Linear Solidification Device for 3D Printing Cost Reduction
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Solution Overview
Problem
Current three-dimensional rapid prototyping technologies are costly due to complex systems with numerous small moving parts, making them inaccessible to many consumers, and there is a need for a more efficient method for solidification in 3D printing.
Innovation Solution
A linear solidification device that applies solidification energy in a linear pattern across a solidifiable material, using a rotating energy deflector or laser scanning micromirror to selectively solidify the material, reducing the complexity and cost of the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rapid prototyping technologies (DMD, laser SLA, SLM) are used, then manufacturing precision and object formation capability are improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the essential solidification function from complex systems by using a simple linear solidification device that applies energy in a linear pattern, eliminating the need for complex pattern generators like DMD devices with thousands of micromirrors or sophisticated laser scanning systems
Solution Approach 2:
The patent uses a linear pattern as a simplified copy of the object cross-section, which is then rotated and stacked to build the three-dimensional object, replacing complex direct pattern projection with a sequential linear approximation approach
2Manufacturing precision
If traditional rapid prototyping technologies are used, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent employs inexpensive, simple components such as a linear energy source and basic rotating mechanism instead of expensive, complex pattern generators, making the system accessible to consumers while maintaining adequate manufacturing precision through the iterative linear solidification process
3Device complexity
If linear solidification with rotating energy deflector is used, then device complexity is reduced, but solidification energy distribution uniformity may worsen
Solution Approach 1:
The patent uses periodic rotation of the energy deflector to systematically distribute solidification energy across different angular positions, ensuring uniform energy distribution over time while maintaining a simple device structure without requiring complex real-time control mechanisms
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 simplifies the 3D printing process, reducing costs and making it more accessible by providing efficient solidification with a linear solidification method that is accurate and effective in producing three-dimensional objects.
Implementation Method 1
A linear solidification device that applies solidification energy in a linear pattern across a solidifiable material, using a rotating energy deflector or laser scanning micromirror to selectively solidify the material
Data Source
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AI summary
An apparatus and method for making a three-dimensional object from a solidifiable material using a linear solidification device is shown and described. In certain examples, the linear solidification device includes a laser diode (90, 90a, 90b) that projects light onto a scanning device (92), such as a rotating polygonal mirror or a linear scanning micromirror, which then deflects the light onto a photohardenable resin. As a result, the linear solidification device scans a line of solidification energy in a direction that is substantially orthogonal to the direction of travel of the laser diode (90, 90a, 90b). In other examples, the linear solidification device is a laser device array or light emitting diode array that extends in a direction substantially orthogonal to the direction of travel of the array.