Additive Manufacturing System for Ophthalmic Devices
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Solution Overview
Problem
Existing methods for additively manufacturing ophthalmic lenses require substantial process time for layering steps, which can hinder high-resolution optical quality and efficiency in mass production, especially when multiple curing devices are needed to cover larger areas.
Innovation Solution
A manufacturing system with multiple movable building platforms and a single curing device that allows simultaneous or sequential curing and layering steps on different platforms, enabling continuous production without waiting for complete curing of all layers, optimized by determining the number of platforms based on curing and layering times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single curing device is used to cure layers on the building platform, then device complexity is reduced, but production time increases due to sequential curing of each layer
Solution Approach 1:
The building platform is divided into multiple segments or zones, each capable of being cured independently by the single curing device. This allows the curing process to proceed in parallel across different segments while using only one curing device, thus reducing device complexity while maintaining productivity.
Solution Approach 2:
The building platform is made movable relative to the curing device, enabling dynamic repositioning during the manufacturing process. This allows the single curing device to efficiently service multiple zones by moving the platform into position, reducing the need for multiple stationary curing devices while maintaining high production throughput.
2Manufacturing precision
If the building platform is moved to perform layering steps, then manufacturing precision is maintained for high resolution optical quality, but process time increases due to substantial layering time
Solution Approach 1:
Multiple layers of material are deposited and positioned on the building platform in advance before the curing process begins. This preliminary layering action allows the subsequent curing step to proceed without interruption, reducing the total process time while maintaining the precision required for optical quality through controlled material deposition.
Solution Approach 2:
The layering and curing processes are made continuous through coordinated movement of the building platform. While one zone undergoes curing, another zone simultaneously undergoes layering, eliminating idle time and maintaining continuous productive action throughout the manufacturing process.
3Productivity
If multiple curing devices are deployed to cure larger areas simultaneously, then production time is reduced, but device complexity and cost increase
Solution Approach 1:
The single curing device is designed with multi-functionality to serve multiple zones of the building platform through coordinated platform movement and positioning. This universal device can cure different segments at different times, achieving the throughput of multiple devices while avoiding the complexity and cost of deploying multiple curing devices simultaneously.
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 reduces production time by allowing continuous curing and layering processes across multiple platforms, improving efficiency and maintaining high optical quality without the need for extensive waiting periods between curing and layering steps.
Implementation Method 1
a curing device configured for curing volumes of the predetermined material so as to harden layers of the ophthalmic devices to be manufactured
Data Source
AI summary
A manufacturing system carries out a method for additively manufacturing ophthalmic devices, and includes a tank filled with a predetermined material, a single curing device for curing volumes of the predetermined material to harden layers of the ophthalmic devices, a layering device for layering volumes of the predetermined material onto harden layers of the ophthalmic devices. The manufacturing system includes building platforms movable relative to the tank and on which are supported the ophthalmic devices. The number of building platforms is determined by the predetermined material, curing time for the single curing device to cure a volume of the predetermined material, and a layering time for the layering device to provide a volume of the predetermined material to form a subsequent layer for hardening, so the layering device and the single curing device perform respectively curing and layering simultaneously on layers from different ophthalmic devices.