Photo-curing 3D Printer LCD Wavelength Optimization
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Solution Overview
Problem
Current photo-curing 3D printing technologies, such as SLA and DLP, face inefficiencies in large object printing due to complex light paths and high costs, with LCD-based printers having short service lives and low curing speeds.
Innovation Solution
A photo-curing 3D printer design utilizing an LCD display unit and a light source emitting 420-460 nm light, with a simplified light path, integrated heat dissipation, and a semipermeable membrane to enhance curing efficiency and extend service life, while reducing costs and improving printing speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If SLA technology uses laser to cure photosensitive resin sequentially from point to line and line to surface, then manufacturing precision can be maintained, but productivity is slow and efficiency is low when printing large three-dimensional objects
Solution Approach 1:
The patent uses an LCD display to project a two-dimensional cross-sectional pattern of the object onto the photosensitive resin, curing the entire cross-section simultaneously. This copying approach replaces the sequential point-by-point laser curing with a parallel full-area curing method, dramatically improving printing speed while maintaining precision through the LCD's pixel-level control capability
Solution Approach 2:
The patent transitions from one-dimensional sequential laser scanning to two-dimensional parallel projection by using an LCD display to illuminate entire cross-sectional layers at once. This dimensional change allows simultaneous curing of multiple points across the entire layer, resolving the contradiction between precision and productivity
2Productivity
If DLP device is used for mask photo-curing to print large three-dimensional objects rapidly, then productivity is improved and resolution is relatively high, but device cost is high which cannot be afforded by common customers
Solution Approach 1:
The patent replaces the expensive DLP projector with a relatively inexpensive LCD display unit that can be easily obtained from consumer electronics. While LCD has shorter lifespan than DLP, it provides sufficient durability for practical use at a fraction of the cost, making rapid 3D printing accessible to common customers
Solution Approach 2:
The patent changes the light source wavelength parameter to 420-460 nm blue light, which is well-matched to the photosensitive resin's curing characteristics. This parameter optimization allows the use of standard LCD displays with blue LED backlights, further reducing cost while maintaining high printing speed and resolution
3Ease of manufacture
If LCD display unit is used with 300 nm ̃700 nm wavelength light source, then device cost is reduced, but service life is very short
Solution Approach 1:
The patent precisely controls the light wavelength parameter to fall within 420-460 nm, which is the optimal range for blue light-cured photosensitive resin. This wavelength optimization protects the LCD display from excessive UV damage while ensuring effective resin curing, thereby extending service life without sacrificing cost-effectiveness
Solution Approach 2:
The patent converts what would normally be harmful high-energy UV light into beneficial blue light at 420-460 nm. This wavelength conversion reduces the damaging effect on the LCD display while maintaining effective photopolymerization of the resin, turning a potential harm into a benefit for both device longevity and curing efficiency
4Manufacturing precision
If complex light paths are used in SLA or DLP devices, then manufacturing precision can be maintained, but light path delay increases which reduces curing efficiency
Solution Approach 1:
The patent extracts and eliminates the complex optical path components (mirrors, lenses, beam splitters) from the SLA system by directly projecting the LCD pattern onto the resin surface. This extraction of unnecessary optical elements removes light path delays while preserving the ability to maintain curing precision through direct optical coupling
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
The solution significantly improves printing speed and precision, with curing times reduced by 5-15 times and service life extended to over 10,000 hours, making the technology more durable and cost-effective for large-scale and industrial applications.
Implementation Method 1
photosensitive resin (UV) in a liquid state performs polymerization under the irradiation of light
Implementation Method 2
bottom of the storage unit is configured to display a pattern composed of a shielding area for shielding the light rays and a transmissive area for passing-through the light rays
Data Source
AI summary
Disclosed is a photo-curing 3D printer comprising a storage unit for accommodating liquid photosensitive resin and a light source disposed underneath the storage unit. Wavelength of light rays emitted by the light source is 420.about.460 nm. A bottom of the storage unit is configured to display a pattern composed of a shielding area for shielding the light rays and a transmissive area for passing-through of the light rays. In addition, the disclosure provides a 3D printing method. Due to the limitations of photopolymerization initiators and the LCD display unit currently available, it was unexpected to complete photo-curing 3D printing with a light source with 420.about.460 nm wavelength. It is unexpected that a photo-curing 3D printer as provided in the present application not only can ensure the service life of the LCD display unit but also that the curing efficiency is significantly higher than existing devices.