Optical Modulator Segmentation for 3D Resin Curing
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Solution Overview
Problem
Existing optical forming devices require complex and costly high-definition liquid crystal shutters to shape three-dimensional objects with wide cross-sectional areas at high resolution, necessitating numerous driver integrated circuits and complex circuitry.
Innovation Solution
An optical forming device utilizing a transverse electric field driven liquid crystal panel with modulation regions having different voltage transmittance characteristics, controlled by a simple configuration of electrodes and polarizing plates, to modulate light for photocurable resin curing, reducing the need for multiple driver ICs and simplifying the driver circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large high-definition liquid crystal shutter is used to shape three-dimensional objects with wide cross-sectional areas at high resolution, then the manufacturing precision and area of the shaped object are improved, but the device complexity and cost increase due to the need for numerous driver integrated circuits
Solution Approach 1:
The liquid crystal panel is divided into multiple modulation regions (first region and second region) with different voltage transmittance characteristics. Each region can be independently controlled through a single driver circuit, enabling high-resolution patterning of wide cross-sectional areas without requiring multiple driver ICs. The segmentation of functional regions within a unified panel structure resolves the contradiction between coverage area and circuit complexity.
Solution Approach 2:
Different regions of the liquid crystal panel are designed with different voltage transmittance characteristics to optimize performance for specific patterning requirements. The first region and second region have tailored transmittance properties that enable precise control over light exposure in different areas, achieving high manufacturing precision without uniformly increasing device complexity across the entire panel.
2Area of stationary object
If a large high-definition liquid crystal shutter is used to shape three-dimensional objects with wide cross-sectional areas, then the area of the shaped object is improved, but the quantity of driver integrated circuits increases
Solution Approach 1:
A single driver circuit is designed to perform multiple functions by controlling different modulation regions (first region and second region) with distinct voltage transmittance characteristics. This multi-functional driver circuit replaces what would traditionally require multiple separate driver ICs, enabling wide cross-sectional area shaping while minimizing the quantity of driver components needed.
Solution Approach 2:
Multiple modulation regions with different transmittance characteristics are merged into a single liquid crystal panel that is controlled by one driver circuit. This consolidation approach achieves wide area coverage and high resolution without proportionally increasing the number of driver ICs, as the driver circuit manages multiple regions through unified control architecture.
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 shaping of three-dimensional objects with wide cross-sectional areas at high resolution with a reduced number of driver ICs and simplified driver circuits, improving efficiency and cost-effectiveness.
Implementation Method 1
the liquid crystal is aligned in a direction parallel to a main surface of the first substrate and the first electrode and the second electrode apply voltage to the liquid crystal to rotate the liquid crystal in a plane parallel to the main surface of the first substrate
Implementation Method 2
the photocurable resin cures when the transmittance of the first region or the second region is greater than or equal to the predetermined transmittance
Data Source
AI summary
An optical forming device includes a resin tank that holds a photocurable resin, a light source that emits light for curing the photocurable resin, and an optical modulator. The optical modulator includes a liquid crystal, a first substrate and a second substrate that sandwich the liquid crystal, and a first electrode and a second electrode that apply voltage to the liquid crystal. The optical modulator modulates, in a pattern based on the shape of a three-dimensional shaped object, light that causes the photocurable resin to cure, and irradiates the modulated light on the photocurable resin. The optical modulator includes a plurality of modulation regions including a first region and a second region that have mutually different voltage transmittance characteristics.