Multi-Projector Array for Large-Area 3D Printing
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Solution Overview
Problem
Existing 3D printing technologies, such as StereoLithographic Approach (SLA) and Digital Light Processing (DLP), face limitations in scaling to larger 2D print beds due to issues with lateral resolution, vertical print rate, and projection power density.
Innovation Solution
The use of an array of energy patterning modules with multi-axis micro-positioning systems and on-board micro-computers for automated alignment and control, enabling the stitching together of micro-patterning modules with high lateral precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single projector is used for 3D printing, then the device complexity is low, but the print bed area is limited and lateral resolution deteriorates when scaling up
Solution Approach 1:
The patent divides the projection system into multiple independent projectors, each covering a specific region of the build volume. This segmentation allows the system to achieve large print bed area while maintaining high lateral resolution in each local region, as each projector operates at optimal resolution for its designated zone.
Solution Approach 2:
The patent transitions from a single-projector 2D projection approach to a multi-projector 3D spatial arrangement. By positioning multiple projectors at different locations and angles around the build volume, the system expands the effective projection area while maintaining resolution through coordinated multi-angle illumination.
2Area of stationary object
If multiple projectors are used to increase print bed area, then the print bed area is improved, but the alignment precision and system complexity worsen
Solution Approach 1:
The patent implements feedback control mechanisms where each projector's position and projection parameters are continuously monitored and adjusted. This feedback system ensures precise alignment between multiple projectors, maintaining measurement precision even as the system scales to accommodate larger print bed areas.
Solution Approach 2:
The patent introduces intermediary alignment elements and control systems that mediate between multiple projectors. These intermediaries facilitate precise relative positioning and coordination, ensuring that alignment precision is maintained across the entire multi-projector array without requiring direct pairwise alignment of all components.
3Area of stationary object
If the projection area is increased, then the print bed area is improved, but the projection power density decreases
Solution Approach 1:
The patent segments the total projection power across multiple projectors, with each projector delivering concentrated power to its specific region. This segmentation maintains high projection power density locally at each projector while collectively covering a large print bed area, avoiding the power density loss that would occur with a single large-area projector.
Solution Approach 2:
The patent applies local quality optimization by ensuring each projector operates at optimal power density for its specific projection region. Rather than uniformly distributing power across the entire large area, the system concentrates power locally at each projector's coverage zone, maintaining high power density wherever projection is active.
4Device complexity
If manual alignment of multiple projectors is used, then the device complexity is low, but the alignment time and productivity are reduced
Solution Approach 1:
The patent employs feedback-based automated alignment systems that use sensors and control algorithms to rapidly determine and correct projector positions. This feedback mechanism eliminates time-consuming manual alignment procedures, significantly reducing alignment time while the automated nature of the system manages the increased device complexity.
Solution Approach 2:
The patent implements self-aligning features where the multi-projector system automatically calibrates and positions itself without external intervention. Through self-service alignment mechanisms, the system rapidly achieves precise configuration, dramatically reducing alignment time while the automated processes handle the complexity of coordinating multiple projectors.
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 the creation of high-resolution optical projection systems over large print beds, overcoming the limitations of conventional methods by enabling precise alignment and efficient data transmission in 3D printing applications.
Implementation Method 1
The spectrum of light projected, power-density of the projected light, and the rate in which the light can be patterned all govern the capabilities of the additive manufacturing device, or printer, that utilizes the light engine
Data Source
AI summary
Devices, systems, and/or methodologies are provided for three dimensional printing, for example, additive manufacturing, wherein an array of energy patterning (e.g., light patterning) modules are used in conjunction with an automated positional control system to coordinate impelementation of patterning modules of the array. Implementaion of the array can be controlled by a sensory feed-back.