Stabilizing Flexible Films in 3D Printing Inhibitor Delivery
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Solution Overview
Problem
In three-dimensional rapid prototyping, the deformation of a photohardening inhibitor-permeable film due to inhibitor flow disrupts the planarity of the photohardenable material interface, leading to inaccuracies in the resulting objects.
Innovation Solution
A system and method involving a photohardening inhibitor delivery device with a flexible, elastomeric film and a reservoir that stabilizes the film, preventing deformation by maximizing oxygen diffusion and using supports to maintain film planarity, thereby creating a non-solidification zone that allows for accurate object formation without film distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a photohardening inhibitor is fed through a flexible film to create a non-solidification zone, then the need for separation means is eliminated, but the film deforms due to inhibitor flow which disrupts the planarity of the photohardenable material interface
Solution Approach 1:
The patent uses a flexible elastomeric film that is permeable to the photohardening inhibitor. This film is supported by a support structure that maintains its planarity while allowing the inhibitor to pass through. The flexible film creates a non-solidification zone at the interface with the photohardenable material, eliminating the need for separation means while maintaining manufacturing precision through the support structure.
Solution Approach 2:
The patent changes the physical state and properties of the film by using an elastomeric material with specific permeability characteristics. The film's flexibility and permeability parameters are optimized to allow inhibitor passage while maintaining planarity when supported. This parameter change enables the film to function as both a barrier and a support structure.
2Productivity
If the build platform moves continuously upward to accelerate the build process, then productivity increases, but the inhibitor flow deforms the film which causes inaccuracies in the resulting objects
Solution Approach 1:
The flexible elastomeric film supported by a support structure maintains its planarity during continuous upward movement of the build platform. This support mechanism prevents film deformation even as the platform accelerates, allowing continuous building without sacrificing object accuracy.
Solution Approach 2:
The supported flexible film acts as an intermediary between the inhibitor source and the photohardenable material. It mediates the inhibitor flow while maintaining a stable, planar interface that ensures accurate object formation even during accelerated continuous building processes.
Data Source
AI summary
A method and apparatus for making a three-dimensional object by solidifying a photohardenable material are shown and described. A photohardening inhibitor is admitted into a surface of a photohardenable material through a flexible film to create a “non-solidification zone” where little or no solidification occurs. The non-solidification zone prevents the exposed surface of the photohardenable material from solidifying in contact with the film. The inhibitor tends to cause the film to deform along the build axis, thereby creating a non-planar interface between the photohardenable material and the film, which distorts the resulting three-dimensional object. An apparatus is provided to stabilize the flexible film and eliminate or minimize such deformation.