Multi-beam Volumetric Resin Curing for High-Speed 3D Printing
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Solution Overview
Problem
Current additive manufacturing techniques face limitations in throughput and geometrical constraints, particularly in producing arbitrary and aperiodic 3D geometries, as they often require mechanical adjustments and are inherently slow due to serial processes and layer-by-layer fabrication.
Innovation Solution
A multi-beam resin curing system and method utilizing a spatial light modulator and projection optics to produce multiple sub-image beams with intensity profiles, allowing for simultaneous curing of select volumetric regions in a 3D pattern within a photosensitive resin bath, enabling whole-volume additive manufacturing with increased speed and improved surface control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If layer-by-layer fabrication is used, then manufacturing precision is maintained, but productivity is reduced
Solution Approach 1:
The patent segments the single light beam into multiple sub-image beams using projection optics, allowing simultaneous curing of multiple regions. This divides the fabrication process into parallel operations while maintaining the precision of each individual beam, resolving the contradiction between precision and productivity.
Solution Approach 2:
The patent transitions from two-dimensional layer-by-layer fabrication to three-dimensional whole-volume fabrication by projecting multiple sub-image beams that intersect within the resin bath. This dimensional change enables simultaneous curing throughout the volume, dramatically increasing productivity while maintaining geometric precision through optical control.
2Device complexity
If serial processes are used, then device complexity is reduced, but productivity is reduced
Solution Approach 1:
The patent merges multiple light beams into a single optical path using projection optics, combining several curing operations into one simultaneous exposure. This merging approach increases productivity through parallel processing while keeping the device relatively simple by using a single light source and optical projection system rather than multiple independent beam generators.
3Adaptability or versatility
If mechanical adjustments are used, then adaptability is improved, but productivity is reduced
Solution Approach 1:
The patent replaces mechanical adjustments with optical control through spatial light modulators and projection optics. The system achieves geometrical flexibility by dynamically programming light patterns rather than physically moving components, eliminating mechanical adjustment time and dramatically increasing productivity while maintaining adaptability to complex geometries.
4Productivity
If whole-volume curing is implemented, then productivity is improved, but manufacturing precision may be compromised
Solution Approach 1:
The patent applies local quality by ensuring each sub-image beam maintains its individual intensity profile and curing characteristics while contributing to the whole-volume fabrication. The projection optics preserve the precision of each beam locally, allowing high-resolution features to be cured simultaneously throughout the volume without sacrificing surface control or geometric accuracy.
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 significantly enhances fabrication speed, reduces geometrical constraints, and allows for the production of complex 3D geometries with superior surface finishes, including overhang structures, by eliminating the need for mechanical adjustments and enabling high-throughput, massively parallel processing.
Implementation Method 1
a spatial light modulator (SLM) adapted to impress an image onto the light beam so as to produce a modulated light beam
Implementation Method 2
projection optics adapted to produce at least two sub-image beams from the modulated light beam with each sub-image beam having an intensity profile corresponding to a section of the image, and project the at least two sub-image beams to intersect each other in the photosensitive resin
Implementation Method 3
simultaneously cure select volumetric regions of a photosensitive resin bath in a 3D pattern representing all of an object
Data Source
AI summary
A multi-beam volumetric resin curing system and method for whole-volume additive manufacturing of an object includes a bath containing a photosensitive resin, a light source for producing a light beam, and a spatial light modulator which produces a phase- or intensity-modulated light beam by impressing a phase profile or intensity profile of an image onto a light beam received from the light source. The system and method also include projection optics which then produces multiple sub-image beams from the modulated light beam which are projected to intersect each other in the photosensitive resin to cure select volumetric regions of the resin in a whole-volume three-dimensional pattern representing the object.