Optical Engine Light Integrator for 3D Printing Cost Reduction
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Solution Overview
Problem
High-cost optical engines in three-dimensional printing systems, such as photo-polymerization printers, hinder their competitiveness while maintaining high resolution output is essential for these devices.
Innovation Solution
Incorporating a light integrator to direct light from a light source to a spatial light modulator, eliminating the need for additional lenses and optimizing light distribution, which reduces costs while maintaining high resolution by using a light source, light integrator, projection optics, and a spatial light modulator configured to provide divergent and modulated light efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional optical engines with multiple lenses are used, then high resolution output is achieved, but device cost increases significantly
Solution Approach 1:
The patent removes unnecessary lenses from the traditional optical engine configuration. Specifically, it eliminates at least one lens from the multi-lens system while maintaining high resolution projection capability through the use of a spatial light modulator and optimized light source arrangement.
Solution Approach 2:
The patent employs cost-effective optical components and design approaches that reduce overall device cost. By using a simplified optical path with fewer expensive lenses and optimizing the arrangement of remaining components, the system achieves high resolution output at lower cost.
2Use of energy by moving object
If additional lenses are added to optimize light distribution, then light distribution is improved, but device cost and complexity increase
Solution Approach 1:
The patent introduces a spatial light modulator as an intermediary component that efficiently distributes light across the projection area. This component modulates the light from the light source to achieve uniform illumination and high resolution patterning without requiring additional lenses for light distribution.
Solution Approach 2:
The spatial light modulator serves multiple functions simultaneously: it modulates light intensity patterns, distributes light uniformly across the projection area, and enables high resolution imaging. This multi-functionality eliminates the need for separate components dedicated to each function.
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 configuration lowers the cost of optical engines while maintaining high resolution output, making three-dimensional printing more financially feasible by efficiently directing light for polymerization without the need for extra lenses, thus enhancing the competitiveness of the technology.
Implementation Method 1
a light source configured to provide light
Implementation Method 2
a spatial light modulator configured to provide the modulated light responsive to the divergent light
Implementation Method 3
projection optics configured to project projection output light at the optics output through the transparent bottom responsive to a modulated light at the optics input
Implementation Method 4
This type of printer uses light to convert a liquid polymer to a solid
Data Source
AI summary
Described examples a three-dimensional printer includes a vat having a transparent bottom, the vat configured to contain a photo-polymerizing resin and a lift plate movably positioned within the vat. The three-dimensional printer also includes an optical device configured to project a pattern of light through the transparent bottom. The optical device includes a light source configured to provide light at a light source output and a light integrator configured to provide divergent light at a light integrator output responsive to the light at the light source output. The optical device also includes projection optics configured to project projection output light at an optics output through the transparent bottom responsive to a modulated light at the optics input and a spatial light modulator configured to provide the modulated light responsive to the divergent light.