Continuous Additive Manufacturing via Dynamic Fluid Surface Control
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Solution Overview
Problem
Conventional vat photopolymerization additive manufacturing methods are limited by slow manufacturing rates due to time-consuming recoating processes and the appearance of undesirable staircase artifacts caused by discrete layer slicing.
Innovation Solution
An additive manufacturing apparatus that dynamically characterizes the surface of a radiation-curable fluid using a radiation sensor, adjusts the curing radiation pattern and intensity in real-time based on the surface topography, and controls the flow rate of the fluid to ensure precise curing, allowing for continuous solidification and reducing artifacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional vat photopolymerization additive manufacturing methods are used, then manufacturing process is simple and well-established, but manufacturing rate is slow due to time-consuming recoating processes
Solution Approach 1:
The patent implements continuous solidification by maintaining the radiation-curable fluid in constant contact with the build platform while continuously supplying fresh fluid. The scraping mechanism continuously removes cured material, and the fluid supply system continuously replenishes the vat, eliminating discrete recoating steps and enabling uninterrupted manufacturing operation.
Solution Approach 2:
The patent introduces dynamic control of the scraping mechanism and fluid supply rate to adapt to changing surface conditions during manufacturing. The scraping force and fluid supply rate are adjusted in real-time to maintain optimal solidification conditions, allowing the system to respond to variations in fluid viscosity, temperature, and surface tension throughout the manufacturing process.
2Manufacturing precision
If discrete layer slicing is used in conventional methods, then manufacturing process is straightforward, but staircase artifacts appear on the product surface
Solution Approach 1:
The patent transitions from discrete horizontal layer slicing to continuous vertical solidification. Instead of building layer by layer with distinct interfaces, the system maintains continuous contact between the radiation-curable fluid and the build platform, solidifying material in a continuous manner that eliminates the staircase artifact and produces smooth surface geometry.
Solution Approach 2:
The continuous supply of radiation-curable fluid and continuous scraping of cured material eliminates the discrete layer boundaries that cause staircase artifacts. The manufacturing process maintains continuous solidification without interruption, resulting in a seamless product surface free from layer-line artifacts.
3Productivity
If conventional recoating process is used, then surface tension effects are minimized, but manufacturing speed is limited
Solution Approach 1:
The patent eliminates the discrete recoating cycle by implementing continuous fluid supply and continuous scraping. The radiation-curable fluid is supplied continuously to maintain the solidification interface, and the scraping mechanism continuously removes cured material, allowing manufacturing to proceed without interruption and significantly increasing manufacturing speed.
Solution Approach 2:
The system performs preliminary actions by pre-positioning the build platform at the optimal height and pre-adjusting the scraping mechanism before manufacturing begins. The fluid supply system is pre-configured to maintain constant contact with the build platform, ensuring that solidification can proceed continuously from the start without requiring subsequent recoating operations.
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 significantly enhances manufacturing speed and product quality by eliminating staircase artifacts and internal material variations, achieving high-resolution, continuous solidification that matches the planned geometry.
Implementation Method 1
a radiation sensor (207) configured to produce a sensor signal representing radiation reflected by and/or emitted from the surface of the radiation-curable fluid
Implementation Method 2
a curing radiation source (205) configured to receive a curing radiation source control signal and to emit a corresponding two-dimensional curing radiation pattern in a direction towards the surface of the radiation-curable fluid, whereby a corresponding part of the radiation-curable fluid is cured
Data Source
AI summary
An additive manufacturing apparatus for building a product according to a planned geometry by successive solidification of a radiation-curable fluid in a solidification layer extending in a vertical direction from a surface of the fluid to a surface of the product. The apparatus includes: a vat holding the fluid; a support holding the product; a mechanism to control feeding of fluid to the solidification layer; a curing radiation source to generate a 2D exposure pattern of curing radiation in the solidification layer. The exposure pattern is defined by a curing radiation pattern geometry and/or curing radiation intensity. A radiation sensor receives radiation from the solidification layer. The radiation sensor generates a sensor signal having information indicative of a solidification process status. A control system is connected to the feed control mechanism and the curing radiation source. The control system receives the sensor signal and responsive thereto adjusts parameters controlling the solidification in the solidification layer.