3D Patterned Bottom Surface for Additive Manufacturing

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Solution Overview

Problem

Existing additive manufacturing devices using radiation-curable resins are limited by the absorption of curing radiation, restricting the thickness of cured layers and making it impractical for the efficient production of large 3D objects due to prolonged manufacturing time and material inefficiency.

Innovation Solution

The apparatus employs a container with a 3D patterned bottom surface that allows for the curing of thicker resin layers, enabling the production of 3D objects as a stack of layers rather than flat layers, using a radiation source that can effectively penetrate and cure the resin across the patterned surface, reducing manufacturing time and increasing the size of objects that can be produced.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If a transparent bottom is used to transmit curing radiation, then radiation can penetrate the container, but the resin absorbs most of the radiation making it impossible to solidify thicker layers

Engineering Contradiction:

Improvethickness of cured resin layerVSAvoidcuring effectiveness

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The bottom surface is segmented into multiple 3D patterns with varying depths. Deeper regions allow radiation to penetrate thicker resin layers, while shallower regions provide better curing for thinner layers. This segmentation enables different parts of the same resin layer to be cured at different thicknesses simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the bottom surface are given different 3D pattern depths to create local variations in radiation penetration. This allows optimal curing conditions to be provided locally - deeper patterns for areas requiring thicker layer curing, shallower patterns for areas requiring precise thin layer curing.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If thin layers of resin are cured one by one, then high dimensional accuracy is achieved, but manufacturing time becomes excessively long for large objects

Engineering Contradiction:

Improvedimensional accuracyVSAvoidmanufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The invention transitions from curing flat 2D layers to curing 3D volumetric layers. By using 3D patterns on the bottom surface, the system can cure resin in three-dimensional shapes directly, reducing the number of layers needed to build an object while maintaining dimensional accuracy.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The resin layer is segmented into multiple zones with different required thicknesses. The 3D patterned bottom surface enables simultaneous curing of these segmented zones at their respective optimal thicknesses, reducing total manufacturing time while maintaining precision in each zone.

Inventive Principle:

Principle #1Segmentation

3Productivity

If the entire object is lifted after each layer is cured, then the next layer can be cured, but this process is too slow for large size objects

Engineering Contradiction:

Improveproduction efficiencyVSAvoidlayer thickness control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Instead of lifting the object after each layer is cured, the invention inverts the approach by keeping the object stationary and using the 3D patterned bottom surface to define layer thickness. The bottom surface patterns act as a template that determines the cured layer geometry without requiring mechanical lifting.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The 3D patterns are pre-formed on the bottom surface before resin deposition. These pre-formed patterns serve as a guide for the resin curing process, determining the final layer geometry in advance and eliminating the need for post-curing adjustments or lifting operations.

Inventive Principle:

Principle #10Preliminary action

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

This approach significantly reduces manufacturing time by 8 to 20 times, making the production of large 3D objects feasible while minimizing material usage and production costs.

Implementation Method 1

a radiation source configured to provide the curing radiation to cure at least a portion of the radiation-curable resin into a solid layer

Methodology Applied

Scientific EffectRadiation curing: Photopolymerisation

Implementation Method 2

The transmitted through the bottom curing radiation interacts/cures a thin, adjacent to the bottom, layer of resin

Methodology Applied

Scientific EffectRadiation absorption: Absorption (EM radiation)

Data Source

PatentUS9914292B2Additive manufacturing device

Publication Date: 2018.03.13 MASSIVIT 3D PRINTING TECH

AI summary

Disclosed is an additive manufacturing device that facilitates the manufacturing of relatively large 3D objects at a short time. The device uses radiation-curable resin and radiation curing system. Layer shaping members are disclosed to provide both for shorter manufacturing time of an object, minimizing waste of resin and reduction of weight. Curing radiation sources are also designed to minimizing waste of resin and manufacturing time.