Phase-Based Resin Imaging for Low-Contrast Polymerization Monitoring
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Solution Overview
Problem
Existing VAM systems struggle to visualize the polymerization process of low-refractive index change materials, resulting in low contrast and sensitivity, which limits the success of additive manufacturing with these materials.
Innovation Solution
A phase-based optical imaging system using a linearly polarized light beam, spatial light modulator, and camera to create composite images with increased contrast by varying the phase shift between un-scattered and scattered light beams, enabling real-time visualization of the polymerization process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional imaging methods are used to visualize the VAM process, then the system is simple to operate, but the contrast and sensitivity are low for low-refractive index change materials
Solution Approach 1:
The patent applies parameter changes by modifying the optical properties of the imaging system - specifically introducing phase modulation capabilities and using interferometric detection methods. This transforms the imaging approach from direct intensity measurement to phase-sensitive measurement, enabling high contrast visualization of low-refractive index change materials during polymerization.
Solution Approach 2:
The patent uses an intermediary optical setup involving reference beams and phase modulators. The interferometric method introduces a reference beam that mediates between the sample beam and the detector, allowing phase information to be converted into measurable intensity variations. This intermediary approach enables detection of subtle refractive index changes that would otherwise be invisible.
2Measurement precision
If phase-based imaging is implemented to improve visualization of low-refractive index change materials, then imaging contrast increases, but the device complexity increases
Solution Approach 1:
The patent segments the optical path into distinct functional components: a reference beam path, a sample beam path through the resin, and a combination path at the detector. This segmentation allows independent optimization and control of each subsystem, making the complex phase-based imaging system more manageable and adaptable.
Solution Approach 2:
The patent introduces dynamic phase modulation capabilities where the phase of either the reference or sample beam can be controllably varied. This dynamic control enables flexible adjustment of the interferometric measurement conditions and allows real-time adaptation to different material properties and polymerization stages.
3Manufacturing precision
If real-time monitoring of polymerization is achieved, then manufacturing precision improves, but the measurement system becomes more complex
Solution Approach 1:
The patent implements feedback by using the phase-based imaging system to continuously monitor the polymerization process in real-time. The measured phase changes provide direct feedback about the degree of polymerization and material property evolution, enabling closed-loop control of the additive manufacturing process to achieve precise fabrication outcomes.
Solution Approach 2:
The patent applies preliminary action by establishing the interferometric measurement setup before the polymerization process begins. The system is calibrated and configured in advance to track phase changes, allowing continuous monitoring from the start of polymerization without interrupting the manufacturing process.
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 provides high-contrast, real-time imaging of the polymerization process, even for materials with low refractive index change, enhancing the visualization and control of additive manufacturing processes.
Implementation Method 1
a polarizer for polarizing the beam of light to create a linearly polarized light beam
Implementation Method 2
passing through a portion of the photo-responsive resin having a first refractive index, and a second scattered sample beam after passing through a second portion of the photo-responsive resin having begun a polymerization process and having a second refractive index
Implementation Method 3
A spatial slight modulator may be included for receiving the first un-scattered beam and the second scattered sample beam and controllably varying a phase of one of the un-scattered beam or the scattered sample beam to create multiple images of the photo-responsive resin. The multiple images represent a phase shift between the first un-scattered beam and the second scattered sample beam.
Data Source
AI summary
The present disclosure relates to a system for monitoring polymerization of a photo-responsive resin during an additive manufacturing operation involving manufacture of a part from the photo-responsive resin. The may have an optical system for generating a beam of light, a polarizer for polarizing the beam of light to create a linearly polarized light beam, with the linearly polarized light beam forming a first un-scattered beam after passing through a portion of the photo-responsive resin having a first refractive index, and a second scattered sample beam after passing through a second portion of the photo-responsive resin having begun a polymerization process and having a second refractive index. A spatial slight modulator receives the un-scattered beam and the scattered sample beam and controllably varies a phase of one or the other to create multiple images of the photo-responsive resin. A controller subsystem receives and combines the multiple images to create a composite image having increased contrast of the photo-responsive resin.