Non-Perpendicular Vertical Stage for Additive Manufacturing
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Solution Overview
Problem
Conventional additive manufacturing systems are limited by the vertical stage's linear motion along the z-axis, restricting the size and complexity of objects that can be created, leading to increased build time, internal stresses, and the need for extensive support structures.
Innovation Solution
A vertical stage that moves in a direction not perpendicular to the image plane, allowing for customized motion paths such as an arch or non-linear trajectories, enabling the creation of larger objects with reduced anisotropy and internal stresses, and utilizing a smaller material tray and actinic radiation source for improved resolution and build efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the vertical stage moves only in a linear manner along the z-axis, then the system structure is simple, but the size of objects that can be made is limited
Solution Approach 1:
The patent applies dimensionality change by transitioning from linear z-axis motion to three-dimensional curved trajectories. The vertical stage combines z-axis movement with x-axis or y-axis components, enabling the platform to follow arches, circles, or other non-linear paths. This allows objects larger than the image plane dimensions to be manufactured by moving the platform along curved paths that extend beyond the rectangular boundary of the light source.
2Productivity
If the vertical stage moves only in a linear manner along the z-axis, then the motion control is simple, but the build time is increased
Solution Approach 1:
The patent implements continuous useful action by enabling the platform to move along continuous curved trajectories without interruption. The vertical stage can transition smoothly between different portions of a curved path, allowing uninterrupted curing operations. This continuous motion reduces idle time and enables more efficient use of the actinic radiation source, thereby decreasing overall build time compared to linear motion systems that require separate positioning steps.
3Stability of the object's composition
If the vertical stage moves only in a linear manner along the z-axis, then the manufacturing process is simple, but anisotropy and internal stresses are increased
Solution Approach 1:
The patent applies local quality by enabling different regions of the object to be cured under different motion conditions. By moving the platform along curved trajectories, the system can adjust the curing environment locally - for example, moving slower in certain areas to reduce thermal gradients or adjusting the curvature to control stress distribution in specific regions. This localized control over motion and curing conditions helps reduce anisotropy and internal stresses throughout the object.
4Ease of manufacture
If the vertical stage moves only in a linear manner along the z-axis, then the system is simple, but support structures are required
Solution Approach 1:
The patent reduces support structure requirements by utilizing three-dimensional curved motion to create overhangs and complex geometries that would otherwise require support structures. By moving the platform along arches or circular paths, the system can form self-supporting geometries where the curved trajectory itself provides structural integrity, eliminating or reducing the need for additional support structures.
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 production of larger, complex objects with reduced build time, internal stresses, and support structure requirements, while improving resolution and material properties like green strength and viscosity tolerance, and reducing system size and cost.
Implementation Method 1
Some existing additive manufacturing ('AM,' which is also known as 3D printing ('3DP'), freeform fabrication ('FFF'), rapid prototyping ('RP'), and the like) techniques use a digital mirror device (DMD), digital light projector (DLP), laser, or other actinic radiation source to selectively cure photocurable materials.
Data Source
AI summary
There is provided an additive manufacturing system comprising a vertical stage (also known as a z-stage) that moves the object being created along an axis of motion that is not perpendicular to the image plane (non-parallel to the z-axis of the image plane). By moving the build platform, upon which the additively manufactured object is being supported, along a predetermined axis of motion, such as one adapted to the dominant axis of the object design, the additive manufacturing system is capable of making larger objects, shortening build times, improving part resolution, and/or reducing the volume of photocurable material needed, among other benefits.