3D Build Platform Leveling for Sub-10 Micron Printing Tolerance
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Solution Overview
Problem
Existing 3D printing systems face challenges in achieving feature size tolerances smaller than 10 microns due to limitations in optical and mechanical systems, leading to difficulties in precisely positioning the build plate during the manufacturing process.
Innovation Solution
The implementation of an elevator with a vertical movement mechanism, a build platform, and an imaging module, along with confocal distance sensors and elevator actuators, allows for precise leveling and compensation of machine tolerances and fluidic drag, enabling dimensional tolerances of less than 10 microns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional 3D printing systems are used, then the manufacturing process is simple, but the manufacturing precision is limited to 20 microns or larger
Solution Approach 1:
The system performs preliminary leveling of the build plate using actuators before the printing process begins. The distance sensor scans the build plate surface and the controller adjusts the plate orientation to achieve a perfectly level surface, preparing the system for high-precision printing before actual manufacturing starts
Solution Approach 2:
The system uses distance sensors to continuously measure the build plate surface position and provides feedback to the controller. The controller processes this information and adjusts the actuators in real-time to maintain precise positioning and leveling, enabling manufacturing precision below 10 microns through closed-loop control
2Measurement precision
If the build plate is lowered into the resin, then the imaging can begin, but mechanical and fluidic drag cause positional discrepancy
Solution Approach 1:
The system applies preliminary counter-actions to compensate for expected fluidic drag forces. Before lowering the build plate into the resin, the controller calculates the anticipated drag based on the resin viscosity and plate movement parameters, and pre-adjusts the motor positions to counteract the expected positional discrepancy, preventing rather than correcting the error
Solution Approach 2:
The distance sensor continuously monitors the actual position of the build plate during resin immersion and provides feedback to the controller. The controller compares the measured position with the commanded position and adjusts the motor commands in real-time to compensate for fluidic drag, maintaining measurement precision despite the harmful forces
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 enables the production of 3D articles with feature sizes as small as 5 microns or even less than one micron, improving the resolution and precision of 3D printing systems.
Implementation Method 1
The distance sensor can be a confocal distance sensor or a plurality of confocal distance sensors
Implementation Method 2
The present disclosure concerns an apparatus and method for fabrication of solid three dimensional (3D) articles of manufacture from radiation curable materials
Data Source
AI summary
A method of manufacturing a 3D article includes operating a 3D printing system including an elevator coupled to a vertical movement mechanism, and a distance sensor. The elevator includes an elevator actuator. The vertical movement mechanism is coupled to the elevator. The build platform includes a build plate having a lower surface. The method includes loading the build platform onto the elevator, operating the vertical movement mechanism to lower the lower surface of the build platform into a measurement range with the distance sensor, scanning the distance sensor along a lateral axis, concurrent with scanning the distance sensor, receiving a signal from the distance sensor indicative of a plurality of vertical locations along the lateral axis of the lower surface of the build platform, and operating the elevator actuator to adjust a height of the lower surface of the build platform.