Light Engine Fine-Displacement Adjustment for Smoother 3D Printing
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Solution Overview
Problem
DLP 3D printing machines face challenges with surface rippling and low surface finishing due to large pixel sizes and inconsistent connections, requiring a cost-effective solution for fine-displacement adjustment between the optical lens and light source without altering the structural configuration.
Innovation Solution
A fine-displacement adjusting device comprising a base portion, retractable elements, and resilient elements, utilizing piezoelectric ceramics and compression springs to achieve two-dimensional nano-scale adjustments, allowing for precise movement of the optical lens relative to the light source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical components are improved to achieve fine-displacement adjustment, then printing accuracy is improved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent replaces complex mechanical adjustment components with a deformable membrane structure that uses pneumatic pressure to achieve fine-displacement adjustment. The membrane (140) deforms in response to pressure changes, moving the lens (130) precisely without requiring traditional mechanical actuators, gears, or linkages, thus reducing device complexity while maintaining printing accuracy.
Solution Approach 2:
The patent changes the physical state of the membrane from rigid to flexible by controlling its deformation through pneumatic pressure. By adjusting the pressure parameter, the membrane's shape and position change, enabling fine-displacement adjustment of the lens. This parameter-based control eliminates the need for complex mechanical adjustment mechanisms.
2Manufacturing precision
If mechanical components are improved to achieve fine-displacement adjustment, then printing accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive mechanical adjustment components with a simpler pneumatic-membrane system. The membrane (140) and pressure control mechanism are less costly to manufacture and assemble than precision mechanical actuators, reducing overall manufacturing cost while achieving the same fine-displacement adjustment capability needed for printing accuracy.
Solution Approach 2:
The membrane structure can be manufactured as a low-cost, potentially disposable component that does not require expensive materials or complex machining. This approach reduces manufacturing cost compared to durable mechanical components, aligning with the goal of cost-effective fine-displacement adjustment.
3Manufacturing precision
If pixel size is reduced to improve printing accuracy, then surface finishing is improved, but device complexity increases
Solution Approach 1:
The patent introduces a dynamic, deformable membrane structure that can adjust its position continuously in response to pressure changes. This dynamic adjustment capability allows for precise control of lens position to optimize pixel projection and surface finishing, without requiring a static complex mechanical adjustment mechanism. The membrane's flexibility provides continuous adjustability.
Solution Approach 2:
By changing the pressure parameter applied to the membrane, the system dynamically adjusts the lens position to achieve optimal printing accuracy and surface finishing. This parameter-based control is simpler than mechanical adjustment systems and enables fine-tuning of the optical system without increasing structural complexity.
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
Improves printing accuracy and surface smoothness by enabling controlled, precise displacement of the optical lens, enhancing the overall quality of 3D printed objects while maintaining a simple and cost-effective structural configuration.
Implementation Method 1
the piezoelectric element is configured to extend or retracts in response to an applied voltage
Implementation Method 2
a compression spring operatively connected to the piezoelectric element and configured to apply a restoring force to the optical lens in response to a displacement of the optical lens
Data Source
AI summary
A fine-displacement adjusting device is constructed to have a first base portion and a second base portion spacedly encircled therewithin. The fine-displacement adjusting device further includes a first retractable element biased between the first and second base portions, and a first resilient element biased between the first and second base portions. The first retractable element is configured to extend and retract its length along a first axis to move the second base portion in a reciprocating manner. When the second base portion is moved by the first retractable element, the first resilient element moves the second base portion along the first axis to restore the second base portion. Therefore, the second base portion is fine-moved along the first axis in a reciprocating manner for adjusting the fine-displacement of an optical lens relative to an optical light source of a light engine in the first axis.