Dynamic Substrate Assembly for 3D Printing Alignment and Resin Waste Reduction
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Solution Overview
Problem
Existing 3D printing systems face challenges in aligning the starting point of objects, maintaining consistent substrate tautness, and efficiently removing printed products without draining resin, leading to errors and resin waste.
Innovation Solution
A dynamic substrate assembly with adjustable tautness, comprising a frame system with pivot brackets and torque screws, allows for customizable substrate tension and easy product removal by pivoting the substrate frames, enabling consistent alignment and minimizing resin bubbles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a solid substrate is used for 3D printing, then manufacturing precision is improved, but device complexity increases due to lifting mechanisms needed for product access
Solution Approach 1:
The substrate assembly transitions from a static solid substrate to a dynamic flexible substrate that can be tensioned and relaxed. The flexible substrate is mounted on a drum assembly that can rotate, allowing the substrate to be dynamically adjusted between a tensioned state during printing and a relaxed state for product removal, eliminating complex lifting mechanisms.
Solution Approach 2:
The substrate's physical state is changed from rigid to flexible, allowing it to be mounted on a rotating drum assembly. This parameter change enables the substrate to be tensioned during printing for precision and relaxed during removal, simplifying the overall device complexity while maintaining manufacturing precision.
2Ease of operation
If the substrate is moved to allow product access, then ease of operation is improved, but manufacturing precision may deteriorate due to alignment issues
Solution Approach 1:
The substrate is mounted on a rotating drum assembly that allows dynamic movement. The drum can rotate to bring different portions of the substrate into position, enabling easy product access while maintaining precise alignment through the consistent rotational reference of the drum assembly.
Solution Approach 2:
The flexible substrate is tensioned uniformly across the drum surface, creating an equipotential condition where the substrate maintains consistent tension and alignment regardless of its rotational position. This ensures that product access operations do not compromise manufacturing precision.
3Ease of operation
If resin is drained to access finished product, then ease of operation is improved, but loss of substance increases due to resin waste
Solution Approach 1:
The finished product is extracted from the resin by rotating the drum assembly to bring the substrate to a removal position, where the product can be accessed without draining the resin. This extracts the product from the resin environment while keeping the resin contained and reusable.
Solution Approach 2:
Instead of discarding the resin by draining it to access the product, the system recovers the resin by keeping it contained in the printing chamber. The flexible substrate on the rotating drum allows product removal while the resin remains in place for reuse in subsequent printing operations.
4Manufacturing precision
If substrate tautness is increased, then manufacturing precision is improved, but device complexity increases due to tension adjustment mechanisms
Solution Approach 1:
The substrate tension is dynamically controlled through the rotation of the drum assembly. By rotating the drum, the system can tension the substrate during printing operations and relax it during product removal, providing precise substrate alignment control without complex additional tension adjustment mechanisms.
Data Source
AI summary
The invention comprises an improved 3D object printer for building three dimensional products for multiple industries, including dental fields like orthodontic tooth aligners, drill guides, castable parts, partial dentures, and prosthetic models. The invention further comprises an improved 3D object printer that builds products using an improved, dynamic substrate base. The invention even further comprises a substrate assembly that is customizeable to build from a database of printed object profiles.