Pixel-Shifted Resin Printing for Large Parts and Sharp Features
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in efficiently printing large components and components with fidelity-critical features, such as achieving high resolution and maintaining feature accuracy.
Innovation Solution
An additive manufacturing apparatus that intelligently shifts and flashes grids of radiant energy to minimize pixelization, allowing for the production of larger components with sharper features and maintaining resolution, using a support plate, stage, and radiant energy device to project and cure resin layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional additive manufacturing processes are used to print large components, then the component size increases, but the resolution and feature sharpness deteriorate
Solution Approach 1:
The patent segments the printing process into multiple passes with different grid positions. Instead of printing the entire layer in one pass with a single grid position, the system divides the layer into multiple sections and prints each section with optimally positioned grids, thereby maintaining high resolution across large component areas
Solution Approach 2:
The patent implements dynamic grid position adjustment during the printing process. The grid is shifted to different positions for different passes based on the specific layer geometry and feature requirements, allowing the system to adaptively optimize resolution for each printing operation rather than using a fixed grid position
2Manufacturing precision
If traditional additive manufacturing processes are used to print components with fidelity-critical features, then feature accuracy improves, but printing efficiency deteriorates
Solution Approach 1:
The patent performs preliminary determination of optimal grid positions before actual printing. The system analyzes layer geometry and pre-calculates the best grid positions for each pass, so that during the printing process, the grids are already optimally positioned to capture fidelity-critical features efficiently without requiring multiple trial passes
Solution Approach 2:
The patent changes the grid position parameter dynamically based on layer characteristics. By adjusting the grid position to match the specific geometric features of each layer, the system achieves high feature accuracy while minimizing the number of passes required, thereby improving printing efficiency
3Manufacturing precision
If pixel shifting is implemented to improve resolution, then feature sharpness improves, but process complexity increases
Solution Approach 1:
The patent replaces complex mechanical repositioning mechanisms with computational grid shifting. Instead of physically moving the entire printing system or using complex mechanical stages to achieve sub-pixel precision, the system uses digital image processing and computational methods to shift the virtual grid positions, significantly reducing mechanical complexity while maintaining high feature sharpness
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
Enables the production of larger components with sharper features and improved resolution, enhancing diverse part creation and reducing apparatus packaging.
Implementation Method 1
a tank of radiant-energy curable photopolymer 'resin' and a curing energy source such as a laser. Similarly, Digital Light Processing (DLP) three-dimensional (3D) printing employs a two-dimensional image projector to build components one layer at a time. For each layer, the energy source draws or flashes a radiation image of the cross section of the component onto the surface of the resin. Exposure to the radiation cures and solidifies the pattern in the resin
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
An additive manufacturing apparatus (10) includes a support plate (14) defining a window (16) and a resin support (26) configured to support an uncured layer (68) of resin. A stage (18) is configured to hold one or more cured layers of the resin to form a component (12) positioned opposite a support plate (14). A radiant energy device (20) is positioned on an opposite side of the resin support (26) from the stage (18) and is operable to project radiant energy in a grid (78) through the window (16). The grid (78) and/or pixels thereof are intelligently shifted to efficiently print one or more layers of a component (12).