Multi-axis Additive Manufacturing Light Guide Tool
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Solution Overview
Problem
Traditional additive manufacturing processes suffer from a stair-stepping effect and struggle to achieve high-resolution fabrication, especially for micro-scale features, due to limitations in resolution control and efficiency.
Innovation Solution
A light guide tool with a tubular structure and reflective sidewalls, coupled with an optical coupling and lens, is used to emit a two-dimensional light pattern for surface-based CNC accumulation, allowing for high-resolution fabrication by dynamically projecting pixel arrays within a liquid resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional layer-by-layer additive manufacturing is used, then material accumulation is achieved, but stair-stepping effect occurs and manufacturing precision deteriorates
Solution Approach 1:
The patent replaces traditional mechanical layer-by-layer deposition with a light-based curing system. A digital micromirror device (DMD) projects 2D light patterns through a light guide tool to selectively cure SLA resin, eliminating the need for physical layer stacking and thereby removing the stair-stepping effect while maintaining high surface quality
Solution Approach 2:
The patent uses optical copying by projecting 2D images of the desired geometry onto the resin surface through a light guide tool. The DMD device creates pixel array images that are optically transferred to the resin, allowing direct formation of 3D features without mechanical layer accumulation, thus achieving smooth surfaces without stair-stepping
2Manufacturing precision
If point-based CNC accumulation process is used, then stair-stepping effect is reduced, but resolution control is limited and manufacturing precision deteriorates for micro-features
Solution Approach 1:
The patent transitions from point-based accumulation to surface-based accumulation by projecting 2D light patterns onto the resin surface. The light guide tool with DMD device illuminates entire 2D cross-sections of the object simultaneously, adding a dimensional aspect that enables high-resolution micro-feature fabrication across the entire surface area rather than point-by-point
Solution Approach 2:
The patent employs dynamic 2D light pattern projection where the DMD device can rapidly change the illuminated area and shape according to the object's geometry. The system dynamically adjusts the light pattern to match the cross-sectional shape at each height level, enabling adaptive high-resolution fabrication for complex micro-features
3Manufacturing precision
If high-resolution fabrication is pursued, then manufacturing precision improves, but fabrication time increases and productivity deteriorates
Solution Approach 1:
The patent implements continuous surface projection where 2D light patterns are continuously projected onto the resin surface as the light guide tool moves through the object. This continuous illumination and curing process eliminates the need for discrete layer-by-layer operations, maintaining high resolution while significantly reducing fabrication time through uninterrupted material accumulation
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 eliminates the stair-stepping effect and enables high-speed, high-resolution fabrication of micro-scale features, achieving resolutions of up to 2.5 μm/pixel and improving surface quality by continuously accumulating geometric features.
Implementation Method 1
emitting a two-dimensional light pattern from an area of the free end of the light-emitting arm to cure a portion of the SLA resin between the area of the free end and the solid accumulation surface
Data Source
AI summary
Methods, systems, and devices including a light guide tool for multi-axis additive manufacturing. The light guide tool includes a tubular light guide. The tubular light guide may be made from an optically transmissive material enclosed by one or more reflective side walls that are interposed between opposing optically transmissive ends. The light guide tool includes an optical coupling fixed to a first end of the optically transmissive ends of the tubular light guide. The optical coupling is configured to couple to a lens. The light guide tool includes a transparent non-stick coating. The transparent non-stick coating is adhered over a second end of the optically transmissive ends of the tubular light guide. The light guide tool includes a lens. The lens is coupled to the optical coupling and configured to emit a two-dimensional light pattern.