Material Deposition Assembly With Periodic Resin Flushing

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Solution Overview

Problem

Additive manufacturing processes face issues with agglomerates, partially cured resin pieces, and foreign objects retained within the deposition assembly, leading to variations in the resin layer deposited on the resin support, which affect the quality of the manufactured components.

Innovation Solution

The deposition assembly includes a reservoir housing with an actuatable application device, such as a doctor blade, and a computing system that initiates a flush operation to move agglomerates and foreign objects downstream, ensuring consistent resin layer thickness and quality by adjusting the position of the application device and optionally using a wiper assembly to remove unwanted materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If resin is continuously deposited through the deposition assembly, then productivity is improved, but agglomerates and foreign objects are retained causing variations in resin layer quality

Engineering Contradiction:

Improvecontinuous resin depositionVSAvoidresin layer thickness consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary actions by periodically flushing the deposition assembly before defects can manifest in the final product. The flush operation proactively removes agglomerates and foreign objects from the deposition assembly, preventing them from causing variations in resin layer thickness during continuous deposition operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention implements periodic action through scheduled flush operations that interrupt continuous resin deposition at predetermined intervals. The computing system is configured to initiate flush operations between successive layers of the component, temporarily stopping production to clean the deposition assembly, then resuming deposition with restored quality consistency.

Inventive Principle:

Principle #19Periodic action

2Manufacturing precision

If the application device is moved to flush the deposition assembly, then resin layer quality is improved, but production time is lost during the flush operation

Engineering Contradiction:

Improveresin layer thickness consistencyVSAvoidproduction interruption during flush

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system maintains continuity of useful action by minimizing the duration and frequency of flush operations. The computing system is configured to initiate flush operations only between successive layers, not during active layer deposition. This ensures that the resin support is translated a predefined distance during flush operations to position the flush zone outside the build zone, maximizing productive deposition time while maintaining quality.

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If a wiper assembly is used to remove unwanted materials, then resin layer purity is improved, but device complexity increases

Engineering Contradiction:

Improveresin layer purityVSAvoidadditional wiper assembly components

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention extracts the contamination removal function from the main deposition process by implementing a separate, dedicated wiper assembly that operates independently during flush operations. The wiper assembly is configured to contact the resin support and remove agglomerates and foreign objects that are flushed onto the resin support, separating the cleaning function from the deposition function and allowing each to be optimized independently.

Inventive Principle:

Principle #2Taking out (Extraction)

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 effectively flushes agglomerates and foreign objects, maintaining consistent resin layer thickness and improving the quality of the manufactured components by preventing defects caused by irregular thickness variations.

Implementation Method 1

Stereolithography (SLA) is a type of additive manufacturing process, which employs a vessel of radiant-energy curable photopolymer 'resin' and a curing energy source, such as a laser. Exposure to the radiation cures and solidifies the pattern in the resin

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 2

a deposition assembly upstream of the stage and configured to deposit a resin on a resin support

Methodology Applied

Scientific EffectMaterial deposition: Deposition (physical)

Data Source

PatentUS20250319652A1Material deposition assembly for additive manufacturing

Publication Date: 2025.10.16 GENERAL ELECTRIC CO

AI summary

An additive manufacturing apparatus includes a stage configured to hold a component. A radiant energy is device operable to generate and project radiant energy in a patterned image. An actuator is configured to change a position of the stage relative to the radiant energy device. A deposition assembly is upstream of the stage and configured to deposit a resin on a resin support. The deposition assembly includes a reservoir housing configured to retain a volume of resin between the upstream wall and the downstream wall. The deposition assembly also includes an application device operably coupled with the reservoir housing. A computing system is operably coupled with the application device. The computing system is configured to intermittently initiate a flush operation between successive layers of the component, wherein the application device is moved from a first position to a second position during the flush operation.