Solid Imaging Apparatus Alignment and Curing Mechanism
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Solution Overview
Problem
Solid imaging devices face challenges such as complex systems, high maintenance costs, and inefficiencies due to excessive moving parts, costly laser and UV imaging systems, contamination of large resin vats, and the need for complex alignment processes, resulting in tacky and incompletely cured three-dimensional products.
Innovation Solution
A redesigned solid imaging apparatus featuring a replaceable cartridge system with a flexible transport surface for layer-by-layer material application, an integrated cleaning assembly for excess material removal, a simplified imager alignment fixture, and a high-intensity UV lamp with air flow channels for improved curing, along with an elevator system to reduce air entrainment and facilitate build release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser or UV imaging systems are used for solid imaging, then imaging precision is improved, but system cost increases
Solution Approach 1:
The patent uses a digital light processor (DLP) device as a cheaper alternative to expensive laser or UV imaging systems. The DLP device projects images onto the build material surface, providing sufficient imaging precision for solid imaging while significantly reducing system cost and complexity.
2Measurement precision
If complex alignment processes are implemented, then imaging alignment precision is improved, but operation time increases
Solution Approach 1:
The patent incorporates an alignment fixture that is pre-integrated with the DLP device and build platform. This fixture includes alignment features that automatically guide the DLP device into the correct position relative to the build platform, eliminating the need for complex manual alignment processes and reducing operation time while maintaining imaging alignment precision.
3Quantity of substance
If large vats of liquid resin are used, then build material availability is improved, but contamination risk increases
Solution Approach 1:
The patent divides the build material supply into multiple smaller containers instead of using one large vat. Each container holds a separate supply of liquid resin, and the system can switch between containers as needed. This segmentation reduces contamination risk because each smaller container can be individually managed and replaced without exposing a large volume of material to contamination, while still providing sufficient build material availability through multiple containers.
4Adaptability or versatility
If excessive moving parts are included, then system functionality is improved, but maintenance complexity increases
Solution Approach 1:
The patent combines multiple functions into integrated assemblies to reduce the number of moving parts. For example, the build platform assembly integrates the build platform, support structures, and elevation mechanism into a single unit. The DLP device assembly combines the imaging device, alignment fixture, and lighting system. This merging maintains system functionality while reducing maintenance complexity by minimizing the number of separate components that require servicing.
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 results in a more efficient, cost-effective, and user-friendly system that produces fully cured, tack-free three-dimensional products with reduced maintenance requirements and simpler operation, enabling flexible and precise solid imaging.
Implementation Method 1
A laser or other source of radiation suitable for solid imaging sequentially irradiates individual thin layers of the build material in response to which the material transforms into a solid
Implementation Method 2
a high-intensity UV lamp with air flow channels for improved curing
Data Source
AI summary
A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build. The invention also provides for tilting the build elevator to reduce air entrainment and for releasing the build from the image plane.