Dual Light Engine Additive Manufacturing for High-Resolution Large Builds
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Solution Overview
Problem
Conventional additive manufacturing systems face limitations in achieving both high resolution and large build space, often resulting in artefacts and material inhomogeneity due to fixed light radiation configurations, and complex solutions like multiple projectors or continuous laser beams have drawbacks such as complexity and limited exposure speed.
Innovation Solution
Employing at least two light engines with different configurations, one of which is movable, and a light altering structure, such as a rotatable mirror or beam splitter, to selectively radiate light onto multiple focal planes within a reservoir, allowing for blending and inline process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed light radiation configuration is used, then the apparatus structure is simple, but the manufacturing precision and resolution are limited
Solution Approach 1:
The patent employs a movable light engine that can dynamically adjust its position and light radiation configuration, transforming a static system into a dynamic one. This allows the system to adapt between different focal planes and resolution requirements, resolving the contradiction between fixed structure simplicity and manufacturing precision requirements.
Solution Approach 2:
The system changes light radiation parameters (focal plane position, radiation configuration) to achieve different printing resolutions. By varying these parameters, the same apparatus can produce both high-resolution and large-scale parts, overcoming the limitation of fixed configurations.
2Manufacturing precision
If high resolution printing is achieved, then the manufacturing precision is improved, but the build space is reduced
Solution Approach 1:
The movable light engine can dynamically reposition itself to focus on different planes within the resin reservoir. This dynamic capability allows high-resolution printing on specific focal planes while maintaining a large overall build space, as the light engine can move to accommodate different object sizes and resolutions.
Solution Approach 2:
The system introduces the dimension of movable positioning for the light engine, allowing it to operate at different focal planes (z-dimension) while maintaining high resolution. This enables high-resolution printing without constraining the overall build space, as the light engine can move to different depths within the resin.
3Manufacturing precision
If multiple projectors or continuous laser beams are used, then the resolution and build space requirements are met, but the device complexity and process complexity increase
Solution Approach 1:
The movable light engine serves multiple functions: it can act as a high-resolution projector when positioned at the first focal plane and as a large-area illumination source when positioned at the second focal plane. This single multi-functional component replaces what would otherwise require multiple separate projectors or complex laser systems.
Solution Approach 2:
By making the light engine movable, the system achieves the functionality of multiple projectors through a single dynamic component. The light engine can be positioned to provide either high-resolution printing or large-area coverage, eliminating the need for multiple static projectors and simplifying the overall device structure.
4Productivity
If a single light engine is used, then the device complexity is reduced, but the productivity and exposure speed are limited
Solution Approach 1:
The movable light engine can continuously move between different focal planes and maintain illumination, providing continuous useful action. This eliminates the need to stop and reconfigure between high-resolution and large-area printing, thereby improving productivity and exposure speed without significantly increasing device complexity.
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 enhances the efficiency and resolution of additive manufacturing by enabling high-resolution printing of large parts with reduced artefacts and improved material homogeneity, while simplifying the process and reducing complexity.
Implementation Method 1
selectively radiating light having a first light radiation configuration from a first movable light engine... At least a portion of the light is directed onto a first focal plane within the hardenable material to selectively form a first portion of hardened material
Data Source
AI summary
The present disclosure provides apparatuses and methods for manufacturing three-dimensional objects. Each additive manufacturing apparatus (1000, 2000, 3000) includes: a) a reservoir (1100, 2100, 3100) for receiving hardenable material; b) a first movable light engine (1200, 2200, 3200) providing a first light radiation configuration; a second light engine (1300, 2300, 3300) providing a second light radiation configuration that is different than the first light radiation configuration; and d) a light altering structure (1400, 2400, 3400). The light altering structure is located between the reservoir and light radiated from at least one of the first movable light engine or the second light engine. The first movable light engine is configured to radiate light onto a first focal plane (2220) within the reservoir containing the hardenable material and the second light engine is configured to radiate light onto a second focal plane (2320) within the reservoir containing the hardenable material. The method includes: a) obtaining a hardenable material disposed in a reservoir; b) selectively radiating light having a first light radiation configuration from a first movable light engine; and c) selectively radiating light having a second light radiation configuration from a second light engine onto a second focal plane within the hardenable material. The apparatuses and methods can advantageously form objects having different resolutions on demand using the same apparatus, plus optionally can blend light from multiple light engines.