Continuous Stereolithography via Multi-Zone Irradiation
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Solution Overview
Problem
Conventional stereolithography processes require multiple steps and layer formation to achieve accurate three-dimensional object construction, leading to inefficiencies and potential construction defects due to the need for separate layer hardening and movement of support plates.
Innovation Solution
A process and device that allow for simultaneous or almost simultaneous exposure of a build area to electromagnetic radiation, enabling continuous solidification of photopolymerizable materials without interrupting the supply of energy, and controlling the hardening depth through adjustable support plate movement and irradiation intensity, allowing for layer-independent operation and extended hardening depths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional stereolithography uses selective laser irradiation to harden layers, then construction accuracy is improved, but productivity deteriorates due to multiple steps per layer
Solution Approach 1:
The invention segments the irradiation process into multiple zones (first irradiation zone, second irradiation zone, third irradiation zone) that can operate simultaneously or in sequence on different portions of the build area, allowing parallel processing that maintains accuracy while increasing overall productivity
Solution Approach 2:
The invention introduces a temporal dimension to the layer construction process by allowing overlapping irradiation zones and continuous support plate movement, transforming the traditional sequential layer-by-layer approach into a continuous multi-zone processing system
2Manufacturing precision
If conventional stereolithography processes layers separately with support plate movement, then construction defects are reduced, but loss of time increases due to repeated positioning
Solution Approach 1:
The invention maintains continuous irradiation across multiple zones while the support plate moves continuously, eliminating the start-stop positioning cycles of conventional systems and maintaining uninterrupted solidification action throughout the build process
Solution Approach 2:
The invention merges multiple irradiation zones and their respective hardening processes into a unified continuous operation, combining what were traditionally separate layer operations into an integrated multi-zone processing system
3Manufacturing precision
If conventional stereolithography uses multiple irradiation steps per layer, then hardening quality is improved, but device complexity increases
Solution Approach 1:
The invention creates a universal irradiation system where multiple zones can handle different portions of the build area simultaneously, with each zone capable of independent control but functioning as part of an integrated multi-functional processing system
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 eliminates the need for multiple steps and layer formation, accelerates the building process, minimizes interface layers, and enables continuous uniform hardening depths exceeding conventional limits, improving computing efficiency and reducing the risk of defects.
Implementation Method 1
a process for producing at least one three-dimensional object by solidifying a material solidifyable under the supply of energy such as electromagnetic radiation wherein the material normally comprises a resin which is photopolymerizable
Data Source
AI summary
The invention describes a process and a device for producing at least one three-dimensional object, a photo-polymerizable material is solidified by means of simultaneous or almost simultaneous exposure of a build area or partial build area in a building plane via electromagnetic radiation, wherein a distance between a support plate, at which the object to be generated is built, and the building plane is changed during at least one exposure phase.It is possible according to the invention to solidify the three-dimensional object in a main direction during a radiation phase exceeding a current prescribed hardening depth, without interrupting supply of electromagnetic energy during the irradiation phase. Further, it is possible to control a current hardening depth of the photopolymerizable material during a building phase. Embodiments of suitable devices are also described.