Coater Bar and Resin Sensor for 3D Imaging Layer Control
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Solution Overview
Problem
Solid imaging systems face challenges in controlling layer thickness and efficiently managing uncured solid imaging material, leading to inconsistencies and material waste during the creation of three-dimensional objects.
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 application and removal of uncured material, ensures accurate layer formation and minimizes waste by preventing unwanted curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a coater bar is used to control layer thickness and remove uncured material, then manufacturing precision and material efficiency are improved, but device complexity increases
Solution Approach 1:
The coater bar is divided into distinct functional zones: a scraping portion for removing uncured material and a coating portion for applying new layers. This segmentation allows each portion to be optimized for its specific function while working together to achieve precise layer thickness control.
Solution Approach 2:
The coater bar serves multiple functions within a single component: it scrapes away uncured material, controls layer thickness, and applies new imaging material. This multi-functionality reduces the need for separate components while maintaining manufacturing precision.
2Loss of substance
If uncured solid imaging material is efficiently managed and removed, then material waste is reduced and productivity is improved, but device complexity increases
Solution Approach 1:
The valve system controls the dispensing of solid imaging material in advance, allowing precise regulation of material flow before it is applied to the build platform. This preliminary control prevents excess material from being dispensed and reduces waste.
Solution Approach 2:
The coater bar's scraping portion efficiently removes uncured material that has not been incorporated into the three-dimensional object. This recovered material can be collected and reused, reducing overall material waste and improving productivity.
3Manufacturing precision
If layer thickness is precisely controlled, then manufacturing precision is improved, but the time required for material application increases
Solution Approach 1:
The coater bar performs periodic scraping and coating actions in a rhythmic sequence. This periodic motion allows the system to maintain precise layer thickness control while optimizing the timing and speed of material application, thereby improving productivity.
4Ease of operation
If a flexible radiation-transparent bottom film is used, then ease of operation and material containment are improved, but reliability may be reduced due to potential deformation
Solution Approach 1:
The system employs a flexible, radiation-transparent bottom film that can be easily manipulated and conform to the tray shape. This flexible film provides ease of operation for loading and unloading material while maintaining sufficient stability through proper tensioning and support structures.
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 efficient material usage, improving the quality and consistency of three-dimensional objects produced by solid imaging systems.
Implementation Method 1
The coater bar removes uncured solid imaging material (as well as any cured solid imaging material that did not adhere to the build pad or previously cured layer of the three-dimensional object) from a previous layer as the coater bar moves in a first direction
Implementation Method 2
an actinic radiation transparent bottom through which 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
Figure 1
Figure 2
Figure 3A~3B
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 hoid 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 un cured 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.