3D Printing Liquid-Matrix Support for Large Objects
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Solution Overview
Problem
Current three-dimensional printing techniques, particularly bottom-to-top DLP methods, face limitations such as mechanical constraints due to full immersion in resin, size restrictions due to heavy build plates, and complications from mechanical separation steps, which slow down the process and can distort the end product.
Innovation Solution
A system utilizing a liquid-matrix support comprising a motor, light polymerizable resin, and a non-aqueous hydrophobic oil, where the stage moves upward or downward to support growing layers, allowing for high-speed printing with reduced surface tension and increased surface energy to enhance wetting, thus eliminating the need for mechanical separation and accommodating larger sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If bottom-to-top DLP printing is used, then large size objects can be printed, but mechanical separation steps are required which slow down the process and can distort the product
Solution Approach 1:
The patent extracts and eliminates the mechanical separation step from the printing process by using a liquid support matrix that automatically releases cured layers through buoyancy and fluid dynamics, removing the harmful mechanical intervention that slows production and risks distortion
Solution Approach 2:
The patent replaces the mechanical separation system with a fluid-based release mechanism where the liquid support matrix naturally releases cured layers through buoyant forces and fluid flow, substituting mechanical action with hydrodynamic action to maintain printing speed and product integrity
2Volume of moving object
If heavy build plates are used for large objects, then large size printing is enabled, but mechanical constraints and distortion increase
Solution Approach 1:
The patent uses a liquid support matrix (hydraulic system) to replace solid build plates, allowing large objects to be supported without mechanical constraints. The fluid adapts to object shape and size, eliminating rigid contact points that cause distortion while enabling unlimited printing dimensions
Solution Approach 2:
The patent changes the physical state of the support from solid (build plate) to liquid (support matrix), fundamentally altering how objects are supported. This parameter change eliminates mechanical constraints and distortion while enabling large-scale printing without size limitations
3Ease of operation
If mechanical separation steps are used, then layer separation is achieved, but the process is slowed down and product quality is reduced
Solution Approach 1:
The liquid support matrix performs separation automatically through buoyancy and fluid dynamics without external mechanical intervention. The system serves itself by using the physical properties of the liquid to naturally release cured layers, eliminating the need for separate mechanical separation steps that slow production
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
Enables high-resolution, high-speed printing of large three-dimensional objects with a smooth texture, achieving speeds up to 20-30 mm/min while maintaining product quality and reducing distortion.
Implementation Method 1
The resin is a light polymerizable liquid. A light from the light projecting source is projected on the resin to provide a shape to the three dimensional objects.
Implementation Method 2
The oil is a non-aqueous hydrophobic and oleo-phobic component and is layered below the resin. The liquid-matrix support comprising a motor, light polymerizable resin, and a non-aqueous hydrophobic oil, where the stage moves upward or downward to support growing layers, allowing for high-speed printing with reduced surface tension and increased surface energy to enhance wetting
Data Source
AI summary
A system for printing three dimensional objects using a liquid-matrix support includes a motor, a resin, a stage, oil, and a light projecting source. The motor is an operating interface that is adapted to move the stage in an upward or in a downward direction. The resin in the system comprises a light polymerizable liquid. The light from the light projecting source is projected onto the resin to provide a shape to the three dimensional objects. The stage is adapted to move in the upward or in the downward direction to support the growing layers of the printed three dimensional objects. The oil is a non-aqueous hydrophobic and oleo-phobic component that is coupled at an interface with the resin by a liquid-matrix support which includes an additive. The light projecting irradiates the resin, and, in a preferred embodiment, irradiation passes through the oil to the resin. The liquid-matrix support enhances speed, resolution and provides smooth finishing texture to the printed three dimensional objects of large and small dimensions.