CNC Additive Manufacturing with Fiber Optic UV Tool
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing (AM) processes based on layering face challenges such as inconsistent material properties and difficulty in embedding existing components due to limited tool motion and material orientation limitations.
Innovation Solution
A CNC additive manufacturing system using a UV-curable liquid resin and a fiber optic cable with a UV-LED, allowing for multi-axis motion and selective curing of resin in various directions, with coatings to manage attaching forces and ensure proper bonding to the base or previously built parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If layer-based additive manufacturing is used, then process planning is simplified, but material properties become inconsistent and embedding existing components becomes difficult
Solution Approach 1:
Instead of moving the tool in traditional X-Y-Z axes to build layers, the patent inverts the approach by moving the workpiece (or embedding components) through the tool path. The tool remains relatively stationary while the workpiece moves through it, allowing consistent material deposition from multiple directions and enabling embedding of existing components within the build path.
Solution Approach 2:
The patent introduces dynamic motion capabilities beyond traditional translational movements. The system allows for complex, multi-axis motion paths that can adapt in real-time, enabling the tool to reach various positions and orientations dynamically. This dynamic approach allows consistent material properties by maintaining optimal deposition angles and speeds throughout the build process.
2Ease of manufacture
If layer-based additive manufacturing is used, then process planning is simplified, but embedding existing components becomes difficult due to limited tool motion
Solution Approach 1:
The patent inverts the traditional approach by allowing the workpiece to move through the tool rather than the tool moving through fixed layers. This inversion enables existing components to be positioned within the build path and embedded as the tool deposits material around them, significantly improving embedding capabilities while maintaining process planning simplicity.
Solution Approach 2:
The patent extends motion beyond the traditional three translational axes by incorporating rotational degrees of freedom and non-linear paths. This additional dimensional freedom allows the tool to access and embed components from multiple angles and orientations, making the process highly adaptable for complex embedding scenarios while keeping process planning manageable through computational path generation.
3Productivity
If multi-axis motion and selective curing is implemented, then building speed and material properties are improved, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional system where a single tool can perform multiple operations (deposition, curing, and potentially other post-processing) and the same system can handle various material types and geometries. The multi-axis motion system serves universal purposes for both complex embedding scenarios and high-speed building, reducing the need for multiple specialized devices and justifying the complexity through versatility.
Solution Approach 2:
The patent utilizes dynamic parameter changes during the build process, including real-time adjustment of curing intensity, deposition rate, and motion speed. By programmatically controlling these parameters based on the specific geometry and material requirements, the system achieves high building speed and material quality without requiring permanently complex hardware configurations, as the complexity is managed through software control.
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 enhances building speed and material properties by enabling the construction of complex geometries with improved material integration and embedding capabilities, reducing the limitations of traditional layer-based methods.
Implementation Method 1
By controlling the on/off state of the UV-LED and the multi-axis motion of the cable, a physical model, having a desired shape, can be built by selectively curing liquid resin into solid.
Data Source
AI summary
An additive manufacturing system and process are described. In one example of the invention, a fiber optic cable connected with an ultraviolet (UV) LED and related lens forms an accumulation tool. The cable is then merged inside a tank filled with liquid resin that is UV-curable. By controlling the on/off state of the UV-LED and the multi-axis motion of the cable, a physical model, having a desired shape, can be built by selectively curing liquid resin into solid.