Force-Feedback CLIP 3D Printing Resolves Surface Defects
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Solution Overview
Problem
In continuous liquid interface production (CLIP) methods, intermediate three-dimensional objects may become increasingly flexible, leading to issues with fluid adhesion to the build surface and premature light activation, resulting in surface defects such as pitting or blooming.
Innovation Solution
A method involving a carrier and an optically transparent member with a build surface, where the polymerizable liquid is drawn into a build region and cyclically advanced and retracted while monitoring transient tension and compression forces, allowing controlled light irradiation to form a three-dimensional object, maintaining a continuous liquid interface and optimizing the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the carrier is advanced in stepped or reciprocal modes to facilitate resin flow, then production speed is improved, but premature light activation occurs causing surface defects
Solution Approach 1:
The patent implements force sensing feedback to monitor the adhesion forces between the compliant object and build surface in real-time. This feedback enables dynamic adjustment of the light exposure activation timing, ensuring it occurs only after sufficient resin has been drawn into the build region, thereby preventing premature activation and associated surface defects while maintaining high production speed
Solution Approach 2:
The system dynamically adjusts the light exposure activation based on real-time force measurements rather than following a fixed stepped or reciprocal schedule. This dynamic control allows the process to adapt to varying resin flow conditions and object compliance, optimizing both speed and surface quality
2Adaptability or versatility
If compliant objects are produced, then material flexibility is improved, but fluid adhesion to the build surface increases preventing resin flow
Solution Approach 1:
Force sensing provides real-time measurement of the adhesion forces between the compliant object and build surface. This feedback enables the system to determine the precise moment when sufficient force has been applied to overcome fluid adhesion, allowing resin flow to proceed successfully even with highly flexible materials
Solution Approach 2:
The system applies preliminary mechanical force to the carrier before initiating light exposure, drawing resin into the build region in advance. This preliminary action ensures that sufficient resin is in position before curing begins, overcoming the adhesion barrier created by compliant materials
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 enables efficient and flexible production of three-dimensional objects, reducing time lost in printing cycles and minimizing surface defects by synchronizing the advancing and retracting steps with force feedback, allowing for faster fabrication speeds and improved object quality.
Implementation Method 1
irradiating the build region with light to form a growing three-dimensional object from the polymerizable liquid
Implementation Method 2
an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween
Data Source
AI summary
A method of making a three-dimensional object (31) is carried out by: (a) providing a carrier (15) and an optically transparent member (12) having a build surface, the carrier (15) and the build surface defining a build region therebetween, the optically transparent member (12) carrying a polymerizable liquid (21); (b) advancing the carrier (15) and the optically transparent member (12) away from one another to draw the polymerizable liquid (21) into the build region; then (c) optionally, partially retracting the carrier (15) and the optically transparent member (12) back towards one another; and then (d) irradiating the build region with light to form a growing three-dimensional object (31) from the polymerizable liquid (21); and then (e) cyclically repeating steps (b) to (d) while maintaining a continuous liquid interface (22) between the growing three-dimensional object (31) and the optically transparent member (12) until at least a portion of the three-dimensional object (31) is formed, while during at least some of the cyclically repeatings: (i) monitoring a transient increase in tension between the carrier (15) and the build surface through the growing three-dimensional object (31) during the advancing step (b), and optionally monitoring a transient increase in compression between the carrier (15) and the build surface through the growing three dimensional object during the partially retracting step (c); and then, when the transient increase in tension has substantially subsided, (ii) initiating the partially retracting step (c) when present, or initiating the irradiating step (d).