efficient digital fabrication.
Innovation Solution
A three-dimensional printing system comprising multiple light engines, an alignment article with reflective targets, and a controller that captures and analyzes images to align the light engines accurately, allowing for precise alignment and improved resolution through mechanical and software adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If multiple light engines are used to increase pixel count and build field size, then larger and higher resolution articles can be produced, but alignment accuracy between light engines becomes difficult to achieve and maintain
Solution Approach 1:
A calibration target serves as an intermediary object between multiple light engines and the camera. The target includes reflective elements and markers that enable each light engine to be individually calibrated and aligned to a common reference frame, solving the alignment accuracy problem when using multiple light engines to expand build field size
Solution Approach 2:
The system uses a camera to capture images of the calibration target, and software analyzes these images to provide feedback on the alignment status of each light engine. This feedback loop enables automated adjustment and verification of alignment accuracy across multiple light engines
2Manufacturing precision
If manual alignment methods are used for multiple light engines, then alignment can be achieved, but the process is time-consuming and difficult to maintain accuracy
Solution Approach 1:
The patent replaces manual mechanical alignment methods with an automated optical measurement and software-based calibration system. The camera captures images of calibration targets, and algorithms automatically compute alignment parameters, eliminating time-consuming manual adjustment while maintaining high alignment accuracy
Solution Approach 2:
The system performs self-calibration by automatically capturing images of the calibration target, analyzing the data, and adjusting light engine alignment without requiring continuous manual intervention. This self-service capability reduces alignment time and maintains accuracy consistently
3Area of stationary object
If overlapping build fields from multiple light engines are used, then larger articles can be manufactured, but ensuring uniform quality across the entire build plane becomes more difficult
Solution Approach 1:
The calibration target with reflective elements serves as a common reference intermediary for all light engines. By calibrating each light engine to this shared reference, the system ensures that all overlapping build fields are uniformly aligned and maintain consistent quality across the entire expanded build plane
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
Enables the creation of larger and higher resolution three-dimensional articles by ensuring accurate alignment of multiple light engines, enhancing the efficiency and quality of the digital fabrication process.
Implementation Method 1
operate the camera to repeatedly capture the alignment calibration image including spots of light reflected from the reflective alignment targets
Implementation Method 2
the selective curing and hardening of radiation curable (photocurable) liquid resins
Data Source
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AI summary
A three dimensional printing system (2) includes a plurality of light engines (4), an alignment article (40), a camera (46), and a controller (26). The plurality of light engines define a corresponding plurality of build fields which overlap and define a build plane (6). The alignment article carries an alignment calibration image and is configured to be mounted in the three dimensional printing system with the alignment calibration image (44) proximate to the build plane and in facing relation with the plurality of light engines. The alignment calibration image defines a dark field with an array of reflective alignment targets. The camera is mounted to be in facing relation to the alignment calibration image. The controller is configured to operate at least the light engines and the camera to individually align the light engines to the alignment calibration image.