Coater Bar and Resin Sensor for Solid Imaging Layer Control
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Solution Overview
Problem
Solid imaging systems face challenges in controlling layer thickness and material management during the creation of three-dimensional objects, leading to inefficiencies and potential errors in the curing process.
Innovation Solution
The use of a coater bar with a flexible, radiation-transparent bottom film and a resin sensor to control layer thickness, combined with a shuttle and valve system for precise material dispensing and removal, ensures accurate application and curing of solid imaging material layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a coater bar is used to control layer thickness, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The coater bar is designed with movable and adjustable components that allow dynamic control of layer thickness. The bar can be positioned at different heights and angles to precisely control the thickness of material layers during the imaging process, transforming a static system into a dynamically adjustable one.
Solution Approach 2:
The coater bar acts as an intermediary element between the material supply system and the imaging surface. It mediates the material flow by scraping and distributing the solid imaging material uniformly across the surface, ensuring precise layer thickness control while isolating the complexity of material handling from the imaging system.
2Manufacturing precision
If material is precisely dispensed and removed, then manufacturing precision is improved, but loss of substance increases
Solution Approach 1:
The coater bar system is designed to self-regulate material distribution. As it moves across the surface, it automatically scrapes excess material and distributes the precise amount needed, using the material's own flow properties to achieve uniform layers without requiring additional control mechanisms that would increase material waste.
Solution Approach 2:
The system controls material application by changing parameters such as coater bar speed, pressure, and position. By adjusting these parameters, the system optimizes material distribution to achieve precise layer thickness while minimizing excess material that would need to be removed and wasted.
3Manufacturing precision
If layer thickness is precisely controlled, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The coater bar operates continuously during the material application process, maintaining constant contact with the surface to ensure uniform layer thickness throughout. This continuous action eliminates the need for multiple passes or adjustments, maintaining high productivity while ensuring precision.
Solution Approach 2:
The coater bar performs preliminary distribution and scraping of material before the curing process begins. By preparing the material layers in advance with precise thickness control, the system eliminates the need for post-application adjustments or rework, maintaining both precision and productivity.
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 allows for precise control over layer thickness and material application, improving the quality and efficiency of three-dimensional object creation by preventing unwanted curing and optimizing material usage.
Implementation Method 1
a resin sensor positioned below the radiation-transparent bottom film and that detects the presence and thickness of the resin layer above the sensor by sending an optical signal, or other detectable signal, that reflects back to the sensor
Implementation Method 2
actinic radiation can be projected to cure cross-sectional patterns of the three-dimensional object onto the photosensitive solid imaging material, thereby curing the material
Data Source
AI summary
There is provided solid imaging methods and apparatus for making three-dimensional objects from solid imaging material. A tray with a film bottom is provided to hold solid imaging material that is selectively cured into cross-sections of the three-dimensional object being built. A coater bar is moved back and forth over the film to remove any uncured solid imaging material from a previous layer and to apply a new layer of solid imaging material. A sensor is provided to measure the amount of resin in the tray to determine the appropriate amount of solid imaging material to be added, from a cartridge, for the next layer. A shuttle, which covers the tray when the exterior door to the solid imaging apparatus is opened for setting up a build or removing a three-dimensional object, can also be used to move the coater bar and to selectively open one or more valves on the cartridge to dispense the desired amount of solid imaging material.