Interlaced 3D Printing Build Planes for High-Viscosity Resin
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Solution Overview
Problem
The formation of layers in 3D printing systems using high viscosity photocurable resins is time-consuming due to the need to raise and lower the build surface to replenish the resin, reducing productivity.
Innovation Solution
A 3D printing system with multiple mechanical print platforms and a controller that alternates layer formation between platforms, allowing simultaneous irradiation and resin replenishment on one platform while translation occurs on another, enhancing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the build surface is raised and lowered to replenish resin in single-platform 3D printing, then resin depletion is resolved, but productivity decreases due to time-consuming operations
Solution Approach 1:
The system divides the build process into two independent platforms: Platform 1 performs layer formation while Platform 2 performs resin replenishment (raising/lowering). This segmentation allows simultaneous execution of previously sequential operations, resolving the contradiction by making resin replenishment independent of layer formation timing.
Solution Approach 2:
The system merges resin replenishment operations with layer formation operations by executing them simultaneously on different platforms. While Platform 1 forms layers, Platform 2 performs the raising and lowering operations, combining two previously separate process sequences into overlapping parallel operations.
2Reliability
If high viscosity photocurable resin is used, then material properties are improved, but resin replenishment time increases significantly
Solution Approach 1:
The system performs resin replenishment actions in advance on Platform 2 before they are needed for layer formation on Platform 1. By preparing the resin supply system ahead of time on a separate platform, the high viscosity resin has sufficient time to flow without delaying the layer formation process.
Solution Approach 2:
The system maintains continuous layer formation on Platform 1 while resin replenishment occurs continuously on Platform 2. This eliminates idle time where the build process would otherwise pause for resin replenishment, maintaining continuous productive action despite the slow flow properties of high viscosity resin.
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 approach significantly increases productivity by enabling concurrent resin replenishment and layer formation, particularly effective for high viscosity resins.
Implementation Method 1
The light engine then selectively irradiates the build plane, thereby accreting a new layer of the 3D article onto the lower face
Data Source
AI summary
A 3D printing system includes a first build platform, a second build platform, a light engine, and a controller. The first build platform contains photocurable resin between a first build surface and a first transparent wall. A first build plane is defined along the first transparent wall. The second build platform contains photocurable resin between a second build surface and a second transparent wall. A second build plane is defined along the second transparent wall. The controller is programmed to: operate the light engine to selectively irradiate the first build plane; translate the light engine to the second mechanical platform; operate the light engine to selectively irradiate the second build plane; translate the light engine back to the first mechanical platform; repeat operating and translating the light engine to alternately accrete photocurable resin at the first and second build surfaces.