Layered 3D Resin Transfer With Uniform Thickness and Clean Delamination
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Solution Overview
Problem
Existing 3D manufacturing methods using radiation-transparent build material carriers result in non-uniform height profiles and excessive uncured resin material at boundaries of elevated sections, leading to inefficiencies and mechanical issues.
Innovation Solution
A method involving a radiation-transparent film with a resin layer, where a first sublayer is substantially cured before lamination, and a second sublayer remains uncured to control resin flow and adhesion, allowing for precise curing and delamination without shear forces, using photon radiation with controlled energy density and oxygen inhibition to achieve uniform layer thickness and minimize resin flow into recessed sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the resin layer is fully cured before lamination, then the layer thickness becomes uniform and resin flow is restricted, but the adhesion between layers may be reduced
Solution Approach 1:
The resin layer is divided into two functional sublayers: a first sublayer that is substantially cured to provide dimensional stability and uniform thickness, and a second sublayer that remains uncured to provide adhesion to the target surface. This segmentation allows each sublayer to fulfill its specific function without compromising the other.
Solution Approach 2:
Different regions of the resin layer have different curing states: the first sublayer is cured to prevent flow and maintain uniformity, while the second sublayer remains uncured to enable bonding. This local differentiation of material properties resolves the contradiction between uniformity and adhesion.
2Stability of the object's composition
If pressure is applied during lamination, then the resin flows into recessed sections to fill gaps, but this causes non-uniform height profiles and excessive resin at boundaries
Solution Approach 1:
The first sublayer is cured before lamination to pre-establish the desired layer thickness and prevent excessive resin flow. This preliminary curing action constrains the resin in place, allowing controlled filling of recessed sections without compromising overall uniformity.
Solution Approach 2:
The curing state of the resin is changed as a key parameter: the first sublayer is cured to reduce viscosity and prevent flow, while the second sublayer remains uncured to allow controlled flow into recessed sections. This parameter change enables precise control over resin distribution.
3Volume of moving object
If the resin layer is made thicker to cover recessed portions, then coverage is improved, but resin flow into recessed sections increases
Solution Approach 1:
The thick resin layer is segmented into two sublayers with different curing states. The first sublayer (thicker portion) is cured to prevent flow, while the second sublayer (thin portion) remains uncured to allow controlled flow into recessed sections. This segmentation enables thick coverage without uncontrolled resin flow.
Solution Approach 2:
Different portions of the resin layer have different curing states and flow characteristics. The cured first sublayer provides structural support and prevents excessive flow, while the uncured second sublayer locally flows into recessed sections to ensure complete coverage.
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 the production of 3D products with uniform layer thickness, reduced resin flow into recessed sections, and enhanced mechanical strength, while avoiding shear forces during delamination, thus improving the manufacturing process for complex geometries and chip packaging applications.
Implementation Method 1
an image from a radiation source is projected through the radiation transparent build material carrier to selectively illuminate pixels in an image plane in a first exposure to selectively solidify the liquid build material
Implementation Method 2
the pressure exerted during lamination causes the curable resin, which is still in a liquid state, to flow towards the recessed sections of the patterned layer
Data Source
AI summary
A method of manufacturing a layered 3D product is described that includes providing a radiation transparent film that carries a resin layer that in at least a first lateral region of a first sublayer at a side of the film is at least substantially cured and that is at least substantially uncured in a second sublayer thereof that has a free surface at a side of the resin layer facing away from the radiation transparent film. The film is laminated with a target, and the resin layer faces the target. The resin layer is fully cured in at least a third lateral region. Subsequently, the film is delaminated from the target. The fully cured material of the resin layer present in the at least a third lateral region remains on the target, and the film and the remainder of resin material thereon are removed from the target.