Dynamic Focus for Scanning Projection Stereolithography
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Solution Overview
Problem
Existing scanning projection stereolithography systems require a flat image plane at the build plane, which compromises focusing accuracy and resolution due to imperfect compensation for off-axis light distortion.
Innovation Solution
A system with a controllably positionable optical element, such as a collimator, that dynamically adjusts focus to optimize the polymerizing optical signal at specific X/Y locations on the build plane, eliminating the need for a flat image plane and enhancing focusing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a flat field F-theta lens is used to achieve a flat image plane, then the image plane flatness is improved, but the focusing accuracy at different X/Y locations deteriorates
Solution Approach 1:
The patent applies dynamics by making the optical system movable rather than static. Specifically, the optics subsystem is positioned at different Z-axis locations depending on the X/Y location being scanned, allowing the focus to be dynamically adjusted for each position. This resolves the contradiction by enabling the system to achieve optimal focus (manufacturing precision) at each location while still covering a large build area, rather than being constrained to a fixed flat image plane configuration.
2Manufacturing precision
If the optics subsystem is positioned to optimize focus at one X/Y location, then the focusing accuracy at that location is improved, but the focusing accuracy at other locations deteriorates
Solution Approach 1:
The patent applies local quality by optimizing the optical configuration for each specific X/Y location independently. Rather than using a single global focus setting, the system adjusts the Z-axis position of the optics subsystem locally for each target location on the build plane. This allows each location to have its own optimized focus parameters, achieving high manufacturing precision at each point while maintaining adaptability across the entire build area through systematic local optimization.
Solution Approach 2:
The system dynamically adjusts the optics subsystem position based on the current X/Y location being scanned. This dynamic repositioning allows the system to maintain optimal focus across different locations sequentially, resolving the contradiction between local optimization and overall adaptability.
3Device complexity
If a fixed optics subsystem position is used, then the system complexity is reduced, but the focusing accuracy across the build plane deteriorates
Solution Approach 1:
The patent introduces dynamic positioning of the optics subsystem along the Z-axis based on the X/Y scan location. This controlled movement adds only one degree of freedom to the system while dramatically improving focusing accuracy across the entire build plane. The dynamic adjustment is coordinated with the scanning subsystem, so the complexity increase is minimal and well-managed, resolving the contradiction between simplicity and precision.
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
Significantly improves focusing accuracy and resolution by allowing independent focus adjustment at each X/Y location, enabling high-resolution imaging over a large area without the limitations of traditional systems.
Implementation Method 1
A collimator for collimating the polymerizing optical signal
Implementation Method 2
a focusing lens system for focusing the polymerizing optical signal
Implementation Method 3
generate a polymerizing optical signal to initiate polymerization of a photopolymerizable resin or material
Data Source
AI summary
The present disclosure relates to a system for performing scanning projection stereolithography. The system uses a light projector which is configured to generate a polymerizing optical signal to initiate polymerization of a photopolymerizable resin or material at a build plane. An optics subsystem collimates and focuses the polymerizing optical signal. The optics subsystem is movable relative to the build plane to optimize focus of the polymerizing optical signal at the build plane. A light scanning subsystem directs the polymerizing optical signal received from the optics subsystem to selected X axis and Y axis locations on the build plane. A positioning subsystem positions the optics subsystem at a selected location relative to the build plane, where the selected location is chosen to optimize focusing of the polymerizing optical signal at a specific, selected X/Y location on the build plane.