Multi-Projector Additive Manufacturing Boundary Control
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Solution Overview
Problem
Additive manufacturing apparatuses face challenges in achieving high manufacturing speed and resolution due to limitations in the projection area and manufacturing cost, with streak patterns and slits often occurring in the boundary regions of projection images when trying to enlarge the manufacturing area without increasing projection magnification.
Innovation Solution
The apparatus employs multiple image projecting units with a controlling unit to adjust the boundary region between projection images, using a camera to photograph and correct positional shifts and illuminance differences, ensuring smooth connection of projection images and maintaining high resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the projection magnification of the projection optical system is increased to enlarge the manufacturing area, then the manufacturing area is increased, but the manufacturing resolution of the product manufactured object is lowered
Solution Approach 1:
The patent divides the manufacturing area into multiple projection regions, each covered by a separate image projecting unit. Multiple projectors are arranged to project exposure images into different regions of the resin material simultaneously, allowing the manufacturing area to be enlarged without increasing the projection magnification of individual optical systems, thus maintaining manufacturing resolution while achieving larger build volume
Solution Approach 2:
The patent transitions from a single-projector system to a multi-projector array configuration, adding spatial dimensionality to the projection system. By arranging multiple image projecting units in a two-dimensional array, the system achieves enlarged manufacturing area through spatial distribution rather than through magnification, thereby preserving resolution while expanding capacity
2Area of stationary object
If a large-sized and high-definition image forming element and a large-aperture projection optical system are used to enlarge the manufacturing area without increasing projection magnification, then the manufacturing area is increased, but the manufacturing cost of the additive manufacturing apparatus is increased
Solution Approach 1:
Instead of using a single large and expensive high-definition image forming element with a large-aperture projection optical system, the patent segments the system into multiple standard-sized projectors. Each projector uses a conventional image forming element and projection optical system, but their combined output achieves the same total manufacturing area, significantly reducing individual component costs and overall system complexity
Solution Approach 2:
The patent uses multiple copies of standard image forming elements and projection optical systems rather than one large, expensive version. By replicating smaller, more affordable projector units across the manufacturing area, the system achieves large-scale production capability without requiring costly custom-large-format components
3Area of stationary object
If additive manufacture is performed using a plurality of image projecting units by dividing the exposure image, then the manufacturing area is enlarged, but a streak pattern and/or a slit are made in the manufacturing direction on the surface of the product manufactured object in a boundary region
Solution Approach 1:
The patent applies preliminary processing to the exposure images before projection, specifically adjusting the boundary regions of adjacent projection images. The controlling unit modifies the exposure data for boundary areas to account for potential stitching issues, and the adjusting unit further refines these boundary regions during projection to prevent streak patterns and slits, ensuring smooth transitions between adjacent projector regions
Solution Approach 2:
The patent implements a feedback mechanism where the system monitors and detects boundary regions between adjacent projection images, then automatically adjusts exposure parameters and projection timing to eliminate artifacts. The controlling unit coordinates the projection timing and intensity of adjacent projectors based on detected boundary conditions, preventing streak patterns and maintaining surface quality across the entire manufacturing 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
This approach allows for large manufacturing areas without compromising resolution, reducing streak patterns and slits, and enabling the production of high-definition, large-sized products with improved shape accuracy.
Implementation Method 1
an additive manufacturing apparatus which manufactures a three-dimensional manufactured (modeled) object by projecting an exposure image into a photosetting (photocurable) liquid resin material
Data Source
AI summary
An additive manufacturing apparatus in which a streak in a manufacturing direction is difficult to be made on the surface of a product manufactured object in a boundary region of projection regions of exposure images is provided. In this apparatus, a vessel holds a photosetting liquid resin material, a first projector makes a first exposure image incident from an incident surface and projects it into the resin material, a second projector makes a second exposure image, continuous with the first exposure image, incident from the incident surface and projects it into the resin material, and a controlling unit adjusts on a projection surface a boundary region between a first projection image obtained by projecting the first exposure image by the first projector and a second projection image obtained by projecting the second exposure image by the second projector.