Continuous Stereolithography via Dynamic Platform Speed and Pixel Intensity

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Solution Overview

Problem

Conventional stereolithography processes require multiple steps and layered construction to achieve accurate three-dimensional objects, leading to inefficiencies and the need for discrete layer formation, which limits the depth and uniformity of material solidification.

Innovation Solution

A method and device that allow for simultaneous or approximately simultaneous irradiation of a construction area with electromagnetic radiation, enabling continuous solidification of photopolymerizable material without interruptions, where the distance between the carrier platform and the construction level can be changed during irradiation, and the instantaneous hardening depth is controlled by traversing speed and radiation intensity, allowing for uniform and deep solidification beyond conventional limits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional stereolithography uses layer-by-layer construction with separate curing and movement steps, then manufacturing precision is improved, but productivity deteriorates due to numerous sequential steps

Engineering Contradiction:

Improvecomponent accuracyVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent implements continuous irradiation of the photopolymerizable material during the entire build process, eliminating the need to interrupt curing for platform movement. The support platform moves continuously through the irradiation field while material solidifies, creating an uninterrupted production process that maintains precision while dramatically improving productivity

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system dynamically adjusts the position of the support platform relative to the irradiation field during the build process. The platform moves at controlled speeds through the radiation field, allowing continuous curing while maintaining precise control over the solidification depth and object geometry

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If conventional stereolithography performs curing and platform movement in separate layers, then manufacturing precision is improved, but loss of time increases due to repeated stopping and starting

Engineering Contradiction:

Improvelayer accuracyVSAvoidprocess cycle time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The irradiation source continuously exposes the photopolymerizable material throughout the build process without interruption. The support platform moves continuously through the irradiation field, eliminating all stopping and starting operations. This continuous action maintains layer accuracy while reducing total process time by eliminating idle periods between layers

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If conventional stereolithography uses point-based energy input with selective laser exposure, then manufacturing precision is improved, but device complexity increases due to separate curing and movement mechanisms

Engineering Contradiction:

Improvecuring accuracyVSAvoidsystem structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical layer-by-layer curing and movement system with a continuous irradiation field and continuous platform movement system. Instead of stopping to cure each layer then moving to the next, the system uses continuous electromagnetic radiation combined with continuous platform motion, simplifying the coordination mechanisms while maintaining curing precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system controls the instantaneous curing depth by adjusting the traverse speed of the support platform and the radiation intensity parameters. By changing these parameters continuously during the build process, the system maintains precise control over material solidification without requiring complex mechanical layer-by-layer positioning

Inventive Principle:

Principle #35Parameter changes

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 layered construction, accelerates the process, minimizes boundary layers, and achieves continuous, uniform solidification depths exceeding conventional limits, enabling the production of three-dimensional objects with varied cross-sectional areas without separate polymerized structural elements.

Implementation Method 1

solidifying a photopolymerizable material by simultaneously or nearly simultaneously irradiating a build area or partial build area in a build plane with electromagnetic radiation

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentEP3187328A1Generative method and device for creating a three dimensional object

Publication Date: 2017.07.05 ENVISIONTEC GMBH DE

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AI summary

A method or device for producing a three-dimensional object, wherein a photopolymerizable material (3) is solidified by simultaneously or nearly simultaneously irradiating a build area in a build plane with electromagnetic radiation (1), wherein the instantaneous curing depth of the photopolymerizable material during a continuous build phase is controlled by the radiation intensity of each individual pixel within a projected rasterized image mask and by controlling the process speed of the support platform carrying the object to be generated away from the build plane. Embodiments of suitable devices are also described.