Kaleidoscopic 3D Printing via Array-Lens Imaging
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Solution Overview
Problem
Current 3D printing technologies face limitations in scalability and feature resolution, with conventional one-to-one imaging systems restricting the ability to fabricate large-scale complex microstructures efficiently without compromising quality.
Innovation Solution
The use of an array-lens and microdisplay device to create kaleidoscopic imaging patterns, allowing for scalable and high-resolution 3D printing by replicating and reconstructing images onto a curable resin, enabling the production of complex structures with fine feature sizes over large areas without the need for scanning optics modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional one-to-one imaging systems are used, then manufacturing precision is maintained, but scalability and fabrication area are limited
Solution Approach 1:
The patent divides the imaging system into multiple independent lens units arranged in an array, where each lens unit independently images the microdisplay to create multiple overlapping images. This segmentation allows the system to cover a large fabrication area while maintaining the ability to control each region with precision, resolving the contradiction between scalability and manufacturing precision.
Solution Approach 2:
The patent combines multiple lens units into a single array-lens system that simultaneously images the microdisplay at multiple positions. By merging the functionality of multiple separate imaging systems into one integrated array, the patent achieves large-scale fabrication without proportionally increasing device complexity, as the array-lens operates as a unified component.
2Area of stationary object
If multiple-focal spot methods are used, then fabrication area is extended, but printing time increases due to serial processing
Solution Approach 1:
The patent prepares the microdisplay with the complete image pattern beforehand, then uses the array-lens to simultaneously project all images onto the resin in parallel. This preliminary preparation of the image data allows for instant parallel processing, eliminating the sequential time penalty associated with traditional multiple-focal-spot methods while maintaining extended fabrication area capability.
Solution Approach 2:
The array-lens system maintains continuous parallel imaging capability across the entire fabrication area simultaneously, rather than transitioning between different focal spots or regions sequentially. This continuous parallel action ensures that the useful imaging process occurs throughout the entire area at the same time, maximizing productivity and minimizing printing time.
3Area of stationary object
If scanning optics modules are incorporated, then total fabrication area is expanded, but device complexity and cost increase
Solution Approach 1:
Instead of using a single optical path that scans across different positions, the patent creates multiple copies of the same microdisplay image simultaneously at different positions using the array-lens. Each lens unit in the array acts as an independent copier, producing parallel images that collectively cover the entire fabrication area, thereby expanding area without requiring complex scanning mechanisms.
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 enables rapid, high-quality, and scalable 3D printing with feature sizes of several micrometers over tens of centimeter squares, breaking traditional scaling limits and improving the efficiency of the printing process.
Implementation Method 1
an array-lens that replicates the image(s) to project a plurality of images that form kaleidoscopic imaging pattern on a resin
Implementation Method 2
a microdisplay device that generates an image(s), and an array-lens that replicates the image(s)
Implementation Method 3
The resin can then be selectively cured, for example on a layer-by-layer basis, based on the kaleidoscopic imaging pattern(s), to form the three-dimensionally printed object
Data Source
AI summary
Systems and methods for improved stereolithographic (SLA) three-dimensional printing are provided. The systems and methods utilize an array-lens to produce kaleidoscopic imaging patterns, which in turn are used to direct the curing of resin to produce a three-dimensional object. The array-lens can be used to replicate, superposition, and/or overlap or otherwise reconstruct an image received by the array-lens, onto a resin that is used to form the desired object. The systems and methods can further use an optical diffuser, with a distance between the optical diffuser and the array-lens being adjustable to provide a desired kaleidoscopic imaging pattern on the resin. Additional features and methods for use with the provided SLA three-dimensional printing systems and methods are also provided.