3D Printing Substrate Angled Through Resin Vat
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Solution Overview
Problem
Existing 3D printing methods are inefficient in printing multiple copies of an article simultaneously due to computational and material inefficiencies, requiring significant time and resources, and often result in gaps in space and time between iterations.
Innovation Solution
The method involves executing multiple print files within a single projection layer, allowing for at least partially simultaneous printing of multiple iterations of the same or different articles by using a 3D printer with a reservoir of photo-curable resin, a conveyor, and a projector, where the substrate is moved through the resin at an acute angle, enabling continuous printing without mechanical recoating assistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional sequential 3D printing methods are used to print multiple copies of an article, then each copy is printed with high precision, but the printing process requires significant time and computational resources, and there are gaps in space and time between iterations
Solution Approach 1:
The patent merges multiple sequential printing operations into a single simultaneous printing operation by executing multiple print files within a single projection layer. This allows multiple copies of an article to be printed at the same time on different segments of a substrate, eliminating the time gaps between iterations and significantly improving printing throughput
Solution Approach 2:
The patent segments the substrate into multiple adjacent segments, with each segment dedicated to printing a specific copy of the article. This segmentation enables parallel processing of multiple print files across different substrate segments while maintaining the integrity and precision of each individual article copy
2Productivity
If traditional 3D printing methods reset the print stage between iterations, then each printing operation starts with optimal positioning, but this resetting process creates time gaps and reduces overall efficiency
Solution Approach 1:
The patent eliminates the discontinuous reset operations between printing iterations by continuously moving the substrate through the resin reservoir and executing multiple print files in sequence across adjacent segments. This continuous operation maintains optimal positioning throughout the process, removing idle reset time and improving overall printing efficiency
3Productivity
If multiple print files are executed sequentially within a single projection layer, then multiple copies can be printed simultaneously on adjacent substrate segments, but this requires precise coordination of substrate movement and projection timing
Solution Approach 1:
The patent implements precise coordination between substrate movement and projection timing through feedback control mechanisms that monitor the substrate position and adjust the projection timing accordingly. This ensures that each print file is executed at the correct moment on the appropriate substrate segment, maintaining high positioning accuracy while enabling simultaneous printing of multiple copies
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 achieves computational, material, and time efficiency by allowing multiple copies of an article to be printed simultaneously, reducing the need for resetting the print stage and minimizing space and time gaps between iterations, thereby increasing throughput.
Implementation Method 1
a projector configured to project radiation at a surface of the photo-curable resin
Data Source
AI summary
Provided herein are systems and methods for efficiently printing 3D articles from a photo-curable resin. The systems and methods may iteratively execute a print file having instructions for printing the article, where a subsequent iteration may begin before a prior iteration has completed printing. In some embodiments, multiple iterations of an article may be printed onto a substrate as the substrate is moved into a vat of resin at an acute angle relative to the surface of the resin. Different portions of the multiple iterations of the article at respective intersection cut heights may be printed simultaneously within the same merged projection plane.