Heated Support Window for Uniform Resin Curing
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Solution Overview
Problem
Vat polymerization in 3D printing faces challenges in achieving uniform and localized heating of photopolymer resin without the need for additional stirring mechanisms, which can lead to uneven curing and reduced print quality.
Innovation Solution
A transparent support window with a transparent conductive coating is used to heat the resin locally, eliminating the need for stirring by generating heat through electrical resistance, and temperature sensors and controllers ensure even heating across the resin layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heating elements are placed in the perimeter walls of the vat, then the resin can be heated, but additional stirring mechanisms are required to achieve uniform heating
Solution Approach 1:
The patent replaces the mechanical stirring system with an electrical heating system. By applying electrical current directly to the resin through transparent conductive coatings on the support window and/or vat walls, heat is generated in-situ within the resin itself, eliminating the need for mechanical stirring to distribute heat.
Solution Approach 2:
The patent changes the physical state and properties of the resin by controlling its temperature through direct electrical heating. By adjusting electrical parameters (voltage, current, resistance) and thermal parameters (heating rate, temperature distribution), the resin's viscosity and reactivity are optimized for uniform curing without mechanical agitation.
2Stability of the object's composition
If additional stirring mechanisms are used to promote uniform heating, then heating uniformity can be improved, but the device complexity and potential for uneven curing increases
Solution Approach 1:
The patent eliminates mechanical stirring by using electrical resistance heating to generate heat directly within the resin. This approach provides uniform heating without the mechanical complexity and potential instability introduced by stirring mechanisms, which can sometimes create uneven heating patterns or air bubbles.
3Productivity
If heating is applied to the resin, then the photo polymerization process is improved, but localized heating control becomes challenging
Solution Approach 1:
The patent applies heating selectively to different regions of the resin by using transparent conductive coatings on specific surfaces (support window, vat walls). By controlling the electrical current distribution and resistance in different areas, localized temperature control is achieved, optimizing photo polymerization in the cure zone while managing heat in other regions.
Solution Approach 2:
The patent uses the resin's own electrical resistance as an intermediary to convert electrical energy directly into thermal energy within the resin itself. This self-heating mechanism provides precise localized temperature control without requiring external heating elements that would be difficult to position and control.
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 method provides consistent and localized heating of the resin, improving the photo polymerization process and enhancing print quality by maintaining the resin at a desired temperature, thus promoting uniform curing without the need for additional stirring mechanisms.
Implementation Method 1
the transparent support window can be provided with a layer of a transparent, conductive coating capable of resistively heating the resin proximate the flexible plastic film
Implementation Method 2
Resins can be cured and thereby hardened using a process of photo polymerization (e.g., using UV light)
Data Source
AI summary
An additive-manufacturing resin vat system can include a resin vat, a flexible plastic film, a transparent support window, a transparent conductive coating, a support tray, and a set of metal contacts. The resin vat can carry a resin-print material mixture. The flexible plastic film can mechanically seal to a bottom of the resin vat. The transparent support window can support the flexible plastic film. The transparent conductive coating can be formed on at least one side of the transparent support window. The support tray can define an outer tray portion and an open tray interior, the outer tray portion carrying the transparent support window. The metal contacts can be carried by the outer tray portion and configured to electrically couple with the transparent conductive coating. The transparent conductive coating is configured to generate heat upon receiving an electrical current via the metal contacts.