Imaging Bar Servicing for Large Array Stereolithography

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current large array stereolithography systems face challenges in processing speed and optical efficiency, particularly in maintaining high-speed operations and effectively cleaning resin residue during the fabrication of three-dimensional articles.

Innovation Solution

The system incorporates a motorized build plate, an imaging bar with an array of light emitters, and a servicing module to position the imaging bar close to the resin surface for efficient curing and cleaning, utilizing a short optical path and periodic cleaning mechanisms to prevent resin hardening and residue accumulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the imaging bar is positioned close to the resin surface for efficient curing, then optical efficiency and processing speed are improved, but resin residue accumulates on the imaging bar more rapidly

Engineering Contradiction:

Improveprocessing speedVSAvoidresin residue accumulation

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The imaging bar is designed with a self-cleaning capability where excess resin is automatically removed during the scanning process. The resin that accumulates on the imaging bar is scraped off by a wiper or blade mechanism that is integrated into the imaging bar assembly, allowing the system to maintain its high-speed operation without manual intervention.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The harmful resin residue is extracted from the imaging bar surface by a separate cleaning mechanism. A wiper blade or scraping element is positioned to contact the imaging bar and remove accumulated resin, separating the curing function from the contamination problem.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If the optical path is shortened to improve imaging precision, then fine features can be imaged more accurately, but the system complexity increases due to additional cleaning mechanisms

Engineering Contradiction:

Improveimaging precisionVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The cleaning function is merged with the imaging bar assembly rather than being a separate system. The wiper or scraping mechanism is integrated directly onto the imaging bar carrier or housing, combining the curing and cleaning functions in a single integrated unit that moves together during operation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

A simple mechanical intermediary element such as a wiper blade or scraping element is introduced to mediate between the imaging bar and the resin reservoir. This intermediary component performs the cleaning function with minimal complexity, using simple contact mechanics rather than complex automated systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If high power light emitters are used to increase curing speed, then processing efficiency improves, but resin residue hardens more quickly on the imaging bar

Engineering Contradiction:

Improvecuring speedVSAvoidresin hardening on imaging bar

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The cleaning action is performed continuously or periodically during the curing process rather than after resin hardening occurs. The wiper or scraping mechanism removes excess resin before it can cure on the imaging bar surface, preventing the formation of hardened residue that would interfere with subsequent curing operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cleaning function operates continuously or in a continuous cycle alongside the curing process. As the imaging bar scans through the resin, the cleaning mechanism continuously removes excess resin, maintaining a consistent cleaning action throughout the entire curing process rather than using intermittent or post-process cleaning.

Inventive Principle:

Principle #20Continuity of useful action

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 configuration enhances processing speed and optical efficiency by allowing precise imaging of fine features and frequent cleaning of the imaging bar, maintaining system performance and preventing resin residue buildup.

Implementation Method 1

The stereolithography system forms a three dimensional (3D) article of manufacture by selectively curing layers of the photocurable resin

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS11458685B2Large array stereolithography with efficient optical path

Publication Date: 2022.10.04 3D SYSTEMS INC

AI summary

A three-dimensional printing system for fabricating a three-dimensional article includes a resin vessel, a motorized platform, an imaging bar, a movement mechanism, a servicing module, and a controller. The motorized platform has an upper surface for supporting the three-dimensional article. The imaging bar has an array of light emitters arranged along a transverse axis which emitting light downwardly from an exit surface. The controller is configured to: operate the motorized build plate, the movement mechanism, and the imaging module to complete fabrication, and periodically during fabrication operate the movement mechanism to position the imaging bar in the servicing module to clean resin residue from the imaging bar.