Optical Shaping Apparatus Using Intersecting Light Beams
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Solution Overview
Problem
The existing optical shaping methods for 3D structures using optically curing resin liquids face a trade-off between precision and productivity, as reducing the slicing pitch to improve precision leads to decreased productivity due to the time required for stage lowering, resin flow, and stabilization between layer formations.
Innovation Solution
An optical shaping method and apparatus that applies a sheet light and a first light beam intersecting the sheet light to form cured resin layers, eliminating the need for stage lowering and resin stabilization time, with the irradiation energy densities adjusted to ensure curing only at the intersection area, and optionally using a digital mirror device and a second light beam to enhance precision and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the slicing pitch is reduced to improve shaping precision, then manufacturing precision is improved, but productivity is lowered due to increased time for stage lowering, resin flow, and stabilization
Solution Approach 1:
The patent replaces the mechanical stage lowering system with an optical field-based curing system. Instead of mechanically lowering the stage to expose new resin surfaces for curing, the invention uses intersecting light beams (sheet light and point light) to selectively cure resin at specific locations without mechanical movement, thereby eliminating the time-consuming stage lowering process while maintaining high shaping precision through optical field control
Solution Approach 2:
The patent changes the curing mechanism from mechanical stage movement to optical parameter control. By adjusting the irradiation energy densities of the sheet light and point light, and controlling their intersection positions, the system achieves precise layer formation without mechanical stage lowering, thus improving productivity while maintaining manufacturing precision
2Manufacturing precision
If the slicing pitch is reduced to improve shaping precision, then manufacturing precision is improved, but the time for resin flow and stabilization increases
Solution Approach 1:
The patent eliminates the need for resin flow and stabilization waiting time by replacing the mechanical stage lowering approach with direct optical curing. The intersecting light beams cure resin immediately at the desired location without requiring the resin to flow over a lowered stage or stabilize after stage movement, thus eliminating this time loss while maintaining precision through optical field control
Solution Approach 2:
The patent performs preliminary optical field positioning and energy density adjustment before curing occurs. By pre-configuring the sheet light and point light intersection parameters, the system ensures that resin curing happens immediately at the correct location without requiring subsequent resin flow or stabilization periods, thereby eliminating time loss while maintaining shaping precision
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 allows for high-accuracy 3D object shaping while maintaining productivity, as the irradiation energy densities are optimized to cure resin layers efficiently without increasing manufacturing time, even at reduced slicing pitches.
Implementation Method 1
a process for forming a cured resin layer by irradiating an optically curing resin liquid with light
Data Source
AI summary
An optical shaping method according to the present invention is an optical shaping method for shaping a three-dimensional structure by repeating a process for forming a cured resin layer 53 by irradiating an optically curing resin liquid 51 with light so that cured resin layers 53 are laminated. The process for forming the cured resin layer 53 includes, while applying a sheet light Ls to the optically curing resin liquid 51, applying a first light beam L1 intersecting the sheet light Ls to this optically curing resin liquid, and thereby forming the cured resin layer 53 in an area where the sheet light Ls intersects the first light beam L1. The irradiation place of the sheet light Ls is moved and the process for forming the cured resin layer 53 is repeated.