Multi-Nozzle Resin Layer Deposition for Uniform 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing recoating methods in additive manufacturing, such as those used in stereolithography, suffer from inaccurate and non-uniform layer deposition due to direct contact with the resin, which leads to waves and non-uniformities, and scaling issues with curtain or screen methods, resulting in flow instabilities and high pressure requirements.
Innovation Solution
A method and system utilizing a nozzle head with multiple non-intersecting nozzles that discharge continuous streams of medium to form a uniform layer, allowing for accurate and stable deposition by preventing stream intersections and using relative movement to cover the entire width in one or more runs, with optional overlap to enhance uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a blade recoater is used to deposit resin layers, then the recoater can be simple in structure, but the layer deposition becomes inaccurate due to resin dragging and contact with the resin
Solution Approach 1:
The patent introduces an air bearing as an intermediary between the recoater and the resin. This air bearing creates a thin air gap that allows the recoater to pass over the resin surface without direct contact, eliminating resin dragging while maintaining precise layer thickness control. The air bearing acts as a mediator that enables contactless deposition.
Solution Approach 2:
The patent replaces the mechanical contact-based recoating system with an aerodynamic system. Instead of relying on mechanical blade contact to level the resin, the system uses aerodynamic forces generated by the air bearing to achieve contactless deposition. This substitution eliminates the harmful mechanical interaction between the recoater and resin.
2Manufacturing precision
If a curtain or screen method is used for contactless deposition, then resin dragging is eliminated, but scaling to larger widths becomes difficult and flow instabilities occur
Solution Approach 1:
The patent segments the continuous air bearing into multiple discrete air bearing elements arranged in an array across the width of the build platform. This segmentation allows the system to scale to larger widths by simply adding more air bearing elements, while each element independently maintains stable airflow and prevents resin dragging in its local zone.
Solution Approach 2:
The patent transitions from a single-point or line-based recoating approach to a two-dimensional array of air bearing elements. This dimensional expansion allows contactless deposition across large surface areas while maintaining the stability benefits of the air bearing mechanism at each location.
3Productivity
If high hydraulic pressure is used to discharge viscous medium through a slit, then the medium can be discharged effectively, but the slit gap deforms and screen thickness becomes inaccurate
Solution Approach 1:
The patent replaces the hydraulic pressure-based discharge system with an aerodynamic assistance system. The air bearing generates upward aerodynamic forces that counteract the weight and viscosity of the resin, enabling effective medium discharge without requiring high hydraulic pressures that would deform the slit gap and compromise thickness accuracy.
4Manufacturing precision
If a single wide slit is used for contactless deposition, then resin dragging is avoided, but creating a slit with small gap thickness and long length with strict gap tolerance becomes extremely costly and difficult
Solution Approach 1:
The patent segments the single wide slit into multiple smaller air bearing elements arranged in an array. Each air bearing element has much smaller dimensions and relaxed gap tolerance requirements, making them significantly easier and less costly to manufacture. The segmented approach maintains contactless deposition capabilities while dramatically improving ease of manufacture.
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 precise, uniform, and scalable layer deposition with improved stability, allowing for the formation of three-dimensional objects through controlled layerwise solidification, using materials like polymer and ceramic resins.
Implementation Method 1
each nozzle (13) having an opening area (15) through which, during application of the successive layer (7), a continuous stream (17) is discharged for impinging a coverage area (19)
Implementation Method 2
from a medium capable of solidification... subsequently solidifying one or more predetermined areas of the layer of the medium
Implementation Method 3
In stereolithography (SLA), complex three-dimensional solid objects can be made by repeatedly laying down thin layers of ultraviolet curable material
Data Source
AI summary
An additive manufacturing method and system for layerwise forming an object from a medium capable of solidification, wherein successive layers of the medium are applied using a nozzle head including a plurality of discrete nozzles being spaced apart from each other, each nozzle having an opening area through which a continuous stream of the medium is dischargeable for impinging a coverage area on a layer of the medium on a support and/or an already formed part of the object. The continuous streams are non-intersecting. The nozzle head and the support are relatively movable with respect to each other in at least one running direction.