3D Optical Structure Printing with Real-Time Feedback Control
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Solution Overview
Problem
Existing printing systems for three-dimensional optical components face challenges in ensuring high-quality production due to deviations in optical properties caused by geometry discrepancies, contaminations, entrapments, and refractive index irregularities, which are not adequately addressed by measuring only geometrical properties.
Innovation Solution
A printing system equipped with a measurement unit comprising a light source and detector to measure optical properties in real-time, allowing for feedback and adjustments during the printing process to align actual optical properties with target properties, thereby rectifying deviations and ensuring high-quality optical structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If only geometrical properties are measured during printing, then the measurement system remains simple, but optical quality cannot be ensured due to undetected deviations in refraction index, surface flow, and contaminations
Solution Approach 1:
The patent implements a feedback mechanism where optical properties are measured in real-time during the printing process using a measurement unit with light sources and detectors. The measured optical properties are fed back to the control unit, which adjusts printing parameters dynamically to compensate for deviations and ensure target optical quality is achieved.
Solution Approach 2:
The patent replaces traditional mechanical/geometrical measurement methods with optical measurement methods. Instead of using physical probes or cameras to measure geometry, the system uses light sources and detectors to measure optical properties such as refraction index, transmission, and reflection, providing more direct and accurate quality assessment.
2Manufacturing precision
If optical properties are measured in real-time during printing, then quality control is improved, but the device complexity and measurement time increase
Solution Approach 1:
The patent implements continuous measurement of optical properties during the printing process without interrupting production. The measurement unit operates simultaneously with the printing unit, allowing real-time quality control while maintaining continuous manufacturing flow, thus minimizing time loss.
Solution Approach 2:
The system performs preliminary optical measurements during intermediate printing steps before final completion. This allows early detection of optical deviations and enables corrective actions to be taken during the printing process itself, preventing the need for time-consuming post-processing or rejection of defective components.
3Measurement precision
If comprehensive optical measurements are performed, then detection accuracy is improved, but productivity decreases due to repeated measurement steps
Solution Approach 1:
The patent merges the measurement function with the printing process by integrating the measurement unit into the printing system. Multiple measurement functions (transmission, reflection, refraction index) are combined into a single integrated system that operates concurrently with printing, eliminating the need for separate measurement stations and reducing overall process time.
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 real-time control of the printing process, reduces rejections and costs, and ensures the production of reliable, reproducible, and verifiable high-quality optical components by directly measuring and correcting optical properties during the printing and curing steps.
Implementation Method 1
measure optical properties of a pre-structure of the three-dimensional optical component... comprising at least one light source and at least one light detector... wherein the measured optical properties are determined by light that has been emitted from the at least one light source and that has passed through and/or has been reflected from the pre-structure
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention refers to a printing system for printing a three-dimensional optical component (2), comprising a printing unit comprising a print head (3) with ejection nozzles (4) for ejecting droplets (6) of printing ink, comprising a measurement unit to measure optical properties of a pre-structure of the three-dimensional optical component (2) characterized in that the measurement unit comprises at least one light source (9) and at least one light detector (11), further comprising a process control unit for determining the difference between the measured optical properties of the pre-structure and target optical properties of the pre-structure. The present invention further relates to a corresponding method.