Additive Fabrication Optics Module Calibration
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Solution Overview
Problem
Stereolithography and other additive fabrication devices face challenges with optical component wear or degradation, leading to sub-optimal performance or complete failure, requiring costly repairs or device replacement due to the sensitive and precise nature of these components.
Innovation Solution
A method for calibrating an optics module independently of other device components, allowing users to replace optics modules without needing to repair or replace the entire device, using techniques such as directing light onto fiducial targets and generating three-dimensional mappings to ensure accurate light direction within the build area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optical components are used in additive fabrication devices, then precise light direction and object fabrication are achieved, but component wear or degradation occurs leading to sub-optimal performance or complete failure
Solution Approach 1:
The patent divides the additive fabrication device into modular components, specifically making the optics module a separate replaceable unit. This segmentation allows the optical components to be independently replaced without affecting the entire device, thus maintaining manufacturing precision while addressing reliability issues through component replacement rather than device replacement.
Solution Approach 2:
The patent implements calibration procedures that change the operational parameters of the optics module to compensate for wear and degradation. By adjusting calibration parameters, the system maintains precise light direction despite component aging, resolving the contradiction between maintaining precision and dealing with component reliability deterioration.
2Reliability
If optical components wear or degrade, then sub-optimal performance or complete failure occurs, but repair or replacement requires replacing the entire device due to the sensitive and precise nature of these components
Solution Approach 1:
The optics module is designed as a distinct, self-contained module that can be removed and replaced independently from the main device body. This modular segmentation simplifies the repair process significantly, allowing users to replace only the worn optical module rather than the entire complex device, thus improving reliability while reducing replacement complexity.
Solution Approach 2:
The patent enables users to perform calibration and replacement of the optics module themselves through simplified procedures. The self-calibration capabilities and user-friendly replacement process allow end-users to maintain and repair the device without requiring specialized service personnel, reducing both operational downtime and service complexity.
3Ease of repair
If calibration is performed independently of other device components, then optics module replacement is simplified, but ensuring accurate light direction within the build area requires complex three-dimensional mapping
Solution Approach 1:
The calibration process is segmented into independent steps that can be performed sequentially without requiring full device disassembly or complex multi-component coordination. The optics module can be calibrated independently using simplified procedures, making replacement easier while the three-dimensional mapping is performed as a separate, manageable process.
Solution Approach 2:
The patent implements preliminary calibration procedures that are performed before the optics module is installed in the device. By pre-calibrating the module and creating three-dimensional mapping data in advance, the actual installation and on-site calibration process is simplified, reducing the apparent complexity during repair while ensuring accurate light direction.
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
Enables users to maintain or replace optics modules without extensive repair, extending the life of the device and reducing maintenance costs by ensuring precise calibration and operation.
Implementation Method 1
directing light onto fiducial targets and generating three-dimensional mappings to ensure accurate light direction
Implementation Method 2
Exposure to actinic radiation cures a thin layer of liquid resin, which causes it to harden, change physical properties, and adhere to previously cured layers or the bottom surface of the build platform
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
According to some aspects, calibration techniques are provided that allow an optics module (1010) of an additive fabrication device to be installed and operated in a stereolithography device (900) by a user. In particular, the calibration techniques enable the optics module to be calibrated in a way that only depends on the characteristics of the optics module, and not upon any other components of the stereolithography device. As a result, the techniques enable a user of a stereolithography device to remove one optics module and replace it with another, without it being necessary to repair or replace the whole device. In some cases, the calibration techniques may include directing light onto one or more fiducial targets within the stereolithography device and measuring light scattered from said targets.