Hybrid 3D Printing Light Layout for Isotropic Large-Area Curing
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Solution Overview
Problem
Existing 3D printing technologies using hybrid lighting systems face limitations in scalability due to the maximum acceptance angle of polarizers, leading to reduced print area and increased printer size, while also suffering from anisotropic object formation and the aliasing phenomenon.
Innovation Solution
A 3D printing apparatus with a hybrid lighting system featuring constant wavelength and variable power and speed, incorporating an optical coupling and expansion system with pre- or post-coupling and fixed or variable post-expansion, which optimizes light beam conditioning and spatial overlapping to overcome polarizer limitations and achieve isotropic object formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a hybrid lighting system with polarizers is used to achieve isotropic object formation, then object isotropy is improved, but the acceptance angle limitation reduces print area and increases printer size
Solution Approach 1:
The patent implements a nested optical configuration where the first and second light sources are positioned at different depths relative to the build plate, with their beams overlapping in a confined spatial region. This nesting approach allows multiple light paths to occupy the same physical space, enabling isotropic curing without requiring large lateral separations that would increase printer footprint.
Solution Approach 2:
The patent transitions from a two-dimensional lateral arrangement of light sources to a three-dimensional vertical arrangement. By positioning light sources at different heights (first light source above the build plate, second light source below), the system exploits the vertical dimension to achieve beam overlap and isotropic curing while maintaining a compact horizontal footprint.
2Stability of the object's composition
If a hybrid lighting system with polarizers is used to achieve isotropic object formation, then object isotropy is improved, but device complexity and cost increase
Solution Approach 1:
The patent makes the build plate serve multiple functions: it acts as both the substrate for object formation and as a structural support for mounting the second light source below it. This multi-functionality reduces the need for additional separate components and simplifies the overall system architecture while maintaining isotropic curing capability.
Solution Approach 2:
The patent combines the optical paths of two light sources with orthogonal polarizations into a single overlapping beam region. By merging the light paths spatially and temporally (synchronized operation), the system achieves isotropic curing through a unified optical configuration rather than requiring separate independent systems.
3Device complexity
If conventional single light source systems are used, then device complexity is reduced, but aliasing phenomenon and anisotropic formation occur
Solution Approach 1:
The patent applies different polarization states to different light sources (first light source with one polarization, second light source with orthogonal polarization), creating local quality variations in the light fields. This local differentiation enables the overlapping regions to cure polymer chains in multiple orientations, eliminating aliasing and achieving uniform surface quality.
Solution Approach 2:
The patent creates a composite light field by combining two light beams with orthogonal polarizations. This composite illumination approach is analogous to using composite materials, where the superposition of differently polarized light provides complementary curing actions that eliminate the defects (aliasing) produced by single light sources.
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
The solution enables compact, cost-effective, and reliable 3D printing with improved scalability, isotropic object production, and reduced aliasing effects, maintaining high resolution across larger print areas.
Implementation Method 1
a polarizer arranged along the path of said first light beam and said second light beam, wherein said polarizer is adapted to polarization-couple said first light beam and said second light beam, to obtain their spatial overlapping (coaxiality) while maintaining the same wavelength
Implementation Method 2
photo-curing or selective laser sintering 3D printing apparatus... for the emission and processing of a first light beam for photo-curing or sintering said object
Data Source
AI summary
An apparatus for 3D printing an object by photo-curing or selective laser sintering with a hybrid lighting system at a constant wavelength and variable power and speed, wherein said apparatus includes:—a first light source and related optical devices of conditioning the light beam, for the emission and processing of a first light beam for photo-curing or sintering said object, wherein said first light beam has a predetermined wavelength and a linear polarization oriented according to a certain angle;—a second light source and related optical devices of conditioning the light beam, for the emission and processing of a second light beam for photo-curing or sintering said object, wherein said second light beam has a wavelength equal to that of said first light beam and a linear polarization oriented according to an angle orthogonal to that of said first light beam.