Overexposed Boundary for Additive Manufacturing Distortion
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Solution Overview
Problem
Dual cure resins in additive manufacturing often result in part distortion and dimensional variability due to the further curing process, such as warping and shrinking, which is not effectively addressed by existing techniques.
Innovation Solution
A method involving stereolithography with a circumferential boundary portion that is overexposed during light polymerization, followed by cleaning and baking, to reduce distortion and enhance dimensional uniformity of three-dimensional objects produced from dual cure resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If dual cure resins are used in additive manufacturing, then manufacturing speed and productivity are improved, but part distortion and dimensional variability occur during the baking step
Solution Approach 1:
The boundary portion is overexposed to light during the stereolithography process before baking, creating a pre-cured, more rigid edge structure that will resist distortion during the subsequent baking step. This preliminary action prepares the part to withstand the thermal curing process without warping or shrinking excessively
Solution Approach 2:
Different regions of the part receive different light exposure intensities - the boundary portion receives higher exposure (overexposure) while the body portion receives standard exposure. This creates local differences in cure state and rigidity, with the overexposed boundary providing structural support during baking while the body portion completes its cure during the baking process
2Manufacturing precision
If the boundary portion is overexposed with light during stereolithography, then distortion during baking is reduced, but the complexity of the manufacturing process increases
Solution Approach 1:
The light exposure parameters are changed locally - the boundary portion is exposed to higher light intensity or longer exposure time compared to the body portion. This parameter change creates the desired differential cure state without requiring additional equipment or complex process steps, as it can be implemented through software control of the light source
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
The method effectively minimizes distortion and dimensional variability, ensuring the production of more uniform and accurate three-dimensional objects, particularly beneficial for batch production where mechanical compatibility is crucial.
Implementation Method 1
producing a green intermediate object by light polymerization of the resin in a stereolithography process
Implementation Method 2
baking the object to produce the three-dimensional object
Data Source
AI summary
A method of making a three-dimensional object (11) from a light polymerizable dual cure resin (16), includes the steps of: (a) producing a green intermediate object by light polymerization of the resin in a stereolithography process (e.g., continuous liquid interface production); (i) the object comprising a body portion and a circumferential boundary portion (12) included in at least part of the body portion i (ii) the stereolithography process including overexposing the boundary portion (as compared to the exposure of the body portion) with light; (b) cleaning the intermediate object; and then (c) baking the object to produce the three-dimensional object.