3D Printing Optical Assembly Using Spacer Rings
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Solution Overview
Problem
Stereolithographic 3D printers face challenges with variability in the scale factor along the optical path from the light engine to the build plane, leading to inaccuracies in the fabrication of three-dimensional articles, which current software corrections do not adequately address.
Innovation Solution
A method involving the use of spacer rings of varying thickness to precisely adjust the scale factor by measuring the scale factor of the light engine and selecting the appropriate spacer rings to achieve a desired scale factor, allowing for accurate assembly and alignment of the light engine components, including the projection lens module and adaptive support apparatus, to ensure precise imaging and curing of resin layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If software scaling error corrections are used, then fabrication accuracy can be improved, but the solution is not optimal and does not adequately address the variability in scale factor
Solution Approach 1:
The patent replaces software-based scaling corrections with a physical mechanical adjustment system. Spacer rings of varying thicknesses are inserted between the light engine and build plane to physically adjust the optical path length, thereby correcting scale factor variability at the hardware level rather than through software compensation.
Solution Approach 2:
The patent changes the physical parameter of optical path length by selecting spacer rings with specific thicknesses. This directly adjusts the distance between the light engine and build plane, modifying the scale factor to achieve the desired 1:1 correspondence between digital model dimensions and physical fabricated dimensions.
2Manufacturing precision
If the optical path distance is fixed, then assembly is simplified, but scale factor variability leads to imaging and fabrication inaccuracies
Solution Approach 1:
The patent segments the optical path distance into adjustable components by introducing removable spacer rings. These spacer rings can be individually selected and combined to achieve precise distance adjustments, allowing the optical path to be divided into modular sections that can be optimized independently.
Solution Approach 2:
The patent transforms the fixed optical path distance into a dynamic, adjustable parameter. The spacer rings enable the distance between the light engine and build plane to be varied to correct scale factor issues, making the system adaptable rather than static.
3Manufacturing precision
If spacer rings of varying thickness are used to adjust scale factor, then fabrication accuracy is improved, but the device complexity increases
Solution Approach 1:
The spacer rings serve multiple functions: they act as spacers to maintain proper spacing, as adjustment mechanisms to correct scale factor, and as alignment references during assembly. This multi-functionality reduces the need for separate components for each purpose.
Solution Approach 2:
The spacer rings are simple, inexpensive components that can be easily replaced or adjusted if needed. Their low cost and simplicity allow for having multiple variations in the kit without significantly increasing overall system complexity or cost.
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 solution enhances the precision and accuracy of three-dimensional printing by stabilizing the optical path, resulting in improved fabrication accuracy and reduced scaling errors, thereby producing higher-quality 3D articles.
Implementation Method 1
The stereolithography system forms a three dimensional (3D) article of manufacture by selectively curing layers of the photocurable resin
Data Source
AI summary
A method of assembling a three-dimensional printing system includes providing a plurality of components, providing a plurality of spacer rings, and measurement, analysis and assembly steps. The components include a light engine, an adaptive support apparatus, a plurality of elongate struts, and a support plate. The measurement, analysis and assembly steps include (1) measuring a scale factor for the light engine, (2) determining a selection of one or more of the spacer rings based upon the measured scale factor, and (3) assembling the components with the determined selection of one or more spacer rings.