DLP 3D Printer Mirror Deflection for Large Area Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current Digital Light Processing (DLP) 3D printing technologies are limited by the small dimensions of objects that can be produced due to the size of the DLP projector's display area, which increases costs when trying to enlarge the printing area.
Innovation Solution
The solution involves an irradiation component with a DLP projector, switching and deflection mirrors, and a control system that allows for the expansion of the display area by deflecting light horizontally using a switching mirror and deflection mirrors, effectively doubling the display area without increasing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the display area of the DLP projector is increased to produce larger 3D objects, then the object dimension is improved, but the cost increases tremendously
Solution Approach 1:
The projection area is divided into multiple segments by using multiple deflection mirrors (first deflection mirror and second deflection mirror) that can be independently positioned. Each mirror projects a portion of the image, and these segments are combined to form a complete large-area projection, effectively increasing the display area without requiring a single large expensive projector
Solution Approach 2:
Deflection mirrors are introduced as intermediary elements between the DLP projector and the photopolymer resin. These mirrors act as mediators that redirect and expand the light path, allowing the projector's native display area to be effectively enlarged through optical manipulation without modifying the projector itself
2Volume of moving object
If the display area of the DLP projector is increased to produce larger 3D objects, then the object dimension is improved, but the device complexity increases
Solution Approach 1:
The deflection mirrors serve multiple functions: they expand the projection area, enable adjustable projection angles, and allow flexible positioning of the first and second projection areas. This multi-functionality reduces the need for additional specialized components, managing device complexity while achieving enlarged object dimensions
Solution Approach 2:
The system employs movable deflection mirrors that can be dynamically adjusted to different positions and angles. This dynamic capability allows the projection area and orientation to be reconfigured for different printing needs, providing flexibility without requiring multiple fixed projection systems
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 enables the production of larger 3D objects with high speed and resolution, suitable for commercial applications, while maintaining cost-effectiveness by doubling the display area without the need for more expensive equipment.
Implementation Method 1
The switching mirror reflects the irritation to the first deflecting mirror and the second deflecting mirror respectively by moving to the first position and the second position. The first deflecting mirror then deflects the irritation to the first area of the solidified lay of the object, and the second deflecting mirror deflects the irritation to the second area of the solidified lay of the object.
Implementation Method 2
liquid solidifiable material (e.g., photopolymer resin) contained in a vat is exposed to visible light or UV light generated by DLP projector. The DLP projector displays the image of the 3D model onto the surface of the liquid solidifiable material. The exposed solidifiable material is solidified (or cured) to form a solid layer with desired pattern according to the image.
Data Source
AI summary
A DLP 3D printer, using a DLP projector to generate two images successively, and using a set of mirrors to deflect the irradiation of the two images through two routs respectively to form a complete image on the curing surface of the solidifiable material. In this manner, the printing area is enlarged without increasing the resolution of the DLP projector.