Light-Emitting Robot for Uniform 3D Printing
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Solution Overview
Problem
Current 3D printing techniques using computed axial lithography are limited by the size and shape of objects due to incomplete curing of photosensitive materials, as light penetration initiates solidification faster at outer regions, preventing the production of larger objects.
Innovation Solution
The use of maneuverable light-emitting robotic devices inserted into photosensitive material, controlled by magnetic fields and wireless signals, to solidify the material in a pattern duplicating the object, allowing for multi-directional light emission and intensity control, enabling the printing of larger objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light projection is used to solidify photosensitive material in CAL techniques, then the material solidifies and forms 3D objects, but light penetration causes faster solidification at outer regions leading to incomplete curing and size limitations
Solution Approach 1:
The light source is segmented from a single external projector into multiple distributed micro-light sources embedded within the photosensitive material itself. Each micro-light source independently illuminates and cures a local region, dividing the curing process into multiple spatial segments that collectively achieve uniform solidification throughout the entire volume, eliminating the outer-region preference problem of single-source projection.
Solution Approach 2:
The light source transitions from a two-dimensional external projection surface to a three-dimensional distributed arrangement within the material volume. Micro-light sources are positioned at multiple depths and locations throughout the photosensitive material, enabling curing from multiple dimensions simultaneously and achieving uniform solidification regardless of object size.
2Productivity
If external light projection is used in CAL techniques, then object printing is achieved, but incomplete curing occurs in certain regions due to light penetration limitations
Solution Approach 1:
Multiple micro-light sources are merged into a coordinated network within the photosensitive material. These distributed sources work together synergistically, with each source contributing to the curing of its local region and overlapping zones ensuring complete coverage. The combined effect of multiple sources guarantees reliable and complete curing throughout the entire object volume.
Solution Approach 2:
The photosensitive material contains embedded micro-light sources that automatically illuminate and cure the material from within. The system serves itself by having the material's own embedded sources perform the curing function, eliminating the need for external light projection and ensuring that every region receives adequate light for complete curing.
3Ease of manufacture
If traditional layer-by-layer 3D printing is used, then objects are built from powder material, but the process is slow and has surface quality constraints
Solution Approach 1:
The photosensitive material undergoes a phase transition from liquid to solid through photopolymerization initiated by UV light from embedded micro-light sources. This phase change allows the material to be cured in place without mechanical layer-by-layer deposition, enabling simultaneous curing throughout the entire object volume and dramatically increasing printing speed while maintaining surface quality.
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 allows for the successful printing of larger objects by ensuring uniform solidification of photosensitive materials, overcoming the limitations of light penetration and size constraints in traditional CAL techniques.
Implementation Method 1
an array of magnetic field generating devices positioned around the container such that one or more of the magnetic devices are activated navigate the light-emitting robot throughout the photosensitive material
Implementation Method 2
a light-emitting robot having a fluid dynamic shape and constructed, at least in part, with ferrous metal capable of being directed by a magnetic field
Implementation Method 3
a light source of a wavelength capable of solidifying a photosensitive material
Implementation Method 4
the light-emitting robot includes a light source of a wavelength capable of solidifying a photosensitive material
Implementation Method 5
a monitoring device detecting the relative position of the light-emitting robot within the photosensitive material by sensing reflective waves
Data Source
AI summary
An apparatus, method, and computer program product. The embodiments include a method for three-dimensional printing of an object. The method provides for one or more processors to receive image data of an object to print. The one or more processors receive a position of a light-emitting robot inserted within photosensitive material. The one or more processors initiate movement of the light-emitting robot within the photosensitive material. The one or more processors control navigation of the light-emitting robot through the photosensitive material, based on continual feedback of the position of the light-emitting robot within photosensitive material and the received image data of the object to print, and the one or more processors control activation and deactivation of emitted light of the light-emitting robot, based on the image data of the object to print, wherein the emitted light of the light-emitting robot solidifies the photosensitive material.