DLP-Laser 3D Printing for Large Sculptures Without Complex Alignment
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Solution Overview
Problem
Conventional three-dimensional printing methods using DLP projectors and laser scanners require multiple devices and complex alignment processes to produce large sculptures, which is inefficient and prone to errors.
Innovation Solution
A three-dimensional printing apparatus utilizing a single DLP projector and a 1-axis laser scanner, where the DLP projector creates a core portion of the sculpture and the laser scanner forms the precise shell portion, with an image processing unit dividing the sculpture into core and shell sections and controlling the printer units to achieve accurate and rapid output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple DLP projectors or xy laser scanners are used to cover a large area, then the area coverage is improved, but the device complexity and alignment process complexity increase
Solution Approach 1:
The patent segments the sculpture formation process into two distinct parts: core portion formation using DLP projector and shell portion formation using laser scanner. This segmentation allows each device to focus on specific regions, enabling large area coverage without requiring multiple complete devices. The image processing unit divides the cross-sectional image into core and shell portions, assigning different printing tasks to different devices optimally.
Solution Approach 2:
The patent makes the laser scanner perform dual functions: it scans both the core portion and shell portion of the sculpture, while the DLP projector handles only the core portion. This multi-functionality reduces the total number of devices needed and eliminates complex alignment processes between multiple scanners or projectors.
2Area of stationary object
If DLP projectors or xy laser scanners are moved in the x- or y-axis direction to cover large areas, then the area coverage is improved, but the alignment process complexity and position correction requirements increase
Solution Approach 1:
The patent performs preliminary division of the sculpture cross-section into core and shell portions before the printing process begins. The image processing unit pre-processes the cross-sectional image to identify which regions should be formed by the DLP projector and which by the laser scanner, eliminating the need for complex real-time alignment corrections during operation.
3Manufacturing precision
If conventional stereolithography methods are used to produce large sculptures, then the surface quality is improved, but the production time and device requirements increase
Solution Approach 1:
The patent applies different printing methods to different regions of the sculpture based on local quality requirements. The shell portion, which requires high surface quality, is formed using laser scanner with precise point-by-point curing. The core portion, where surface quality is less critical, is formed using DLP projector for faster bulk curing. This local quality approach optimizes both surface quality and production time.
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
Enables the rapid and precise production of large three-dimensional sculptures using a single DLP projector and 1-axis laser scanner, eliminating the need for complex alignment algorithms and reducing production time by allowing high-speed core formation and precise shell creation.
Implementation Method 1
a DLP projector unit disposed above the resin storage unit and projecting light corresponding to a core portion of an axial cross section of a sculpture to the resin storage unit
Implementation Method 2
a laser scanner unit disposed above the resin storage unit and performing scanning of light corresponding to a shell portion of the axial cross section of the sculpture for the resin storage unit
Data Source
AI summary
The present invention relates to a three-dimensional printing apparatus using a digital light processing (DLP) projector with a laser scanner, the apparatus comprising: a resin storage unit storing a photocurable resin; a DLP projector unit projecting light to the resin storage unit; a molding stage unit provided to be capable of being lifted and lowered in a vertical direction from a bottom of the resin storage unit; a laser scanner unit performing scanning of light for the resin storage unit; a scanner transfer unit allowing the laser scanner unit to move in an x-axis direction; an image processing unit dividing one sectional image of a sculpture into a core portion and a shell portion; and a controller receiving data on the core portion and the shell portion from the image processing unit, controlling the DLP projector, the laser scanner unit, the scanner transfer unit, and the molding stage unit.