Optical Shaping Apparatus Resin Contraction Offset
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Solution Overview
Problem
Existing optical shaping technologies face challenges in achieving high precision and strength when creating three-dimensional models using light hardening resins, as the contraction of the resin during hardening can lead to gaps and reduced joint strength between layers.
Innovation Solution
The optical shaping apparatus divides cross-sectional shape data into work small areas, enlarges the data based on the resin's contraction ratio, and applies one-shot exposure to areas wider than the work small areas, with additional offset processing to ensure border line alignment and overlap, enhancing the strength and precision of the hardening layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional optical shaping methods are used to create three-dimensional models, then the shaping process can be completed, but gaps and weak joints occur between layers due to resin contraction during hardening
Solution Approach 1:
The patent applies preliminary anti-action by performing offset processing on the cross-sectional shape data before exposure. The control unit calculates offset data by expanding the cross-sectional shape in the radial direction based on the resin's linear contraction ratio, thereby pre-compensating for the contraction that will occur during hardening. This prevents gaps between adjacent work small areas and ensures continuous hardening layers with strong joints, directly addressing the weakness caused by resin contraction.
Solution Approach 2:
The patent implements preliminary action by dividing the cross-sectional shape data into multiple work small areas and performing offset processing on each area before exposure. The control unit prepares the offset data in advance by calculating the expansion based on contraction ratio, then uses this pre-processed data for subsequent one-shot exposure. This preliminary preparation ensures that when the resin hardens and contracts, the layers will join seamlessly without gaps, improving both strength and precision.
2Productivity
If the work entire area is divided into multiple work small areas for exposure, then the exposure process can be completed, but gaps may occur between adjacent areas due to resin contraction
Solution Approach 1:
The patent applies segmentation by dividing the work entire area into multiple work small areas that can be processed independently through one-shot exposure. The control unit separates the cross-sectional shape data into discrete work small areas, each with its own offset data, allowing parallel or sequential processing. This segmentation improves productivity while the offset processing ensures that the segmented areas will join continuously after hardening, maintaining composition stability.
Solution Approach 2:
The patent implements parameter changes by modifying the cross-sectional shape data parameters through offset processing. The control unit changes the radial dimensions of each work small area by expanding them according to the contraction ratio, thereby adjusting the geometric parameters to compensate for future contraction. This parameter modification ensures that segmented work areas will form continuous hardening layers, maintaining stability while enabling efficient segmented processing.
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 the creation of high-precision three-dimensional models with improved strength by preventing gaps between layers and enhancing the joint strength, resulting in a higher quality final product compared to traditional methods.
Implementation Method 1
irradiate light according to the cross-sectional shape data of a three-dimensional model on the surface of a light hardening resin to form a hardening layer
Data Source
AI summary
The cross-sectional shape data of a three-dimensional model is divided according to work small areas obtained by dividing a work entire area where optical shaping work is performed into a plurality of areas, and work small area data which is cross-sectional shape data corresponding to said work small areas is generated. Also, the work small area data is enlarged with offset width based on the contracting ratio of a light hardening resin, and areas, which are wider than the work small areas on the surface of the light hardening resin by the offset width, are subjected to one-shot exposure based on the enlarged work small area data to form a hardening layer for each of the work small areas. The present invention can be applied to, for example, an optical shaping apparatus.