Flexible Vat Base Deformation Detection in 3D Printing

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Solution Overview

Problem

Current 3D printing technologies lack comprehensive detection and control of process parameters, leading to inefficiencies and errors in the layer-by-layer construction of three-dimensional bodies from substances hardened by radiation, resulting in excessive waste and potential damage to the produced bodies.

Innovation Solution

A device and method that utilize a flexible vat base with a sensor system to detect volume changes in a chamber, allowing for real-time monitoring and control of process parameters, such as pressure and fluid flow, to optimize the layer formation process and minimize waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a flexible vat base is used to minimize pulling forces during layer separation, then the reliability of body production is improved, but the ability to detect and control process parameters deteriorates

Engineering Contradiction:

Improvereliability of body productionVSAvoiddetection of process parameters

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

A sensor is introduced as an intermediary element between the flexible vat base and the control system. The sensor detects volume changes in the chamber caused by vat base deformation, converting mechanical deformation into measurable electrical signals that can be used for process control while preserving the flexible vat base's function.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The sensor provides real-time feedback about the vat base's deformation state and chamber volume changes to the control system. This feedback enables dynamic adjustment of process parameters during layer separation, improving both reliability and controllability simultaneously.

Inventive Principle:

Principle #23Feedback

2Device complexity

If empirical values are used for process control without comprehensive detection, then the device complexity is reduced, but the manufacturing precision and productivity deteriorate

Engineering Contradiction:

Improvecomplexity of detection systemVSAvoidproduction efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent replaces complex mechanical measurement systems with a simpler sensor-based detection system. Instead of using elaborate mechanical gauges or direct measurement apparatus, the system uses a sensor to detect chamber volume changes, significantly reducing device complexity while improving productivity through faster, more reliable process control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If the building platform is moved away from the vat base to create space for next layer, then the manufacturing precision is improved, but the loss of time increases due to lack of real-time detection

Engineering Contradiction:

Improveprecision of layer formationVSAvoidtime for layer separation

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The sensor detects chamber volume changes in advance, providing early warning that layer separation is complete or about to occur. This allows the control system to initiate the building platform movement at the optimal moment, reducing idle time while maintaining precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The real-time detection enables continuous monitoring of the layer separation process, allowing the building platform to be moved away immediately when separation is detected. This eliminates waiting time and keeps the production process continuous, improving productivity without sacrificing precision.

Inventive Principle:

Principle #20Continuity of useful action

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

Enables rapid, reliable, and efficient production with reduced waste by accurately detecting and controlling process parameters, ensuring precise layer formation and minimizing errors in the 3D printing process.

Implementation Method 1

the sensor is adapted to detect a volume change of the chamber and to provide a sensor signal from which a sign of the volume change can be determined

Methodology Applied

Scientific EffectPressure detection:

Implementation Method 2

the substance which can be hardened by radiation is selectively hardened by irradiation by means of a radiation source to form the layer of the body

Methodology Applied

Scientific EffectRadiation hardening: Photopolymerisation

Data Source

PatentUS11780157B2Detection of deformation of vats

Publication Date: 2023.10.10 DENTSPLY SIRONA INC

AI summary

Device for a system for layer-by-layer construction of a body (K) from a substance (S) which can be hardened by radiation, comprising a vat having a vat base for receiving the substance (S) which can be hardened by radiation, comprising a building platform which is arranged above the vat base and which is height-adjustable in relation to the vat base and comprising a sensor cooperating with the vat base, wherein the vat base is configured to be at least partially flexible, wherein a chamber is provided wherein the chamber is delimited by an underside of the vat base, wherein the sensor is adapted to detect a volume change of the chamber and to provide a sensor signal from which a sign of the volume change can be determined.