Optical Shaping Apparatus Temperature-Adaptive Curing Control
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Solution Overview
Problem
Existing three-dimensional shaping methods using photocurable resins face challenges in achieving accurate shaping due to temperature distribution and changes caused by environmental fluctuations and heat generated during photocuring, leading to insufficient or unnecessary curing areas.
Innovation Solution
An optical shaping apparatus with a light-transmissive container, a light modulation element, and a controller that adjusts the light modulation based on temperature distribution and changes to ensure the correct light amount is applied to each resin area, using a light-transmissive portion to prevent premature curing and allow precise control of the curing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If light is irradiated uniformly onto the photocurable resin to cure it, then the curing process is simplified and faster, but temperature distribution and changes cause insufficient or unnecessary curing areas, reducing shaping accuracy
Solution Approach 1:
The patent applies local quality by varying the light amount irradiated to different regions of the photocurable resin based on their respective temperatures. The light modulation element adjusts the irradiation light amount for each resin area according to the temperature distribution, ensuring that each region receives the appropriate light dosage for complete curing without over-curing or under-curing adjacent areas.
Solution Approach 2:
The patent utilizes parameter changes by dynamically adjusting the irradiation light amount parameter based on temperature variations in the resin. The controller modifies the light parameters (intensity, duration) for each resin area according to real-time temperature measurements, adapting the curing process to compensate for temperature-induced variations in light amount required for curing.
2Manufacturing precision
If the light amount required for curing is adjusted for each resin area based on temperature, then shaping accuracy is improved, but the control system becomes more complex
Solution Approach 1:
The patent implements feedback control by measuring the temperature distribution in the photocurable resin and using this information to adjust the irradiation light amount for each resin area. The temperature measurement unit continuously monitors the resin temperature, and the controller uses this feedback to dynamically modify the light modulation, creating a closed-loop control system that maintains high shaping accuracy.
Solution Approach 2:
The patent introduces an intermediary light modulation element that acts as a mediator between the light source and the photocurable resin. This element adjusts the light distribution according to temperature variations, serving as an intermediate control mechanism that simplifies the overall system architecture while achieving precise local control of the curing process.
3Manufacturing precision
If a light-transmissive portion is used at the bottom of the container, then premature curing is prevented and precise control is enabled, but the device structure becomes more complex
Solution Approach 1:
The light-transmissive portion acts as an intermediary element that enables precise control of light irradiation from the bottom side. This structural feature allows the light to pass through uniformly while the control system modulates the light amount for different resin areas, providing a simple yet effective solution for preventing premature curing and enabling accurate curing control.
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 ensures accurate and uniform curing of photocurable resins, preventing defective shaping and improving the overall shaping accuracy by dynamically adjusting the light irradiation according to temperature variations.
Implementation Method 1
a light modulation element having a plurality of pixels and configured to modulate light from a light source for each pixel
Implementation Method 2
an optical system configured to irradiate modulation light from the light modulation element onto the photocurable resin through the light-transmissive portion
Implementation Method 3
the photocurable resin is cured by the light irradiated from a bottom side of the light transmitting plate through the light transmitting plate
Implementation Method 4
a moving member configured to move a cured portion cured by the modulation light among the photocurable resin in a direction separating from the light-transmissive portion
Data Source
AI summary
An optical shaping apparatus includes a light modulation element having a plurality of pixels and configured to modulate light from a light source for each pixel, a controller configured to control the light modulation element based on each of a plurality of two-dimensional shape data obtained from three-dimensional shape data, and a moving member configured to move a cured portion cured by the modulation light among the photocurable resin in a direction separating from the light-transmissive portion. The controller controls the light modulation element so as to irradiate the modulation light of an irradiation light amount corresponding to a light amount necessary for curing for each resin area, onto each of a plurality of resin areas in the photocurable resin based on a temperature distribution or a temperature change in the photocurable resin.