3D Printing System with Dual Light Sources for Surface Finish
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional DLP 3D printing processes are hindered by the adherence of polymerized resin to the transparent projection window, requiring time-consuming separation and repositioning steps, and result in objects with rough surfaces due to stair-step layering and vertical printing paths.
Innovation Solution
A 3D printing system incorporating a first light source within a vat to form an object and a second light source to cure the object externally, using a control arm with multiple degrees of freedom for precise movement and a sensor for real-time feedback to ensure accurate curing and smoothing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional DLP 3D printing process uses a transparent projection window and vertical printing path, then the object can be formed layer by layer, but the polymerized resin adheres to the window requiring time-consuming separation and repositioning steps
Solution Approach 1:
The patent applies preliminary action by performing the curing process in advance. A second light source cures the object externally before the build platform is separated from the vat, preventing resin adhesion issues before they occur. This eliminates the need for time-consuming separation and repositioning steps, directly resolving the contradiction between maintaining layer-by-layer formation and avoiding productivity loss from separation operations.
2Ease of manufacture
If conventional DLP printing uses vertical printing path and flat layers, then the object can be constructed systematically, but the surface finish is rough with stair-step appearance requiring post-processing
Solution Approach 1:
The patent applies curvature by enabling curvilinear printing paths instead of strict vertical movement. The build platform can move along curved trajectories, allowing layers to be deposited at angles that better conform to the desired object geometry. This reduces the stair-step effect and improves surface finish quality while maintaining systematic construction through controlled robotic movement.
Solution Approach 2:
The patent introduces dimensional flexibility by moving from one-dimensional vertical layer deposition to multi-dimensional curvilinear paths. The robotic arm with multiple degrees of freedom enables the build platform to traverse in complex three-dimensional trajectories, allowing layers to be deposited along curved surfaces and improving surface finish without sacrificing systematic construction.
3Reliability
If the build platform is repeatedly separated and repositioned during printing, then resin adhesion can be managed, but the overall printing process becomes slower and less efficient
Solution Approach 1:
The second light source performs preliminary curing of the object externally before separation is needed. This advance curing strengthens the object and prevents excessive resin adhesion, allowing the build platform to remain in the vat longer without manual intervention. This maintains reliable resin adhesion control while minimizing the frequency of separation operations, thereby improving printing efficiency.
Solution Approach 2:
The patent enables continuous printing operation by keeping the build platform in the vat throughout the printing process. The second light source provides continuous external curing without requiring platform removal, eliminating interruptions and maintaining continuous useful action. This resolves the contradiction by maintaining reliable adhesion control through continuous curing while maximizing printing efficiency through uninterrupted operation.
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 reduces the time-consuming separation and repositioning steps and improves surface finish by allowing for curvilinear printing paths and external curing, resulting in more accurate and smooth printed objects.
Implementation Method 1
A first light source is configured to emit light to a vat containing a liquid photopolymer resin to form an object on a rigid base
Implementation Method 2
A second light source is configured to emit light on the printed object externally of the liquid photopolymer resin in the vat to fully cure and smooth the printed object
Data Source
AI summary
A 3D printing system includes a vat containing a liquid photopolymer resin and a rigid base on which an object is configured to be printed. A control arm connected to the rigid base is configured to move the rigid base relative to the vat. A first light source is configured to emit light to the vat to form the object on the rigid base. A second light source is configured to emit light on the object externally of the liquid photopolymer resin in the vat to cure the object.