Linear-Immersed Tooltip for 3D Printing
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Solution Overview
Problem
Current additive manufacturing processes are often slow and limited in building large part sizes due to layer-based approaches, which complicate the separation of built layers from resin tanks and require recoating, leading to inefficiencies in both speed and cost.
Innovation Solution
A line-based CNC accumulation process using a laser tooltip immersed in a resin tank, with a multi-axis motion control stage and gyro-mirror system, delivers focused laser light through a linear opening to cure resin in distinct lines, allowing for faster building and larger part sizes without the need for recoating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If layer-based additive manufacturing is used, then the process planning is simplified, but the building speed is slow and part size is limited
Solution Approach 1:
The patent transitions from layer-based (2D slicing) to line-based (1D scanning) additive manufacturing. By delivering laser light through a linear opening in the tooltip, the system cures resin in continuous lines rather than layer-by-layer, effectively changing the dimensional approach from 2D to 1D and eliminating the need for recoating operations.
Solution Approach 2:
The patent extracts the laser delivery mechanism from the traditional SLA setup by immersing the tooltip with a linear opening directly into the resin tank. This allows the laser to cure resin through the linear opening while the tooltip remains submerged, eliminating the need to lift and recoat the build platform after each layer.
2Ease of manufacture
If layer-based additive manufacturing is used, then the process planning is simplified, but the part size is limited
Solution Approach 1:
By transitioning from layer-based to line-based manufacturing with an immersed tooltip, the system can build larger parts continuously without the size constraints imposed by layer thickness and recoating requirements. The linear opening allows laser delivery through the resin, enabling unrestricted part dimensions.
3Productivity
If the output end of the tooltip is immersed in liquid resin, then light can be delivered to cure resin in distinct lines, but the attachment force between the output end and cured material increases
Solution Approach 1:
The patent applies a coating to the output end of the tooltip that changes the surface properties to reduce attachment force. This coating allows the cured resin to release from the tooltip surface after curing, preventing excessive adhesion while maintaining the ability to deliver laser light through the linear opening for high-speed building.
4Productivity
If a linear opening is used to deliver light, then the building speed increases, but the precision of light delivery becomes more challenging
Solution Approach 1:
The patent replaces traditional mechanical focusing mechanisms with an optical system that delivers laser light through the linear opening. The laser beam is precisely controlled and focused through the linear opening to cure resin with high precision, maintaining manufacturing accuracy while enabling high-speed line-based manufacturing.
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 process significantly reduces building time and enables the creation of larger part sizes while being more cost-effective, achieving speeds comparable to digital-light-projection-based SLA processes, with the ability to fabricate complex objects using varied scanning patterns and orientations.
Implementation Method 1
By controlling the on/off state of the UV-LED and the multi-axis motion of the cable, a physical model, having a desired shape, can be built by selectively curing liquid resin into solid
Implementation Method 2
The light used in the tooltip can include focused laser light having a laser spot size
Data Source
AI summary
The present disclosure describes systems and techniques relating to computer numerical control (CNC) additive manufacturing. According to an aspect, a tooltip for an additive manufacturing machine includes: an input end configured to receive light from an optical system; and an output end configured to deliver the light to a workpiece on a build platform in the additive manufacturing machine; wherein the output end of the tooltip is configured to be immersed in a liquid resin in a tank of the additive manufacturing machine, and the output end defines a linear opening through which the light is delivered to the workpiece on the build platform.