Multi-material Stereolithography with Rotating Platform
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Solution Overview
Problem
Current stereolithography systems are limited in their ability to handle multiple building materials and maintain a sterile environment, which is crucial for biomedical applications, and they lack the capability to efficiently incorporate additives that alter material properties on a layer-by-layer basis.
Innovation Solution
The system incorporates multiple polymer retaining receptacles, a platform that can transport parts for intermediate washing and curing, and allows for the incorporation of additives such as color and other materials that alter mechanical, optical, thermal, and biofunctional properties on a layer-by-layer basis, while maintaining a sterile environment through a pump system and rotating platform for angled washing and curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single resin retaining receptacle is used in SL machines, then the device complexity is low, but the adaptability to handle multiple building materials is limited
Solution Approach 1:
The single resin retaining receptacle is divided into multiple separate receptacles, each capable of holding different resin materials. This segmentation allows the system to handle multiple building materials simultaneously while maintaining manageable complexity through modular architecture.
Solution Approach 2:
The SL machine system is designed with multi-functional capability to accommodate multiple resin receptacles and switch between different materials. The system can selectively access different receptacles based on build requirements, providing universal adaptability for various material types including hydrogels and other biocompatible materials.
2Manufacturing precision
If intermediate cleaning and curing steps are added for multi-material builds, then the manufacturing precision and material purity are improved, but the build time increases
Solution Approach 1:
Cleaning and curing operations are performed as preliminary intermediate steps between material transitions during the build process. By proactively addressing material contamination risks before they affect subsequent layers, the system maintains high material purity without requiring extensive post-processing, thus balancing precision with productivity.
Solution Approach 2:
The system maintains continuous build operation by performing cleaning and curing steps in an integrated manner that minimizes idle time. The useful action of building is continued throughout the process with intermediate steps seamlessly incorporated, preventing complete interruptions and maintaining overall productivity while ensuring material purity.
3Adaptability or versatility
If multiple resin receptacles are implemented, then the versatility for biomedical applications is improved, but the risk of cross-contamination between materials increases
Solution Approach 1:
The potential cross-contamination issue is extracted and addressed as a separate concern through dedicated cleaning mechanisms and isolated receptacle designs. Each receptacle is designed to prevent material mixing, and cleaning protocols are specifically targeted at removing residual materials between builds, effectively removing the contamination risk while preserving multi-material versatility.
Solution Approach 2:
Intermediate cleaning steps and protective barriers act as mediators between different resin materials. These intermediary elements prevent direct contact and potential cross-contamination between materials from different receptacles, allowing the system to safely handle multiple biocompatible materials including hydrogels without compromising material integrity.
4Manufacturing precision
If support structures are removed after building, then the manufacturing precision of the final part is improved, but the loss of time for post-processing increases
Solution Approach 1:
Support structure design and placement are performed as preliminary actions during the build planning stage. By optimizing support structure configuration beforehand and using material-specific support designs, the removal process is streamlined and requires minimal post-processing time, thus maintaining high part quality while reducing time loss.
Solution Approach 2:
The properties of support structures are changed by using different materials with varying strength and solubility characteristics. Support structures are designed with parameters that facilitate easy removal or degradation after building, allowing for reduced post-processing time while maintaining the necessary support function during the build process and achieving high final part quality.
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 solution significantly reduces build times for multi-material applications, enhances cell viability, and allows for the direct manufacturing of complex, multi-material constructs suitable for biomedical implants, while maintaining a sterile environment and enabling the creation of prototypes with varied properties.
Implementation Method 1
SL machines typically focus an ultraviolet (UV) laser onto a cross-section of a liquid photopolymer resin. The laser, in turn, selectively cures a resin to form a structure, such as anatomical shapes (i.e., organs and tissues), layer by layer.
Implementation Method 2
A pump system fills and removes polymers from individual vats and facilitates the exchange of materials, if necessary, while maintaining a sterile building environment.
Implementation Method 3
a series of optics and controllable mirrors raster a UV laser beam to solidify a photocurable polymer resin
Data Source
AI summary
Methods and systems of stereolithography for building cost-efficient and time-saving multi-material, multi-functional and multi-colored prototypes, models and devices configured for intermediate washing and curing/drying is disclosed including: laser(s), liquid and/or platform level sensing system(s), controllable optical system(s), moveable platform(s), elevator platform(s), recoating system(s) and at least one polymer retaining receptacle. Multiple polymer retaining receptacles may be arranged in a moveable apparatus, wherein each receptacle is adapted to actively/passively maintain a uniform, desired level of polymer by including a recoating device and a material fill/remove system. The platform is movably accessible to the polymer retaining receptacle(s), elevator mechanism(s) and washing and curing/drying area(s) which may be housed in a shielded enclosure(s). The elevator mechanism is configured to vertically traverse and rotate the platform, thus providing angled building, washing and curing/drying capabilities. A horizontal traversing mechanism may be included to facilitate manufacturing between components of SL cabinet(s) and/or alternative manufacturing technologies.