Digital Masking Optical Combiner for DMD-Limited 3D Printing
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Solution Overview
Problem
Conventional 3D printing projectors are limited by the maximum optical power input of digital micromirror devices (DMDs), restricting light intensity and printing speed.
Innovation Solution
A digital masking system utilizing multiple light sources and imaging devices, each with power below the maximum input limit, combined through a combiner to create a single high-intensity light beam, overcoming the power limitations of individual devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a single imaging device is used to project light onto the photo-curable material, then the device structure is simple, but the light intensity is limited due to the maximum power input limit of the imaging device
Solution Approach 1:
The patent divides the single imaging device into multiple imaging devices (first imaging device and second imaging device), each operating below the maximum power input limit. This segmentation allows each device to work within safe power limits while collectively providing higher light intensity through combination of multiple light beams.
Solution Approach 2:
The patent combines multiple light beams from separate imaging devices using a combiner to create a single composite light beam with higher intensity. The combiner merges the light paths while maintaining image alignment, achieving increased illumination without requiring a single high-power device.
2Illumination intensity
If a single imaging device operates at maximum power input, then the light intensity is maximized, but the device may be damaged or its lifespan reduced
Solution Approach 1:
By segmenting the power load across multiple imaging devices, each device operates at a lower power level below the maximum input limit. This prevents any single device from being overloaded or damaged, improving system reliability while maintaining high overall light intensity through the combination of multiple devices.
Solution Approach 2:
Each imaging device is assigned a specific portion of the light beam generation task, operating within its safe power capacity. The local quality of each device's operation is optimized to stay within reliable operating parameters, while the collective output achieves the desired high intensity.
3Productivity
If higher light intensity is achieved using a single high-power imaging device, then the printing speed increases, but the device complexity and power management become more difficult
Solution Approach 1:
The patent combines multiple standard-power imaging devices to achieve the light intensity required for fast printing. The combiner integrates the light paths and images from multiple devices into a single high-intensity beam, achieving high productivity without requiring a single complex high-power device.
Solution Approach 2:
The printing system segments the light generation function across multiple imaging devices, each handling a portion of the overall light output requirement. This segmentation allows use of standard, well-understood devices rather than a single high-power device, simplifying power management and system reliability.
4Productivity
If multiple imaging devices are used to increase light intensity, then the printing speed improves, but the device complexity increases
Solution Approach 1:
The combiner serves as a key component that merges multiple light beams and their corresponding images into a single integrated output. This merging function allows multiple imaging devices to work together as a unified system, achieving high printing speed while managing complexity through the combiner's integration role.
Solution Approach 2:
The combiner acts as an intermediary component between multiple imaging devices and the photo-curable material. It receives light beams from multiple devices, combines them with proper alignment, and delivers the integrated high-intensity beam to the material, simplifying the interaction between multiple devices.
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
Enhances light intensity and printing speed by combining multiple low-power light beams into a single high-intensity beam, exceeding the limitations imposed by individual DMD chips.
Implementation Method 1
Each of the imaging devices converts the light component provided by the light sources into a light beam representing an image
Implementation Method 2
the combiner receives, combines and redirects the light beams provided by the imaging devices into a single light beam output
Data Source
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AI summary
A digital masking system includes a supporting structure for supporting a material, and a pattern imaging apparatus. The pattern imaging apparatus includes a light source device, multiple imaging devices that convert light from the light source device into a plurality of light beams each representing an image, and a combiner that combines the light beams into a single light beam which is projected toward a material.