3D Printed Optical Element Variable Nozzle Discharge

Solution Overview

Problem

3D printing of optical elements faces challenges in achieving both high shape accuracy and reducing production time, as reducing the amount of droplets discharged increases the number of discharges required, thereby prolonging the production time.

Innovation Solution

A method and apparatus using a 3D printer with a variable nozzle that switches between two discharge amounts of transmissive material, allowing for high shape accuracy on the surface portion while forming the base portion quickly, by adjusting the nozzle opening area to control the amount of droplets and movement precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the amount of droplets discharged from the nozzle is reduced, then the shape accuracy of the optical element is improved, but the number of discharges required increases and the production time increases

Engineering Contradiction:

Improveshape accuracyVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The optical element is divided into two distinct portions: a base portion formed with larger droplet discharge amounts for rapid material deposition, and a curved surface portion formed with smaller droplet discharge amounts for high precision. This segmentation allows each region to be optimized independently for its specific functional requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different discharge amounts are applied to different regions of the optical element based on local requirements. The base portion uses a first discharge amount optimized for speed and structural support, while the curved surface portion uses a second discharge amount optimized for shape accuracy and surface quality.

Inventive Principle:

Principle #3Local quality

2Productivity

If the amount of droplets discharged from the nozzle is increased, then the production time is reduced, but the shape accuracy of the optical element deteriorates

Engineering Contradiction:

Improveproduction timeVSAvoidshape accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The optical element is divided into two distinct portions: a base portion formed with larger droplet discharge amounts for rapid material deposition, and a curved surface portion formed with smaller droplet discharge amounts for high precision. This segmentation allows each region to be optimized independently for its specific functional requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different discharge amounts are applied to different regions of the optical element based on local requirements. The base portion uses a first discharge amount optimized for speed and structural support, while the curved surface portion uses a second discharge amount optimized for shape accuracy and surface quality.

Inventive Principle:

Principle #3Local quality

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 enables the production of optical elements with high shape accuracy and reduced production time by optimizing the discharge amount and movement precision, balancing speed and accuracy.

Implementation Method 1

a transmissive material that allows transmission of light

Methodology Applied

Scientific EffectLight transmission: Light

Data Source

PatentUS11345085B2Method of producing optical element and apparatus for producing optical element

Publication Date: 2022.05.31 OLYMPUS CORPORATION(JP)

AI summary

A method of producing an optical element includes forming a base portion that supports a curved surface of the optical element by discharging a transmissive material that allows transmission of light in a first amount, and forming the curved surface by discharging, to the base portion, the transmissive material in a second discharge amount smaller than the first discharge amount.