LCD Screen Light Source for 3D Printing Resolution

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Solution Overview

Problem

Existing 3D printing methods using stereolithography with high-intensity light sources for stereolithography face issues of high cost, reduced longevity, and poor image resolution due to light diffraction, particularly when creating flexographic printing plates, which are not commercially viable.

Innovation Solution

A 3D printing method utilizing a visual display screen that emits less than 5% UV light, such as a computer monitor, to create 3D objects by selectively polymerizing liquid photopolymer with a visible light photoinitiator, allowing for the production of high-resolution images using 'off-the-shelf' LCD devices, which are cost-effective and safer for human use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high-intensity light sources are used for stereolithography, then the curing speed and polymerization efficiency are improved, but the cost increases and the longevity of the light source decreases

Engineering Contradiction:

Improvecuring speedVSAvoidlongevity of light source

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the wavelength parameter of the light source from UV to visible light range, and adjusts the intensity parameter to match human viewing standards. This allows using standard LCD screens instead of specialized high-intensity UV sources, improving longevity while maintaining curing efficiency through appropriate photoinitiator selection

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses standard commercial LCD display screens as a copy of the light source function, rather than requiring specialized high-intensity UV lighting systems. This copying approach allows off-the-shelf components to replace expensive, short-lived specialized equipment

Inventive Principle:

Principle #26Copying

2Productivity

If high-intensity light sources are used for stereolithography, then the polymerization efficiency is improved, but the production cost increases

Engineering Contradiction:

Improvepolymerization efficiencyVSAvoidproduction cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent employs inexpensive, readily available LCD display screens from consumer electronics as the light source, replacing expensive specialized UV lighting equipment. The standard LCD components can be sourced at low cost while maintaining sufficient performance for photopolymerization

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent makes the LCD screen serve multiple functions: it acts as both a visual display device and a controlled light source for stereolithography. This multi-functionality eliminates the need for separate specialized lighting systems, reducing overall system cost

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If standard LCD screens are used as light source, then the cost is reduced and safety is improved, but the image resolution deteriorates due to light diffraction

Engineering Contradiction:

ImprovecostVSAvoidimage resolution

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies local quality by using a release layer specifically at the interface between the LCD screen and photopolymer, and by optimizing the photoinitiator concentration locally in the photopolymer formulation. These localized adjustments compensate for the lower intensity of standard LCD screens while maintaining high resolution

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses a composite photopolymer system containing specific photoinitiators that are highly sensitive to visible light wavelengths emitted by LCD screens. This composite material approach enables effective curing with lower intensity light sources while maintaining image quality

Inventive Principle:

Principle #40Composite materials

4Productivity

If UV light emitting screens are used, then the polymerization effectiveness is improved, but the safety for human use deteriorates

Engineering Contradiction:

Improvepolymerization effectivenessVSAvoidsafety for human use

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent fundamentally changes the wavelength parameter from UV to visible light range, eliminating the harmful UV radiation while maintaining polymerization effectiveness through selection of photoinitiators that are activated by visible light wavelengths that are safe for human exposure

Inventive Principle:

Principle #35Parameter changes

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 achieves commercially acceptable resolution and cost-effectiveness while ensuring safety, as it uses low-intensity light sources, reducing production costs and potentially increasing the longevity of the 3D printing equipment.

Implementation Method 1

forming more than two layers of a cured polymer by exposing liquid photopolymer to light emitted by a visual display screen, wherein the photopolymer contains a visible light photoinitiator

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentEP3295246B1Method for making an object

Publication Date: 2019.05.01 PHOTOCENTRIC

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Figure 3A~3D
Figure 3E~3F

AI summary

This invention describes a method for making a three dimensional (3D) image by additive manufacturing using, as a light source, an off-the-shelf visual display screen. The invention also relates to apparatus for carrying out said methods.