Imaging Bar with Transparent Sheet for Submerged Build Plane
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Solution Overview
Problem
Existing three-dimensional printing systems using stereolithography face challenges in increasing processing speed and achieving high resolution, particularly for large build plane systems.
Innovation Solution
A three-dimensional printing system that includes a resin vessel, a motorized build plate, an imaging bar with light emitting devices, and a transparent sheet below the resin surface, allowing for precise light emission and inhibition of curing, enabling the system to minimize off-angle light issues and achieve high resolution by positioning the build plane below the resin surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the build plane is positioned at or near the resin surface, then the processing speed is improved, but the resolution and feature definition deteriorate due to off-angle light issues
Solution Approach 1:
The patent positions the build plane in the vertical dimension below the resin surface rather than at the surface level. This dimensional change allows the light to travel a shorter perpendicular distance to the build plane, reducing off-angle light effects and improving resolution while maintaining processing speed through efficient light delivery.
Solution Approach 2:
The transparent sheet acts as an intermediary element positioned between the light source and the resin. It defines the build plane location below the resin surface and facilitates precise light delivery to this submerged position, enabling high-resolution feature definition while maintaining processing efficiency.
2Manufacturing precision
If the physical distance between light sources and build plane is reduced, then the resolution is improved, but the system complexity increases
Solution Approach 1:
The patent extracts the build plane definition function from the resin surface and relocates it to a transparent sheet positioned below the surface. This separation allows precise control of the build plane location independent of the resin surface, achieving high feature definition without requiring complex light source positioning systems.
Solution Approach 2:
The transparent sheet serves as a simple intermediary structure that physically defines the build plane location below the resin surface. This passive element eliminates the need for complex active control systems to maintain precise light-source-to-build-plane distances, reducing system complexity while improving feature definition.
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 system enables precise feature definition and high-resolution printing by minimizing the physical distance between light sources and the build plane, improving processing speed and resolution compared to traditional systems.
Implementation Method 1
selectively harden the photocurable resin at the build plane
Implementation Method 2
The transparent sheet is at least partially permeable to a gaseous inhibitor to inhibit curing of the resin upon the transparent sheet
Data Source
AI summary
A three-dimensional printing system for fabricating a three-dimensional article includes a resin vessel, a motorized build plate, an imaging bar, and a movement mechanism. The resin vessel is for containing a photocurable resin, the photocurable resin having an upper resin surface. The motorized build plate is for supporting the three-dimensional article in the photocurable resin. The imaging bar includes a plurality of light emitting devices arranged along a transverse axis for emitting light generally downwardly and a transparent sheet disposed below the plurality of light emitting devices. The transparent sheet has a lower surface to contact the resin and define a build plane below the upper surface of the resin. The movement mechanism is for imparting movement of the imaging bar along a scan axis.