Multi-Stage 3D Printed Part Washing for Resin Removal
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Solution Overview
Problem
Existing 3D printing systems for vat polymerization processes struggle with efficiently removing residual resin and solvent from 3D printed parts, leading to dimensional inaccuracies and health hazards, while also requiring excessive solvent use and inefficient disposal.
Innovation Solution
A multi-stage wash system with a wash reservoir, agitator, and air-drying system, incorporating solvent monitoring and recycling features, to effectively remove residual resin and solvent using multiple stages and solvent recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-stage wash process is used, then the system is simple, but residual resin removal is incomplete leading to dimensional inaccuracies
Solution Approach 1:
The wash system is divided into multiple stages (first wash stage, second wash stage, air drying stage) with each stage performing a specific function. The first stage removes bulk resin, the second stage removes remaining resin and solvent, and the air drying stage removes solvent. This segmentation allows complete resin removal for dimensional accuracy while keeping each individual stage relatively simple.
Solution Approach 2:
Different wash solutions are used as intermediaries in different stages. The first wash solution is optimized for bulk resin removal, while the second wash solution is optimized for removing remaining resin and solvent. This use of intermediary substances with different properties allows each stage to be optimized for its specific purpose, achieving complete cleaning without requiring a single complex stage.
2Reliability
If excessive solvent is used, then resin removal is effective, but solvent consumption and disposal issues increase
Solution Approach 1:
The wash process is segmented into multiple stages, each using a specific volume of wash solution optimized for that stage's purpose. This prevents the use of excessive solvent in a single stage while ensuring effective resin removal through cumulative action across stages. The system recycles wash solutions between stages to reduce overall consumption.
Solution Approach 2:
The system recovers and recycles wash solutions between stages. The wash solution from the first stage is transferred to the second stage, and spent solutions are collected for potential reuse. This recovering approach maintains effective resin removal while significantly reducing solvent consumption and disposal requirements compared to using fresh solvent for each washing operation.
3Productivity
If residual resin remains on parts, then the process is faster, but post-curing causes dimensional changes and health hazards
Solution Approach 1:
The system performs preliminary washing actions in multiple stages before the final air drying stage. The first and second wash stages completely remove residual resin through systematic cleaning with different wash solutions, eliminating the need for prolonged post-curing that would cause dimensional changes. This preliminary complete removal maintains productivity while eliminating harmful effects.
Solution Approach 2:
The washing process continues through multiple continuous stages (first wash, second wash, air drying) without interruption, ensuring complete resin removal. This continuous multi-stage action achieves thorough cleaning faster than single-stage methods, maintaining productivity while eliminating residual resin that would cause dimensional inaccuracies and health hazards during post-curing.
4Productivity
If manual washing is used, then equipment is simple, but the process is time-consuming and inefficient
Solution Approach 1:
The system performs washing operations automatically without manual intervention. The controller automatically manages the sequence of operations including pumping wash solutions, operating the agitator, controlling heating, and managing air drying. This self-service automation significantly improves washing efficiency and productivity while the modular design keeps individual components relatively simple.
Solution Approach 2:
The system replaces manual mechanical washing with automated mechanical and thermal processes. The controller manages automated pumping, mechanical agitation through the agitator, thermal heating of wash solutions, and automated air drying. This substitution of manual operations with automated systems dramatically improves washing efficiency and productivity while maintaining reasonable system complexity through standardized components.
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
The system achieves efficient, reliable, and safe removal of residual resin and solvent, reducing solvent consumption and disposal issues, while ensuring dimensional accuracy and user safety.
Implementation Method 1
an agitator adapted to stir the wash solvent
Implementation Method 2
a heater adapted to heat the wash solvent in the wash chamber
Data Source
AI summary
The invention is generally a system for drying, recycling, and washing off residual resin from three-dimensionally (3D) printed objects. Exemplary systems may include a wash reservoir, a fan module, and one or more air exchange vents. The wash reservoir contains a wash solvent and a propeller fully or partially submerged into the wash solvent. The propeller splashes the wash solvent upwards to disperse on the 3D printed object, thereby largely washing away the resin residue present in the 3D printer object. The fan module is connected to the wash reservoir to create a positive or negative air pressure inside the wash reservoir, thereby redirecting the airflow to the wash reservoir. The air exchange vents are provided between a splash guard and a platform/lid of the wash reservoir to act as an air intake when the fan module blows air out of the wash reservoir and as an exhaust vice versa.