Alternating Exposure Pattern for 3D Printing Separation Force
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Solution Overview
Problem
In three-dimensional object manufacturing, the force required to separate solidified objects from substrates can be excessive, leading to deformation or breakage due to strong adhesion, especially when using flexible films or blades as solidification substrates.
Innovation Solution
The method involves alternately sequencing the exposure of different solidifiable material surface positions relative to the build axis during object building, reducing the surface area of adhesion between the solidified object and the substrate by subdividing voxel or pixel data into exposure subsets and applying energy in a pattern that minimizes the force needed for separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a transparent or translucent rigid layer is used as a reference plane for solidification, then the solidifiable material can be supported during curing, but the separation force required to remove the solidified object becomes excessive causing deformation or breakage
Solution Approach 1:
The solidification process is segmented into multiple sequential steps where different regions of the solidifiable material are cured at different times. This creates a checkerboard pattern of cured and uncured regions, reducing the total contact area between the solidified object and reference plane at any given moment, thereby reducing separation force while maintaining support stability during the overall solidification process
Solution Approach 2:
The curing process uses periodic action by alternating between exposing and non-exposing regions in a repeating pattern. This periodic exposure creates alternating bands of cured and uncured material, allowing the object to be supported during curing while minimizing the adhesion area that would require excessive force for separation
2Ease of operation
If a flexible film or belt is used to transport solidifiable material, then the material can be delivered to the pattern generator, but the film or belt breaks or deforms when the object is separated
Solution Approach 1:
The adhesion between the solidified object and flexible film is segmented through alternating exposure patterns. By curing only certain regions while leaving others uncured, the total bonding area is reduced, allowing the flexible film to transport the material without experiencing excessive stress that would cause breaking or deformation during separation
3Stability of the object's composition
If the entire surface of solidifiable material is exposed to solidification energy simultaneously, then the object solidifies uniformly, but the adhesion area increases requiring excessive separation force
Solution Approach 1:
Instead of simultaneous exposure, the patent uses periodic action by alternating between exposing and non-exposing regions in a systematic pattern. This creates a checkerboard or banded distribution of cured and uncured areas, maintaining overall solidification progress while limiting the contact area that generates separation force
Solution Approach 2:
The solidification process is divided into multiple sequential exposure steps rather than a single simultaneous exposure. Each step cures a specific subset of regions, and by managing the sequence and pattern of these segmented exposure steps, the patent achieves uniform overall solidification while controlling the adhesion area at any given moment
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 reduces the separation force required, minimizing the risk of object deformation or breakage and allowing for more efficient and controlled removal of solidified objects from the substrate.
Implementation Method 1
photo-polymer hardening using light or laser curing methods
Data Source
AI summary
A method and apparatus for making a three-dimensional object from a solidifiable material such as a photopolymer is shown and described. In accordance with the method, positions relative to a build axis are subdivided into first and second exposure data subsets, and the first and second exposure data subsets are solidified in alternating sequences to reduce the surface area of solidified material in contact with a solidification substrate.