3D Over-Printing Device Multi-Direction UV Projection
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Solution Overview
Problem
Existing 3D over-printing methods face challenges in printing on existing structures with opaque or high absorbance materials due to shadow areas caused by UV light penetration issues, particularly in top-down methods, and limitations in projector installation and system complexity in rotating projector systems.
Innovation Solution
A 3D over-printing device and method utilizing a projector and multiple mirrors to project UV light in multiple directions, allowing simultaneous photocuring of light-curable materials on existing structures, including opaque materials, by dividing and reflecting images through a mirror structure to avoid shadow areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If UV light is projected from a single direction onto an existing structure in light-curable material, then the projection system is simple, but shadow areas occur depending on the shape of the structure making it impossible to print properly
Solution Approach 1:
The patent divides the projection task into multiple segments by using multiple projectors positioned at different angles. Each projector handles a specific viewing angle of the existing structure, ensuring complete coverage without shadow areas. The projection images from multiple projectors are integrated to form the complete 3D overprinted structure.
Solution Approach 2:
The patent transitions from single-direction projection to multi-directional projection by adding spatial dimensions to the projection system. Projectors are arranged around the existing structure at various angles, projecting UV light from multiple directions simultaneously to eliminate shadow areas and achieve complete coverage.
2Manufacturing precision
If a rotating projector system is used to project UV light images in several directions, then shadow areas are eliminated, but the system complexity increases and installation becomes difficult
Solution Approach 1:
The patent combines multiple stationary projectors into a coordinated system that functions as an integrated multi-directional projection unit. Instead of rotating a single projector, multiple projectors are fixed in position and synchronized to project simultaneously, merging their capabilities to achieve complete coverage while maintaining structural simplicity.
Solution Approach 2:
The patent introduces dynamic coordination and synchronization control among multiple stationary projectors. The system dynamically manages the timing and alignment of projections from different angles to ensure seamless integration of images and complete coverage of the existing structure without requiring physical rotation.
3Device complexity
If top-down UV light projection is used on opaque resin, then the projection system is simple, but shadow areas occur making it impossible to print properly
Solution Approach 1:
The patent segments the projection coverage by positioning projectors at multiple angles around the existing structure. This segmentation ensures that no shadow areas are created, with each projector contributing to a specific portion of the overall projection, achieving complete and reliable coverage of opaque materials.
Solution Approach 2:
The patent changes the projection parameters by transitioning from single-angle to multi-angle projection. This parameter change in the projection geometry ensures that UV light reaches all surfaces of the existing structure from appropriate angles, eliminating shadow areas and ensuring reliable printing on opaque materials.
4Manufacturing precision
If multiple projectors are used to project UV light images simultaneously in several directions, then shadow areas are eliminated, but the number of projectors and system complexity increase
Solution Approach 1:
The patent segments the projection task among multiple projectors, with each projector responsible for a specific angular sector. This segmentation allows the system to achieve complete coverage using a reasonable number of projectors rather than requiring excessive quantities, optimizing the balance between coverage and component count.
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 easy over-printing of 3D shapes on existing structures with opaque or high absorbance materials by preventing shadow areas and reducing system complexity and printing time, while maintaining efficient photocuring.
Implementation Method 1
an image of a shape to be cured on the surface of the light-curable material contained in the vat is divided into several areas according to projection directions and when the several areas are converted and simultaneously projected with the projector, split images are reflected from the mirror structure and projected in several directions
Implementation Method 2
light energy increases in an UV light overlap area in the light-curable material, thus inducing light curing
Data Source
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AI summary
Proposed is a 3D over-printing device for over-printing a 3D shape on an existing structure, the device including: a vat containing a light-curable material; a driving part configured to fix the existing structure and move the existing structure vertically, layer by layer, within the vat; and an optical part comprising a projector and a mirror structure, and configured to photocure an area to be cured on a surface of the light-curable material by projecting UV light in several directions simultaneously from above the surface of the light-curable material toward the surface of the light-curable material that is upward exposed and in contact with the existing structure.