3D Light Guide Printing via Digital Micromirror Array
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Solution Overview
Problem
Existing methods for printing three-dimensional light-guiding structures using UV-light are limited by the need for specific components suitable for UV-light, which are costly and require frequent adaptation and replacement to achieve desired intensity profiles, restricting flexibility and precision in the curing process.
Innovation Solution
A method utilizing an array of mirror elements and/or fiber means that can adjust light intensity and direction to cure droplets of printing material, allowing for flexible and precise control of light properties, including inhomogeneous and time-dependent intensity profiles, using a UV-light source and potentially multiple light sources, with computer-controlled orientation and integration in a microchip or DLP-chip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If UV-light is used for curing droplets, then curing effectiveness is improved, but component cost and complexity increase due to requirement of quartz lenses and specialized UV-components
Solution Approach 1:
The patent changes the wavelength parameter of the light source from UV to visible light (e.g., blue laser at 450nm), which allows using standard optical components like glass lenses instead of expensive quartz components, thereby reducing device complexity while maintaining curing effectiveness through photopolymerization
Solution Approach 2:
The patent uses a digital micromirror device (DMD) to create a digital copy of the desired light pattern, allowing precise control of light distribution without requiring complex mechanical adjustment of optical components, thus simplifying the overall system
2Manufacturing precision
If UV-light intensity is adjusted to achieve desired curing profile, then curing precision is improved, but time is lost due to frequent adaptation and replacement of light guiding components
Solution Approach 1:
The patent employs a dynamic digital micromirror device that can rapidly change light reflection angles and intensities for different regions, enabling real-time adjustment of curing profiles without any physical component changes, thus eliminating downtime associated with component replacement
Solution Approach 2:
The DMD chip serves multiple functions: it acts as a beam splitter, intensity modulator, and pattern generator simultaneously, allowing a single component to achieve what previously required multiple specialized UV-components, thereby eliminating frequent adaptations
3Productivity
If light intensity is increased to accelerate curing, then productivity is improved, but risk of overheating and material degradation increases
Solution Approach 1:
The patent uses pulsed or modulated light delivery through the DMD, providing periodic curing exposure that allows heat dissipation between pulses, thereby maintaining high overall curing speed while preventing excessive heat accumulation and material degradation
Solution Approach 2:
The DMD enables different regions of the print head to receive different light intensities simultaneously, allowing high intensity to be applied only where needed for rapid curing, while other regions receive lower intensity to avoid overheating, thus balancing productivity and thermal management
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 enables accelerated and precisely controlled curing of three-dimensional light-guiding structures, optimizing the printing process by adjusting light properties according to the growth of the structure and material distribution, reducing material waste, and improving accuracy and efficiency.
Implementation Method 1
curing droplets of a printing material by light irradiation
Implementation Method 2
at least one mirror element of the array and/or the fiber mean reflects indirectly or directly light either onto a screen or onto the layer formed by the droplets of printing material
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to a method for printing a three- dimensional light guiding structure (1) by curing droplets (7) of a printing material by light irradiation, wherein in a first step the droplets (7) of printing material are deposited by a nozzle (30) or a print head of an inkjet printer such that the droplets (7) of printing material form a layer (10) and in a second step light is directed from a light source to an array (5), wherein the array (5) comprises a plurality of mirror elements (6), wherein at least one mirror element (6) of the array (5) can be orientated such that the at least one mirror element (6) of the array (5) reflects indirectly or directly light either onto a screen (3) or onto the layer (10) formed by the droplets (7) of printing material.