Multi-Stage Wash System for Uncured Resin Removal
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Solution Overview
Problem
Existing 3D printing systems for vat polymerization processes struggle with inefficient removal of uncured resin and residual solvent, leading to dimensional inaccuracies and health hazards, while consuming large amounts of hazardous chemicals and lacking effective recycling features.
Innovation Solution
A multi-stage wash system with solvent reservoirs, agitation mechanisms, and air-drying systems, incorporating resin concentration monitoring and solvent recycling, to efficiently remove uncured resin and solvent from 3D printed objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-stage wash process is used to remove residual resin, then the process is simple and quick, but the resin removal is incomplete leading to dimensional inaccuracies
Solution Approach 1:
The wash system is divided into multiple stages (first wash reservoir, second wash reservoir, third wash reservoir) with each stage performing a specific washing function. This segmentation allows progressive removal of residual resin while maintaining manageable system complexity through modular design.
2Productivity
If large amounts of wash solvent are used to ensure complete resin removal, then resin removal efficiency is high, but chemical consumption and disposal costs increase
Solution Approach 1:
The system implements solvent recycling by collecting used wash solvent from the first wash reservoir and reusing it in subsequent wash stages. This recovery approach maintains high resin removal efficiency while significantly reducing overall solvent consumption and disposal requirements.
3Manufacturing precision
If residual solvent remains on 3D printed parts after washing, then the drying process is skipped saving time, but dimensional accuracy is compromised
Solution Approach 1:
The system uses self-drying through controlled airflow where the wash process itself creates conditions for solvent evaporation. The multi-stage washing with progressive solvent removal allows parts to dry naturally without additional energy-intensive drying equipment, maintaining dimensional accuracy while minimizing processing time.
4Ease of operation
If traditional wash systems are used without recycling features, then the system is simple to operate, but environmental impact and operational costs increase
Solution Approach 1:
The system automatically recycles wash solvent through integrated pumping and filtration mechanisms, reducing environmental impact by minimizing chemical disposal. The recycling process is automated to maintain ease of operation, with the system handling solvent recovery without requiring complex user intervention.
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 provides efficient, reliable, and user-friendly resin and solvent removal, ensuring dimensional accuracy, reducing health risks, and facilitating solvent recycling, thus enhancing the efficacy of 3D printing processes.
Implementation Method 1
a wash process is necessary to remove all the residual resin before sending the 3D printed parts for post curing
Implementation Method 2
The reactive specie opens the n-bond of the monomer or oligomer and appends itself to the monomer or oligomer to form a new radical, cation, or anion
Implementation Method 3
removing residual wash solvent from the surface of the 3D printed objects
Data Source
AI summary
The invention is generally a system for drying, recycling, and washing off residual resin from 3D-printed objects. Exemplary systems may include a system for drying off residual resin from 3D-printed objects. The system may include a wash reservoir including a chamber for housing the 3D printed object and containing a wash solvent or liquid solvent adapted to at least partially remove residual residue present in the 3D printer object. Air exchange vents provided between a splash guard or a lid of the wash reservoir may be adapted to act as an air intake or an air exhaust. An airflow module in fluid communication with the air vents and the chamber may be adapted to create a positive or negative air pressure inside the wash reservoir for redirecting airflow to the chamber housing the 3D printed object, and blowing air out or into the chamber to dry the 3D-printed object.