3D Printing Particle Trapping Sheet for Stereolithography
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Solution Overview
Problem
Three-dimensional (3D) printing systems using stereolithography 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 fabrication.
Innovation Solution
A three-dimensional printing system that includes a particle trapping sheet formed by the light engine and movement mechanism to trap particles at the build plane, with features such as tapering designs and conduits to facilitate particle removal and minimize contact with the transparent sheet, allowing for the creation of a particle trapping sheet that spans the build plane and supports the three-dimensional article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the support surface is positioned close to the transparent sheet to enable selective curing, then the light transmission and curing precision are improved, but particles become compressed and embedded in the article causing defects
Solution Approach 1:
A particle trapping sheet is introduced as an intermediary layer between the transparent sheet and the build plane. This mediator captures particles before they can be compressed into the article, allowing the support surface to remain close to the transparent sheet for precise curing while preventing particle embedding defects
Solution Approach 2:
The harmful particles are extracted from the build area by transferring them onto the particle trapping sheet. The sheet selectively removes particles from the resin between the transparent sheet and support surface, separating the particles from the curing zone to prevent them from being embedded in the final article
2Duration of action of stationary object
If particles accumulate on the transparent sheet, then the sheet can be reused multiple times, but the light transmissive properties are degraded affecting subsequent fabrication quality
Solution Approach 1:
The particle trapping sheet serves as a mediator that intercepts particles before they reach the transparent sheet. By capturing particles on the trapping sheet instead of allowing them to accumulate on the transparent sheet, the light transmissive properties of the transparent sheet are preserved, maintaining fabrication quality over extended reuse periods
Solution Approach 2:
The particle trapping sheet is designed as a disposable or easily replaceable component that absorbs the harm of particle accumulation. Instead of degrading the expensive transparent sheet, the trapping sheet is sacrificed or regenerated, allowing the transparent sheet to maintain its optical properties for longer durations
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, reducing defects in the printed articles and extending the life of the transparent sheet by trapping particles during the printing process, ensuring higher quality and longer sheet durability.
Implementation Method 1
The light engine is configured to selectively project radiation up through the transparent sheet and over a build plane... operate the light engine to solidify a particle trapping sheet that spans the central opening
Data Source
AI summary
A three dimensional printing system includes a resin vessel, a light engine, a movement mechanism, a support 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 support fixture is coupled to the movement mechanism and has a lower rim that surrounds a central opening and faces the transparent sheet. The controller is configured to: (1) operate the movement mechanism to position the rim at an operating distance from the transparent sheet, (2) operate the light engine and the movement mechanism to form a particle trapping sheet that spans the central opening, and (3) operate the light engine and the movement mechanism to form the three dimensional article.