3D Printing Particle Trapping Sheet for Build Plane Maintenance

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Solution Overview

Problem

Three-dimensional (3D) printing systems face challenges with particle accumulation on the transparent sheet and within the photocurable resin, leading to defects in the printed articles due to particle compression and embedding, which damages the transparent sheet and affects the quality of subsequent fabrications.

Innovation Solution

A three-dimensional printing system that includes a controller and a fixture with a particle trapping sheet, which is solidified proximate to the build plane to trap particles, allowing for their removal before the fixture is lowered into the resin, thereby preventing damage to the transparent sheet and ensuring the quality of the printed articles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the support surface is positioned very close to the transparent sheet to maintain a small gap for curing, then the light transmissive properties are maintained, but particles become compressed between the sheet and support surface causing damage and defects

Engineering Contradiction:

Improvegap control precisionVSAvoidparticle compression damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary particle removal by activating the blade to scrape particles from the transparent sheet before the support surface is lowered into the resin. This preliminary action prevents particles from being compressed between the sheet and support surface during subsequent operation, resolving the contradiction by eliminating harmful particles while maintaining the required small gap for precise curing.

Inventive Principle:

Principle #10Preliminary action

2Duration of action of stationary object

If particles accumulate on the transparent sheet, then the sheet can be used for multiple fabrications, but particle compression damages the sheet and embeds particles in articles creating defects

Engineering Contradiction:

Improvetransparent sheet lifespanVSAvoidfabrication quality consistency

Core Design Contradiction:

Duration of action of stationary objectVSReliability

Solution Approach 1:

The transparent sheet performs self-service by using its own surface to trap particles during the fabrication process. Particles naturally settle on the sheet and are then removed by the blade scraping action. This self-service mechanism allows the sheet to maintain its function over multiple fabrications while preventing particle accumulation from causing damage or defects, thus extending lifespan while maintaining reliability.

Inventive Principle:

Principle #25Self-service

3Reliability

If the transparent sheet is replaced frequently to maintain quality, then fabrication quality is ensured, but system productivity decreases and costs increase

Engineering Contradiction:

Improvefabrication qualityVSAvoidfabrication throughput

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system employs a disposable blade that is inexpensive and easily replaceable. Instead of replacing the expensive transparent sheet frequently, the cheap blade is used to remove particles from the sheet, allowing the sheet to be reused multiple times. This approach maintains fabrication quality by continuously removing particles while preserving productivity by avoiding frequent sheet replacements and associated downtime.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Object-affected harmful factors

If a particle removal mechanism is added to the system, then particle damage is prevented, but device complexity increases

Engineering Contradiction:

Improveparticle damage preventionVSAvoidsystem structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The blade acts as an intermediary element between the transparent sheet and the particle removal function. Rather than requiring a complex integrated particle removal system, the simple blade mechanically scrapes particles from the sheet surface. This intermediary approach prevents particle damage while adding minimal complexity to the overall system structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 system effectively prevents particle accumulation on the transparent sheet, minimizing defects and extending its lifespan by trapping particles during the printing process, ensuring consistent quality and reducing the need for frequent replacements.

Implementation Method 1

The light engine is configured to selectively project radiation up through the transparent sheet and over a build plane to solidify a particle trapping sheet proximate to the build plane

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS10960602B2Three dimensional printing system that automatically removes particles from build plane

Publication Date: 2021.03.30 3D SYSTEMS INC

AI summary

A three dimensional printing system includes a resin vessel, a light engine, a movement mechanism, a fixture, and a controller. The resin vessel is for containing a photocurable resin and has a lower portion with a transparent sheet. The light engine is configured to selectively project radiation up through the transparent sheet and over a build plane. The fixture is coupled to the movement mechanism and has a lower face that faces the transparent sheet. The controller is configured to operate the light engine to solidify a particle trapping sheet proximate to the build plane thereby trapping particles that extend upwardly from the transparent sheet into the build plane.