Optical Resin Level Detection in Stereolithography Apparatus

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Solution Overview

Problem

Stereolithography 3D printing faces challenges in efficiently and conveniently measuring the resin level in vats, particularly due to the sticky and expensive nature of resins, which requires automated handling and optimal operating parameter settings for different resin types.

Innovation Solution

Equipping the stereolithography apparatus with an optical radiator and an optical imaging detector that projects a pattern on the vat rim, allowing the controller to calculate the resin level using optical image data, enabling automated and accurate resin monitoring without direct contact with the resin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional contact-based methods are used to measure resin level, then measurement can be performed, but the sticky resin contaminates the measuring components and requires frequent cleaning

Engineering Contradiction:

Improveresin level measurementVSAvoidcleaning and maintenance

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent introduces an optical intermediary (light) to measure resin level without direct contact. The optical sensor detects changes in light reflection or transmission caused by the resin surface, allowing measurement while the light acts as a mediator between the sensor and resin, eliminating contamination of measuring components

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces mechanical/contact-based level measurement with an optical detection system. Instead of using physical probes that touch the resin, the system uses light reflection or transmission properties to determine resin level, substituting mechanical interaction with optical field interaction

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of substance

If manual monitoring of resin level is performed, then cost can be controlled, but the process is time-consuming and labor-intensive

Engineering Contradiction:

Improveresin wasteVSAvoidmonitoring time

Core Design Contradiction:

Loss of substanceVSLoss of time

Solution Approach 1:

The system performs self-monitoring of resin level through automated optical detection. The controller continuously or periodically checks resin level without human intervention, allowing the system to serve itself in monitoring its own material consumption status, eliminating the need for manual checking while preventing resin waste

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent implements a feedback mechanism where the optical sensor continuously monitors resin level and provides real-time information to the controller. The controller can then respond by alerting the user or automatically controlling resin supply, creating a closed-loop system that prevents both waste and runs-out conditions

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If generic measurement methods are used, then device complexity is low, but the method is not applicable to all vat types and resin colors

Engineering Contradiction:

Improvecompatibility with different vats and resinsVSAvoidoptical detection system

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The optical detection system is designed to be universal and work with different vat types (transparent, translucent, opaque) and various resin colors. By using multiple detection modes (reflection, transmission, absorption) and adjustable optical parameters, the single system can adapt to diverse measurement scenarios without requiring separate dedicated devices for each case

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 simplifies and automates resin level detection, ensuring efficient use of resin, reducing waste, and optimizing operating parameters for different resin types, making the process more user-friendly and cost-effective.

Implementation Method 1

an optical radiator and an optical imaging detector, the field of view of which covers at least part of the working region of the apparatus... an optical radiator configured to project a pattern upon a portion of said fixed or removable vat

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS20210268743A1Stereolithography apparatus equipped for detecting amount of resin, and method of operating same

Publication Date: 2021.09.02 PLANMECA

AI summary

A stereolithography apparatus comprises a fixed vat (401) or a holder for receiving a removable vat for holding resin for use in a stereolithographic 3D printing process, an optical radiator (901) configured to project a pattern upon a portion of said vat (401), an optical imaging detector *501 (field of view, installed and directed so that said portion of said vat (401) and/or a surface onto which the projected pattern is reflected—is within said field of view when said optical imaging detector (501) is in an operating position, and a controller (502, 2001) coupled to said optical imaging detector (501) for receiving optical image data from said optical imaging detector (501). Said controller (502, 2001) is configured to use said optical image data to calculate an amount of resin in said vat (401).