Multi-Screen Stereolithography 3D Printer
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Solution Overview
Problem
Commercially available large screens for stereolithographic 3D printing have reduced pixel density, limiting resolution and are unsuitable for simultaneous production of multiple components, leading to 'exposure contamination' and non-uniformity.
Innovation Solution
A 3D printer design featuring a screen assembly with multiple screens, each with a pixel array surrounded by a border or gaps, and a control mechanism for precise positioning, allowing for patterned electromagnetic radiation exposure to build multiple objects simultaneously, minimizing contamination and enhancing uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single large screen is used to produce multiple components simultaneously, then productivity increases, but manufacturing precision deteriorates due to exposure contamination and reduced pixel density
Solution Approach 1:
The patent divides a single large screen into multiple smaller screens arranged in an array. Each smaller screen has its own pixel array surrounded by borders with no active pixels, creating isolated exposure zones. This segmentation allows multiple components to be printed simultaneously on different screens while maintaining high resolution on each screen, as each screen's pixel density is preserved without being diluted across a large area.
2Productivity
If a single large screen is used to produce multiple components simultaneously, then productivity increases, but manufacturing precision deteriorates due to exposure contamination between adjacent components
Solution Approach 1:
Each screen in the array is segmented with borders containing no active pixels, creating isolated exposure zones. This prevents light from one exposure zone from contaminating adjacent zones on the same screen or on neighboring screens, thereby maintaining uniformity and precision across all simultaneously printed components.
Solution Approach 2:
The border regions with no active pixels act as intermediary zones between adjacent pixel arrays on the same screen and between adjacent screens. These intermediary borders block or absorb stray light, preventing exposure contamination from spreading to adjacent components, thus maintaining manufacturing precision and uniformity across all components being printed simultaneously.
3Device complexity
If screens are positioned close together to maximize vat space utilization, then device complexity reduces, but manufacturing precision deteriorates due to increased exposure contamination between screens
Solution Approach 1:
The borders surrounding each pixel array and the gaps between adjacent screens create segmented, isolated exposure zones. Even when screens are positioned close together to maximize vat space utilization, these segmented borders ensure that exposure contamination does not spread between adjacent screens or pixel arrays, thereby maintaining manufacturing precision and uniformity across all 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
Enables the simultaneous production of multiple 3D printed objects with improved resolution and reduced contamination, increasing throughput and reducing waste while maintaining high-quality output.
Implementation Method 1
successive layers of liquid photopolymer are exposed to respective illumination patterns causing a pattern of polymerisation
Data Source
AI summary
A 3D printer comprising: a vat for liquid photopolymer; a print platform for extending into the vat; a screen assembly have an arrangement of screens for providing an exposure of patterned electromagnetic radiation for selectively polymerising successive layers of photopolymer to build a 3D printed object on the print platform; and a control mechanism for controlling the separation of the print platform and screen assembly parallel to a build direction.