Continuous-Pull 3D Printing for Faster Resin Layer Curing
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Solution Overview
Problem
Stereolithography 3D printing is time-consuming due to the need to remove and re-dip resin objects in the vat after each layer is cured, which wastes time and can lead to imperfections.
Innovation Solution
A continuous-pull 3D printing system where the base plate moves upward with each layer formed, keeping the cured resin surface in contact with the liquid resin, allowing for sequential layer formation without complete removal from the resin vat, using a light source and robotic arm for precise control and agitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the object is completely removed from liquid resin after each layer is cured, then the curing process can be completed, but the printing time increases due to removal and re-dipping operations
Solution Approach 1:
The base plate remains continuously submerged in the liquid resin throughout the printing process, eliminating the need for removal and re-dipping operations between layers. This continuous positioning allows uninterrupted sequential curing of layers, maintaining manufacturing precision while dramatically improving printing speed through elimination of repetitive removal/re-dipping cycles
2Productivity
If the base plate is moved upward after each layer formation, then the printing process is accelerated, but maintaining resin contact throughout the process requires precise control
Solution Approach 1:
The control system monitors the base plate position and resin contact status, automatically adjusting the base plate upward movement to maintain optimal contact between the cured resin surface and liquid resin. This feedback mechanism enables rapid layer-by-layer printing while ensuring consistent resin contact for complete curing, managing device complexity through automated control
3Manufacturing precision
If the object remains in contact with resin throughout printing, then surface smoothness is improved, but the risk of resin adhesion to cured surfaces increases
Solution Approach 1:
The system periodically agitates the liquid resin between layers to break surface tension and prevent cured resin from adhering to the liquid resin surface. This periodic agitation maintains continuous resin contact for smooth surfaces while eliminating harmful adhesion, allowing the base plate to remain submerged throughout printing
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 method reduces printing time and improves surface smoothness and structural integrity by maintaining resin contact throughout the process, enabling the creation of larger and more complex objects with reduced need for support structures.
Implementation Method 1
a light source arranged below the resin container, wherein the light source is operable to emit electromagnetic radiation that causes a portion of the resin in the resin container to cure
Implementation Method 2
agitating the resin to break the surface tension
Data Source
AI summary
Described herein are three-dimensional (3D) printer systems and methods, which may provide for “continuous pull” 3D printing. An illustrative 3D printer includes: a resin container, a base plate, a light source arranged below the resin container and operable to cure resin in the resin container; and a control system operable to: (a) receive model data specifying a 3D structure; (b) determine 2D images corresponding to layers of the 3D object; and (c) generate control signals to operate the light source and the base plate to sequentially form the layers of the 3D object onto the base plate, wherein the base plate moves a formed portion of the 3D object upward after formation of each layer, and wherein at least a surface of a formed portion of the 3D object remains in contact with the resin in the resin container throughout the formation of the layers of the 3D object.