Liquid Interface Leveling in Additive Fabrication
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Solution Overview
Problem
Conventional additive fabrication devices face challenges in maintaining a consistent and even liquid-liquid interface due to movement and turbulence, leading to inconsistent layer formation and increased time required for equilibrium, especially with viscous photopolymers and thinner layers.
Innovation Solution
Incorporating a leveling element that moves through the supporting liquid to smooth the interface and a film between the liquid photopolymer and supporting liquid to limit intermixing and maintain a flat surface, along with selecting immiscible liquids based on density and reactivity to reduce adhesive forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a supporting liquid is used in additive fabrication, then layer formation is enabled, but the liquid-liquid interface becomes unstable and turbulent, leading to inconsistent layer formation
Solution Approach 1:
A film is introduced as an intermediary barrier between the liquid photopolymer and supporting liquid, preventing direct contact and turbulence at the liquid-liquid interface while still allowing the supporting liquid to provide structural support for layer formation
Solution Approach 2:
A thin film is placed between the liquid photopolymer and supporting liquid to stabilize the interface, prevent mixing, and eliminate turbulence while maintaining the functional benefits of both liquids
2Reliability
If the liquid photopolymer and supporting liquid are allowed to mix, then equilibrium is reached, but the process time increases significantly
Solution Approach 1:
The film acts as a selective barrier that prevents mixing between the liquid photopolymer and supporting liquid, allowing the system to maintain a stable equilibrium state without requiring extensive mixing time
Solution Approach 2:
The film is pre-installed between the liquids to prevent mixing from occurring in the first place, eliminating the need for time-consuming equilibrium processes
3Ease of manufacture
If thicker layers are used, then manufacturing is easier, but the precision and consistency of layer formation decreases
Solution Approach 1:
The thin film provides a stable, flat interface that enables precise control over thin layer formation, allowing for high manufacturing precision while maintaining ease of operation through the film's structural support
4Object-affected harmful factors
If incompatible liquids are used, then adhesive forces are reduced, but the liquids may react or mix adversely
Solution Approach 1:
The film serves as a protective intermediary that allows incompatible liquids to be used together by preventing direct contact and adverse reactions while maintaining the benefit of reduced adhesive forces
Solution Approach 2:
The thin film creates a physical barrier that prevents mixing and adverse reactions between incompatible liquids while still allowing the system to benefit from using liquids with reduced adhesive properties
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 enables faster and more consistent layer formation by minimizing bulges and distortion, allowing for the use of incompatible liquids and reducing the time needed for the liquids to reach equilibrium, thereby improving the efficiency and accuracy of the additive fabrication process.
Implementation Method 1
a leveling element arranged adjacent to the supporting liquid and at least one controller configured to move the leveling element through the supporting liquid along an upper surface of the supporting liquid
Implementation Method 2
a film coupled to the container and arranged over and in contact with the supporting liquid
Implementation Method 3
an apparatus for additive fabrication configured to form a plurality of layers of material on a build platform by directing actinic radiation onto a liquid photopolymer
Implementation Method 4
the build platform configured to be movable through the liquid photopolymer
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
According to some aspects, an additive fabrication apparatus is provided configured to form layers of material on a build platform (203), each layer of material being formed so as to contact a supporting liquid (205) or a film (507) disposed within a container (201), in addition to the build platform, a liquid photopolymer (206), and/or a previously formed layer (220) of a material. The additive fabrication apparatus may comprise a container (201) and a leveling element (207), wherein the leveling element (207) is configured to move across a liquid-liquid interface (204) to promote or create a flat interface between the two liquids. According to some aspects, the additive fabrication comprises a film (507) disposed between two liquids, wherein the film (507) maintains or provides a flat surface at the interface of the two liquids.