Linear Solidification 3D Printing Apparatus
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Solution Overview
Problem
Current three-dimensional rapid prototyping and manufacturing technologies are costly due to complex systems with many small moving parts, making them inaccessible to many consumers, and there is a need for a more affordable method using linear solidification processes.
Innovation Solution
A system and method for manufacturing three-dimensional objects using a linear solidification device that applies solidification energy in a linear pattern across a solidifiable material, moving in a direction other than the length of the pattern, with a scanning device that deflects energy in a scanning pattern, and a solidification substrate for improved accuracy and separation of solidified material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex systems with many small moving parts are used for three-dimensional rapid prototyping, then manufacturing precision and reliability are improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts and eliminates the complex pattern generator subsystem (DMD, LCD, laser scanning systems) from the rapid prototyping apparatus. Instead of using these complex optical modulation systems, the invention directly projects images onto the photopolymer resin, simplifying the overall system architecture while maintaining manufacturing precision through direct digital light processing
Solution Approach 2:
The patent uses digital image copying technology where computer-generated images are directly projected onto the photopolymer resin layer by layer. This copying approach replaces complex mechanical pattern generation systems with a simpler digital projection system that achieves the same manufacturing precision through optical replication of digital models
2Manufacturing precision
If complex systems with many small moving parts are used for three-dimensional rapid prototyping, then manufacturing precision is improved, but cost increases making the technology inaccessible
Solution Approach 1:
The patent removes the expensive pattern generator components (DMD devices with thousands of micromirrors, LCD systems, or complex laser scanning mechanisms) from the apparatus. This extraction of costly subsystems directly reduces manufacturing cost while maintaining manufacturing precision through the simplified direct projection methodology
Solution Approach 2:
The patent employs a disposable or easily replaceable photopolymer resin container system with a simple transparent bottom surface that serves as the projection screen. This replaces expensive, precision-machined optical components with a simple, inexpensive transparent substrate that can be easily replaced, significantly reducing overall system cost
3Productivity
If linear solidification with scanning device is used, then productivity is improved through faster solidification, but device complexity increases due to additional moving parts
Solution Approach 1:
The patent merges the image projection system with the linear solidification process by directly projecting images onto the photopolymer resin surface. This integration eliminates the need for separate scanning mechanisms, achieving high productivity through simultaneous multi-point solidification while avoiding additional device complexity from separate scanning components
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
The solution reduces costs by simplifying the system and improving accuracy in building three-dimensional objects, making three-dimensional manufacturing more accessible and efficient.
Implementation Method 1
a solidification energy source that applies electromagnetic radiation to the solidifiable material
Data Source
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 that projects light onto a scanning device, 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. 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.