Linear UV LED Array for Photopolymer 3D Printing
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Solution Overview
Problem
Current photopolymerization 3D printing technologies, such as DLP and SLA, face limitations in equipment cost, scalability, and production speed, necessitating a more efficient method for curing photopolymers.
Innovation Solution
A linear light source using an ultraviolet LED array with a linear arrangement in the X-axis direction and a quasi-linear arrangement in the Y-axis direction at an oblique angle, combined with an optical device to reduce beam spot size, allows for precise projection of ultraviolet light and rapid curing of photopolymers in a single scanning process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If DLP technique is used, then printing precision and surface roughness are improved, but equipment cost increases and scalability is limited
Solution Approach 1:
The patent segments the light source into multiple ultraviolet LEDs arranged in a linear array, replacing the single DLP projector with a modular LED configuration that can be distributed and scaled independently
Solution Approach 2:
The patent replaces the mechanical DLP projection system with a direct ultraviolet LED light emission system, eliminating complex projection optics and reducing equipment complexity while maintaining printing precision
2Manufacturing precision
If SLA technique is used, then printing precision is improved, but equipment cost increases and production speed decreases
Solution Approach 1:
The patent implements continuous linear scanning of the ultraviolet LED array across the photopolymer surface, maintaining continuous curing action without the intermittent layer-by-layer processing of traditional SLA, thereby increasing production speed while preserving precision
Solution Approach 2:
The patent introduces dynamic movement of the linear LED array along the Y-axis direction, enabling the light source to scan across the build area and cure multiple locations sequentially, which accelerates production compared to static SLA systems
3Productivity
If linear LED array with oblique arrangement is used, then production speed is improved through single scanning process, but device complexity increases
Solution Approach 1:
The patent employs an asymmetric oblique arrangement of ultraviolet LEDs where the Y-axis direction is positioned at a 45-degree angle relative to the linear array, creating an optimized scanning geometry that enables single-process layer production
Solution Approach 2:
The patent adds the Y-axis scanning dimension to the traditional X-axis linear array, creating a two-dimensional oblique arrangement that enables comprehensive coverage of the photopolymer surface through diagonal scanning motion
4Manufacturing precision
If optical device is added to reduce beam spot size, then printing precision is improved, but device complexity increases
Solution Approach 1:
The patent introduces an optical device as an intermediary element between the ultraviolet LED and photopolymer, which focuses and concentrates the light into a reduced beam spot size, thereby improving printing precision with a single added component
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 printing precision and speed by enabling the projection of a desired pattern linearly and reducing the beam spot size, thereby improving the scalability and cost-effectiveness of photopolymerization 3D printing.
Implementation Method 1
an ultraviolet LED array formed of a plurality of ultraviolet LEDs disposed on the substrate to project ultraviolet light
Implementation Method 2
curing a photopolymer in accordance with a printing form
Data Source
AI summary
The present application relates to a linear light source using ultraviolet light emitting diodes (LEDs), and a photopolymer 3D printer comprising the linear light source. The linear light source may include a substrate distanced from a polymer case of the photopolymer 3D printer and an ultraviolet LED array in which a plurality of ultraviolet LEDs, which project ultraviolet rays toward the polymer case, are arranged on the substrate in multiple rows in the X-axis direction. The arrangement of the multiple columns in the Y-axis direction is at an oblique angle to the multiple rows.