3D Printed Optical Surface Orientation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D printing techniques, such as FDM, struggle to produce surfaces with varying smoothness suitable for optical functionality, as the surface roughness of printed objects is often uniform and not easily controllable, especially when printing conical or faceted objects intended for lighting applications.
Innovation Solution
The method involves orienting the 3D printing object during the printing process such that the intended optical functional surface faces away from the support platform, allowing for greater smoothness compared to the opposite surface by controlling the path of the printing head and the inclination of the wall, ensuring the surface smoothness is enhanced by the lack of support during deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If FDM printing is used to produce objects with uniform surface texture, then manufacturing complexity is reduced, but surface smoothness suitable for optical functionality cannot be achieved
Solution Approach 1:
The patent applies asymmetry by orienting the object during printing so that the optical functional surface faces away from the support platform, creating an asymmetric printing configuration where one surface (facing away) is smoother than the opposite surface (facing the platform). This asymmetric orientation allows the optical surface to achieve the required smoothness without complex process modifications.
2Manufacturing precision
If polyjet technique is used to produce smooth surfaces, then surface smoothness is improved, but material stability and thermal conductivity are insufficient for injection molding applications
Solution Approach 1:
The patent applies local quality by achieving high surface smoothness only on the specific optical functional surface that faces away from the support platform, while other surfaces may have different properties. This localized approach to surface quality allows the use of FDM with thermoplastics that have good mechanical properties and stability, rather than requiring polyjet materials throughout the entire object.
3Manufacturing precision
If FDM printing is used with standard orientation, then printing speed is maintained, but surface roughness is uniform and not suitable for optical applications
Solution Approach 1:
The patent applies preliminary action by pre-planning the object orientation before printing begins. The orientation is selected in advance to ensure that the optical functional surface will face away from the support platform during printing, thereby achieving the desired smoothness without requiring post-processing or speed reductions during the actual printing process.
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 results in a smoother optical functional surface, which can be further enhanced with coatings, effectively addressing the challenge of achieving desired surface quality for applications like light collimation and aesthetics.
Implementation Method 1
FDM printers use a thermoplastic filament, which is heated to its melting point and then extruded
Implementation Method 2
heated to its melting point and then extruded
Implementation Method 3
layer by layer deposition of photo-polymerisable material which is cured after each deposition to form a solid structure
Data Source
AI summary
A method for 3D printing an object with at least one wall (2) having a first surface and a second, opposite surface, wherein the first surface is intended to serve as an optical functional surface, wherein the wall is formed by printing one track (16) on top of another track (17). An orientation of the object during printing is selected such that the wall has a tangent (or tangent surface) non-parallel to the z-axis, such that the first surface faces away from the x-y plane and the second surface faces the x-y plane. According to the invention, the 3D object is thus oriented during printing such that the first surface, intended to be used as an optical functional surface, faces away from the x-y plane, i.e. typically away from the support or platform on which the 3D object is printed upon. By ensuring this orientation during printing, the first surface becomes smoother than the second, opposite surface of the wall.