Bidirectional Foil Applicator for Additive Fabrication Speed
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Solution Overview
Problem
Current additive fabrication methods are limited by slow production speed and suboptimal layer quality in the layerwise production of tangible objects, particularly due to the need for repeated reconditioning of non-solidified liquid layers and the inefficiencies in the separation and solidification processes.
Innovation Solution
An additive fabrication apparatus and method that employs a carrier plate and a flexible, transparent foil with a movable energy source and an applicator system capable of alternating between supply and uptake conditions, allowing for bidirectional movement to enhance the speed and quality of layer formation by partially solidifying the liquid layer and efficiently managing the liquid layer's adhesion and separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the foil guiding stage is moved to peel off the foil after each layer solidification, then the liquid layer can be separated from the foil, but the production speed is reduced due to repeated movement cycles
Solution Approach 1:
Instead of moving the foil guiding stage back and forth to peel off the foil after each layer, the patent inverts the approach by using a bidirectional applicator system that can both deposit and remove liquid material in alternating directions. This eliminates the need for repeated stage movements and foil peeling operations, thereby increasing production speed while maintaining reliable layer separation.
Solution Approach 2:
The bidirectional applicator enables continuous operation by alternating between supply and uptake conditions without requiring the stage to return to initial positions. The applicator can continuously deposit liquid in one direction and remove excess liquid in the opposite direction, maintaining continuous useful action and eliminating idle movement time.
2Ease of manufacture
If the applicator returns to initial positions after each operation, then the process can be repeated, but the production speed is limited by these return movements
Solution Approach 1:
The patent inverts the traditional unidirectional approach by implementing a bidirectional applicator that alternates between supply and uptake conditions in opposite directions. This allows the process to repeat continuously without the applicator needing to return to initial positions, as the uptake operation in one direction prepares the foil for the next supply operation in the opposite direction.
Solution Approach 2:
The bidirectional applicator system maintains continuous useful action by alternating between material supply and material uptake in alternating directions. This eliminates idle return movements and ensures that the applicator is always performing a useful function, thereby increasing production speed while maintaining process repeatability.
3Productivity
If liquid is continuously supplied to the foil, then layer formation can proceed, but evaporation increases reducing layer quality
Solution Approach 1:
The bidirectional applicator alternates between supply and uptake conditions in a continuous cycle, preventing liquid from remaining stationary on the foil for extended periods. This continuous motion reduces evaporation time and minimizes quality degradation, allowing fast layer formation while maintaining layer quality.
Solution Approach 2:
The uptake condition allows the applicator to remove and recover liquid material from the foil surface, preventing excessive liquid accumulation and reducing evaporation losses. The recovered liquid can be reused in subsequent supply operations, maintaining productivity while improving layer quality by reducing evaporation.
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 significantly increases the speed of the production process while improving layer quality by allowing for continuous operation without returning stages to their initial positions, reducing evaporation, and ensuring stable adhesion of newly formed layers, thus enhancing the overall efficiency and precision of the additive fabrication process.
Implementation Method 1
an energy source (90) arranged for at least partially solidifying at least part of an intersection pattern in the liquid layer arranged on the foil and in contact with the tangible object
Implementation Method 2
an applicator system (2) for applying the liquid layer (30) on the foil (6) comprising a first applicator, wherein the first applicator is arranged to alternate between providing a supply condition wherein liquid is supplied to the foil via an orifice
Implementation Method 3
providing an uptake condition wherein liquid is taken up from the foil via the orifice
Data Source
Figure 1
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AI summary
An additive fabrication apparatus is provided comprising a movable foil guiding stage (180) having a contact face (181) and comprising on opposite sides of the contact face a pair of upper and lower foil guiding elements (190, 191), the lower foil guiding element (190) defining a foil height position (HO) distanced from the contact face (181), for guiding a foil (6) including a liquid layer (30) to or from the contact face to contact a tangible object (50) by movement of the foil guiding stage along the tangible object while keeping the foil stationary relative to the object (50). An energy source (90) is arranged for at least partially solidifying at least part of an intersection pattern in the liquid layer arranged on the foil and in contact with the tangible object.