Linear Solidification Axis Correction and Power Control
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Solution Overview
Problem
Existing linear solidification devices for three-dimensional object manufacturing face challenges with slow build times at low travel speeds and inaccuracies due to non-orthogonal scanning and travel axes, as well as variations in solidification energy delivery along the scanning axis, leading to inconsistencies in the depth of solidification and object accuracy.
Innovation Solution
The system employs a linear solidification device with a rotating energy deflector and a scanning device that compensates for non-orthogonal axes by modifying object data and maintaining constant solidification power along the scanning axis, using techniques such as shearing and power compensation algorithms to ensure accurate and consistent energy delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the linear solidification device travels at high speed along the travel axis, then build time is reduced and productivity is improved, but the scanning axis becomes non-orthogonal to the travel axis, causing manufacturing precision to deteriorate
Solution Approach 1:
The system pre-calculates and stores correction values for the relationship between travel axis position and scanning axis orientation before the actual manufacturing process. This preliminary preparation allows the system to quickly compensate for non-orthogonal effects during high-speed operation without sacrificing precision
Solution Approach 2:
The system continuously monitors the travel axis position and uses this feedback to dynamically adjust the scanning axis orientation or apply corrective transformations to the object data, ensuring that manufacturing precision is maintained even at high travel speeds
2Manufacturing precision
If the linear solidification device travels at slow speed along the travel axis, then manufacturing precision is maintained with orthogonal scanning, but build time increases and productivity deteriorates
Solution Approach 1:
Correction data and transformation parameters are pre-computed and stored in memory before manufacturing begins. This allows the system to operate at high speeds while maintaining precision through pre-prepared compensation data, eliminating the need for slow operation
Solution Approach 2:
The system transforms the object data parameters to account for non-orthogonal scanning conditions, allowing high-speed travel while maintaining the effective orthogonal relationship needed for precision through mathematical parameter adjustments rather than physical constraint
3Device complexity
If solidification power varies along the scanning axis, then the device complexity is reduced without power control mechanisms, but manufacturing precision deteriorates due to inconsistent solidification depth
Solution Approach 1:
The system pre-calculates the required power adjustments at different scanning positions and stores this correction data in advance. This preliminary preparation enables consistent solidification depth without requiring complex real-time power control hardware, as the power variations are compensated through pre-computed parameters
Solution Approach 2:
Instead of using complex mechanical or electronic power control mechanisms to maintain constant solidification power, the system substitutes a software-based approach that transforms object data and applies correction factors, replacing physical power control complexity with computational compensation
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 enhances the accuracy and speed of three-dimensional object manufacturing by maintaining orthogonal scanning and travel axes, ensuring consistent solidification depth and reducing build time inconsistencies, thereby improving the overall precision and efficiency of the process.
Implementation Method 1
a rotating reflector member deflects and scans a laser beam along the surface of a heat fusible material
Implementation Method 2
photo-polymer hardening using light or laser curing methods
Implementation Method 3
a source of solidification energy, the solidification device scans the solidification energy from the laser diode along a scanning axis
Data Source
Figure 1A~1B
Figure 1C
Figure 1D
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. The apparatus and method compensate for a non-orthogonal angle between the travel axis and scanning axis of a linear scanning device and also provide a substantially constant solidification depth along the scanning axis. In certain examples, a solidification energy control system is also provided to regulate the solidification power supplied to the solidifiable material by modulating the power supplied to the linear solidification device's solidification energy source, examples of which include laser diodes.