Centrifugal Photopolymer 3D Printing for Uniform Layer Formation

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Solution Overview

Problem

Current additive manufacturing techniques face challenges such as part inaccuracies due to meniscus formation, voids, and process failures from separation forces, especially in methods involving vacuum delivery and non-uniform layer distribution.

Innovation Solution

A centrifuge-based system with a rotating drum and light source module that utilizes centrifugal force to evenly distribute photopolymer material, combined with controlled light solidification and pressure management to ensure uniform layer formation without mechanical contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If photopolymer material is delivered using vacuum delivery or stationary vat methods, then material can be applied to the build surface, but meniscus formation and voids occur causing part inaccuracies

Engineering Contradiction:

Improvepart accuracyVSAvoidprocess stability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The system transitions from stationary material delivery to dynamic centrifugal delivery. The rotating drum creates continuous motion that distributes photopolymer material uniformly across the build surface, eliminating the static conditions that cause meniscus formation and voids while maintaining material application reliability

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes the physical parameters of material delivery by introducing centrifugal force through rotation. This transforms the material application process from vacuum-based or gravity-based delivery to centrifugal force-driven distribution, fundamentally altering how material contacts the build surface and eliminating defect formation

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If material is delivered through transparent membrane at bottom of vat, then layers can be polymerized, but separation forces cause process failures and object destruction

Engineering Contradiction:

Improvelayer polymerization qualityVSAvoidobject integrity

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The invention inverts the traditional approach by delivering material from above the build surface rather than from below through a membrane. This reversal eliminates the need for membrane-based delivery and the associated separation forces that damage objects, while still achieving uniform layer polymerization through centrifugal distribution

Inventive Principle:

Principle #13The other way round (Inversion)

3Quantity of substance

If single-nozzle or multi-nozzle print heads are used to jet resin downward, then material can be deposited, but uniform distribution of newly formed layer is difficult to achieve

Engineering Contradiction:

Improvematerial depositionVSAvoidlayer uniformity

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The invention replaces the mechanical jetting system with a centrifugal field-based distribution system. Instead of using nozzles to mechanically eject material, the rotating drum uses centrifugal force to naturally distribute material uniformly across the build surface, achieving both deposition and uniformity without mechanical contact

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Achieves precise and uniform deposition of photopolymer layers, reducing defects like meniscus and voids, and enhancing the overall accuracy and reliability of 3D object manufacturing.

Implementation Method 1

the photopolymer material spreads evenly over an item being manufactured when the rotating drum is in motion

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

a photopolymer material that solidifies when irradiated by a light source

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 3

air pressure within the rotating drum is raised above surrounding atmospheric air pressure while the rotating drum is in operation

Methodology Applied

Scientific EffectPressure increase: Pressurisation

Data Source

PatentUS12521939B2Additive manufacturing apparatus, system and method

Publication Date: 2026.01.13 TURBO 3D LLC

AI summary

A system and method for providing centrifuge-based additive object manufacturing includes a rotating drum containing a material that solidifies when irradiated by a light source, the material spreads evenly over an item being manufactured when the rotating drum is in motion, a light source module emitting a light capable of solidifying the photopolymer material, and a material delivery module for adding a controlled amount of the photopolymer material into the rotating drum. The light source module moves inside the rotating drum and selectively emits its light solidifying the part of the layer in the areas crossing the object currently being manufactured.