Multiple Light Source DLP 3D Printer Voxel Distortion
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Solution Overview
Problem
Conventional DLP 3D printers are limited by single light sources, which restrict print area and precision, leading to prolonged operation times and reduced printing accuracy due to voxel distortion and projector vibration.
Innovation Solution
A DLP 3D printer with multiple light sources that flash discrete images simultaneously to create a combined image, correcting voxel distortion and maintaining immovable light sources to enhance printing speed, area, and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single digital projector is used to project images for layer solidification, then the device structure is simple, but the printing area is limited and printing speed is reduced
Solution Approach 1:
The patent divides the single projector function into multiple independent light sources (first light source and second light source), each projecting discrete images simultaneously. This segmentation allows the printing area to be expanded by combining multiple light fields without requiring a single complex high-power projector, thus resolving the contradiction between printing area and device complexity.
Solution Approach 2:
The patent merges the output of multiple light sources by combining discrete images from the first and second light sources into a composite image that covers a larger printing area. This merging approach allows the system to achieve a larger effective printing area while maintaining the simplicity of individual light source components.
2Area of stationary object
If the digital projector is moved to project subsequent images for larger print area, then the printing area is enlarged, but the operation time is prolonged and vibration affects printing precision
Solution Approach 1:
Instead of moving a single projector, the patent segments the projection function into multiple stationary light sources positioned at different locations. Each light source remains fixed during operation, eliminating vibration-induced precision errors while collectively covering a larger printing area through simultaneous projection of discrete images.
Solution Approach 2:
The patent enables continuous and simultaneous projection from multiple light sources throughout the printing process. This continuous action eliminates the need to stop and move the projector between image projections, maintaining printing precision by keeping light sources stationary while continuously enlarging the effective printing area.
3Productivity
If the digital projector flashes single images sequentially, then the device structure is simple, but the printing speed is reduced
Solution Approach 1:
The patent segments the projection task into multiple parallel light sources that flash discrete images simultaneously rather than sequentially. This segmentation enables multiple regions of the resin layer to be cured at the same time, significantly increasing printing speed while keeping each individual light source relatively simple in structure.
Solution Approach 2:
The patent performs preliminary arrangement of multiple light sources in fixed positions before the printing process begins. This preliminary configuration allows simultaneous projection of discrete images across different areas, establishing a parallel processing capability that increases printing speed without requiring complex real-time control mechanisms during operation.
4Manufacturing precision
If a single light source is used, then the device is simple to manufacture, but the printing area and precision are limited
Solution Approach 1:
The patent divides the projection system into multiple independent light sources, each with its own simple structure that is easy to manufacture. By segmenting the system, each component can be produced using standard, well-established manufacturing processes, and then assembled into a configuration that achieves higher overall printing precision through simultaneous multi-region curing.
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 faster, more precise, and larger 3D object creation with improved printing quality and reduced vibration, allowing for easier and cost-effective production of bigger 3D objects.
Implementation Method 1
each of the light sources is arranged for flashing a discrete image to solidify the liquid resin in the resin reservoir
Data Source
AI summary
A 3D printer includes a resin reservoir arranged for being filled with a predetermined amount of liquid resin, a light exposure module, and a control processor. The light exposure module includes a plurality of light sources supported above the resin reservoir, wherein each of the light sources is arranged for flashing a discrete image to solidify the liquid resin in the resin reservoir. The control processor controls the light sources to flash the discrete images at the same time and to combine the discrete images into a combined image for forming a layer of a 3D object when the liquid resin is solidified.