Lateral Vacuum Release for Continuous Photopolymer Curing
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Solution Overview
Problem
Existing 3D printing technologies face challenges in continuous additive manufacturing due to issues like delamination and warping caused by printing at the open surface of photopolymers, which require significant time and resources to address.
Innovation Solution
The system employs a submerged or partially submerged end effector with a non-stick coating and continuous lateral motion to cure photopolymers, allowing for continuous separation and release of cured layers without stopping the printing process, using a light source and gas barrier to manage vacuum forces and prevent ingress of liquid photopolymer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional 3D printing methods are used with open surface photopolymer curing, then the printing process can be completed, but delamination and warping occur due to vacuum forces during curing
Solution Approach 1:
A release liner is introduced as an intermediary layer between the photopolymer and the print bed. This release liner prevents direct adhesion of the cured photopolymer to the print bed, eliminating delamination and warping caused by vacuum forces during curing. The release liner acts as a mediator that allows the photopolymer to cure without being subjected to harmful vacuum forces.
Solution Approach 2:
The harmful vacuum forces are extracted or removed from the system by using a release liner that prevents the formation of strong vacuum adhesion between the photopolymer and print bed. The release liner effectively extracts the problematic vacuum effect that causes delamination and warping.
2Reliability
If traditional release mechanisms are used to separate cured layers, then separation can be achieved, but the process stops and significant time is required
Solution Approach 1:
The release liner enables continuous printing by allowing the photopolymer to be cured and separated without stopping the printing process. The release liner maintains its function throughout the entire printing process, enabling continuous deposition and curing of photopolymer layers without interruption for manual separation or release mechanism activation.
Solution Approach 2:
The release liner performs the separation function automatically as the photopolymer cures and contracts. The vacuum forces that would normally cause delamination are converted into a gentle separation mechanism that automatically releases the cured layer from the print bed without requiring external intervention or stopping the printing process.
3Productivity
If end effector is submerged in photopolymer for curing, then continuous separation curing is enabled, but vacuum forces may cause ingress of liquid photopolymer
Solution Approach 1:
A gas barrier is introduced as an intermediary between the end effector and the liquid photopolymer. This gas barrier prevents the liquid photopolymer from ingressing into the vacuum region created by photopolymer shrinkage during curing. The gas barrier acts as a mediator that allows the end effector to remain submerged for continuous curing while preventing harmful liquid ingress.
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 method enables faster, cost-effective, and scalable 3D printing with reduced risk of damage to the printed object, as it maintains a constant release force and prevents the limitations of traditional release mechanisms, allowing for larger and more complex prints.
Implementation Method 1
A light source is operably coupled to the first end effector, the light source being configured to emit and electromagnetic radiation. Wherein at least one of the print bed or first end effector is movable relative to the other to perform continuous separation curing of the photopolymer on the print bed with the electromagnetic radiation.
Implementation Method 2
the first end effector having a nonstick coating on an end, the end being adjacent the print bed
Implementation Method 3
the continuous separation curing being performed by lateral movement of the first end effector relative to the print bed to release or neutralize a vacuum or low pressure area formed between the print bed and the first end effector that is caused by polymer shrinkage
Implementation Method 4
the first end effector is configured to flow the gas to prevent an ingress of liquid photopolymer into a low pressure region caused by photopolymer shrinkage during curing
Data Source
AI summary
A system and method for continuous additive manufacturing of objects is provided. The system includes a container configured to receive a photopolymer and a print bed disposed within the container. An first end effector is movably disposed within the container. A light source is operably coupled to the first end effector, the light source being configured to emit and electromagnetic radiation. Wherein at least one of the print bed or first end effector is movable relative to the other to perform continuous separation curing of the photopolymer on the print bed with the electromagnetic radiation.