MicroLED Array Control for Precision Photopolymerization 3D Printing
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Solution Overview
Problem
Existing 3D printers using LCD or DLP technologies face limitations in precision, size, and light intensity, necessitating improved light emitting mechanisms for enhanced performance.
Innovation Solution
A photopolymerization 3D printing system utilizing a microLED array with individually addressable microLED emitters, allowing dynamic control of light intensity, wavelength, and resolution across different printing layers through Pulse Width Modulation (PWM) and Pulse Frequency Modulation (PFM), and optical collimation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If LCD or DLP technology is used for light projection, then the system can achieve basic 3D printing functionality, but the precision, light intensity, and service life are limited
Solution Approach 1:
The light source is segmented into individually addressable microLED emitters arranged in a grid array, allowing selective activation of specific regions for different printing layers. This segmentation enables precise spatial control of light exposure while extending overall system service life through regional wear management.
Solution Approach 2:
The system dynamically adjusts light emission parameters including intensity, wavelength, and temporal characteristics through PWM and PFM modulation. This dynamic control optimizes printing precision for different material properties and layer requirements while managing light source durability.
2Productivity
If higher light intensity is used to improve printing speed and precision, then the quality of print output improves, but the service life of the light source decreases
Solution Approach 1:
The system employs periodic pulsed light emission through PWM modulation, delivering high-intensity light in controlled bursts rather than continuous operation. This periodic action achieves high printing speed and precision during active exposure while reducing cumulative stress on the light source, thereby extending service life.
Solution Approach 2:
The system changes light emission parameters including intensity, duty cycle, and temporal frequency dynamically during the printing process. By adjusting these parameters based on real-time printing requirements, the system optimizes both productivity and light source durability.
3Area of stationary object
If the display size is increased to print larger objects, then the applicability expands, but the light uniformity and precision across the display area deteriorate
Solution Approach 1:
The extended display area is segmented into multiple independently controllable microLED regions, each capable of precise intensity and timing control. This segmentation maintains light uniformity across the entire build area by allowing individual region optimization.
Solution Approach 2:
Different regions of the display area can have tailored light emission characteristics optimized for their specific printing requirements. This local quality approach ensures consistent precision across the entire extended build plate area.
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
Enhances light control and extends the service life of the light source, providing improved precision and intensity for 3D printing applications.
Implementation Method 1
a light irradiating device including a micro light emitting diode (microLED) array
Implementation Method 2
Each layer may be formed by projecting a two-dimensional pattern for that layer into a photopolymerizable liquid, thus curing the liquid to form a solid shape
Data Source
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AI summary
A method and system (100) for photopolymerization 3D printing is provided. The system (100) includes a processing device (140), a micro light emitting diode (microLED) array (1810) including one or more individually addressable microLED emitters(611, 934), and a printing componen t(110). The processing device(140) is configured to determine one or more printing layers (560a, 560b) of an object (560). The microLED array (1810) is configured to generate light for each of the one or more printing layers (560a, 560b). The printing component (110) is configured to print the one or more printing layers (560a, 560b). To generate the light for each of the one or more printing layers (560a, 560b), the processing device (140) is further configured to dynamically determine one or more microLED regions (811, 812, 1820) in the microLED array (1810), determine one or more region printing parameters for each of the one or more microLED regions (811, 812, 1820); and determine one or more control signals for the one or more individually addressable microLED emitters (611, 934) included in each of the one or more microLED regions (811, 812, 1820) based on the one or more region printing parameters.