Light-Cured Printing Chunking Strategy for Resin Heat Stress
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Solution Overview
Problem
Existing light-cured printing technologies face issues with heat accumulation and shrinkage stress during the resin curing process, leading to deformation and potential print failure due to large cross-sectional areas, which cause damage to release films and result in pulling forces that can detach models and break supports.
Innovation Solution
The method involves chunking the projected picture into smaller exposed pictures, superimposing and intersecting them to reduce the cross-sectional area of single exposure, mimicking the strategy of concrete pouring in large structures like the Hoover Dam, thereby reducing heat stress and pulling forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large cross-sectional area is exposed in a single exposure, then the printing efficiency is improved, but heat accumulation increases causing release film damage and deformation
Solution Approach 1:
The patent divides the large cross-sectional exposure area into multiple smaller sub-areas by segmenting the exposure picture into several exposed pictures. Each sub-area is cured separately with reduced light intensity and exposure time, preventing heat accumulation and release film damage while maintaining overall printing efficiency through parallel or sequential processing of multiple layers.
2Speed
If a large cross-sectional area is exposed in a single exposure, then the printing speed is improved, but shrinkage stress accumulates causing model detachment and print failure
Solution Approach 1:
The exposure area is segmented into multiple layers with smaller cross-sectional areas. Each layer cures independently with reduced shrinkage stress, preventing cumulative stress buildup that would cause model detachment or support breakage. The multi-layer approach allows controlled stress distribution throughout the printing process.
3Productivity
If a large cross-sectional area is cured, then the layer thickness is increased improving productivity, but pulling force increases causing model detachment
Solution Approach 1:
Instead of curing a single thick layer with large pulling force, the patent segments the curing process into multiple thinner layers. Each layer experiences reduced pulling force during release, preventing model detachment while achieving the same overall thickness through cumulative layering. The pulling force is distributed across multiple smaller curing operations rather than one large operation.
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 effectively minimizes deformation and damage to release films, reduces pulling forces, and prevents model detachment and print failure by dividing large cross-sectional areas into smaller chunks, ensuring successful and stable light-cured printing.
Implementation Method 1
Exposure of a large cross-sectional area generates a large amount of heat during a resin curing process
Data Source
AI summary
Methods and systems for processing a graphic for light-cured printing, an electronic apparatus, and/or a storage medium are disclosed. In some embodiments, the method includes following steps: obtaining 3D model data of an object to be printed; slicing the 3D model data to obtain sliced data; converting the sliced data to a projected picture; and chunking the projected picture to obtain a plurality of exposed pictures. The plurality of exposed pictures are superimposed and intersected to have an exposed result of the projected picture. In other embodiments, the method includes following steps: placing a photosensitive resin in a material tray, placing a molding platform in the material tray, and placing a molding end surface of the molding platform in contact with the photosensitive resin; sending the plurality of exposed pictures to a bottom surface of the material tray; and curing a corresponding layer of photosensitive resin.