Additive Manufacturing System Inverted Resin Build
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Solution Overview
Problem
Current additive manufacturing techniques, such as tape casting, are limited in forming larger components as they primarily build in a bottom-up manner, resulting in smaller parts, whereas there is a need for a method to create larger components in a top-down fashion.
Innovation Solution
An additive manufacturing apparatus that includes a stage to hold layers of resin, a radiant energy device to cure the resin, and a support system with a pivot device and viscosity modification assembly, allowing the resin to be inverted and maintained in position for precise layer formation and curing, enabling the creation of larger components by translating the resin support and applying radiant energy in a predetermined pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional bottom-up tape casting process is used, then smaller components can be formed, but the ability to form larger components is limited
Solution Approach 1:
The patent inverts the traditional bottom-up tape casting process by implementing a top-down approach where the resin support with resin is positioned above the stage and cured layers are built downward. This inversion allows for the formation of larger components by changing the fundamental building direction of the additive manufacturing process
Solution Approach 2:
The patent introduces a new dimensional approach by implementing vertical movement of the stage in the Z-axis direction to lower the cured layer beneath the resin support. This adds a vertical dimension to the traditional horizontal layer-by-layer building process, enabling larger component formation
2Volume of moving object
If resin is inverted during build process, then larger components can be formed, but resin positioning accuracy may be compromised
Solution Approach 1:
The patent applies preliminary action by using a viscosity modification assembly to treat the resin before it is deposited onto the resin support. This pre-treatment ensures the resin has appropriate adhesive properties to maintain positioning accuracy during the inverted build process, preventing sagging or displacement
Solution Approach 2:
The patent changes the viscosity parameter of the resin through the viscosity modification assembly, transforming it from a potentially unstable state to an optimized state for inverted processing. This parameter modification ensures the resin maintains its position accurately while allowing for larger component formation
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
Enables the formation of larger components by maintaining the resin in an inverted position during the build process, ensuring accurate layer formation and curing, thus overcoming the limitations of traditional bottom-up methods.
Implementation Method 1
Stereo lithography (SLA) is a type of additive manufacturing process, which employs a tank of radiant-energy curable photopolymer 'resin' and a curing energy source such as a laser. Similarly, Digital Light Processing (DLP) three-dimensional (3D) printing employs a two-dimensional image projector to build components one layer at a time.
Data Source
AI summary
An additive manufacturing apparatus can include a stage configured to hold a component formed by one or more layers of resin. A support plate can be positioned above the stage. A radiant energy device can be positioned above the stage. The radiant energy device can be operable to generate and project energy in a predetermined pattern. A feed module can be configured to operably couple with a first end portion of a resin support and can be positioned upstream of the stage. A take-up module can be configured to operably couple with a second end portion of the resin support and can be positioned downstream of the stage.