Pixel Shifting in Additive Manufacturing for Precision
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Solution Overview
Problem
Additive manufacturing processes face challenges in efficiently printing large components and components with fidelity-critical features, such as achieving precise shapes and minimizing pixelization, while maintaining resolution and reducing apparatus complexity.
Innovation Solution
An additive manufacturing apparatus that intelligently shifts and flashes a grid of pixels to align with the features of the component being printed, allowing for the creation of diverse parts with improved edge sharpness and roundness, and enabling the production of larger components without loss of resolution by optimizing the positioning and flashing of pixels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed grid of pixels is used for additive manufacturing, then the apparatus structure is simple, but the manufacturing precision deteriorates due to pixelization effects and inability to align with component features
Solution Approach 1:
The patent applies the dynamics principle by making the pixel grid movable rather than fixed. The pixel array can be shifted to different positions and orientations to align with the features of the component being printed. This dynamic repositioning capability allows the same pixel grid to adapt to different component geometries, improving edge sharpness and reducing pixelization effects without requiring a completely different apparatus for each component type.
2Manufacturing precision
If a fixed grid of pixels is used for additive manufacturing, then the apparatus structure is simple, but the manufacturing precision deteriorates due to inability to print large components without loss of resolution
Solution Approach 1:
The patent applies the dynamics principle by making the pixel grid movable rather than fixed. The pixel array can be shifted to different positions and orientations to align with the features of the component being printed. This dynamic repositioning capability allows the same pixel grid to adapt to different component geometries, improving edge sharpness and reducing pixelization effects without requiring a completely different apparatus for each component type.
3Manufacturing precision
If the pixel grid is shifted to align with component features, then the manufacturing precision improves, but the productivity deteriorates due to additional positioning time
Solution Approach 1:
The patent applies the preliminary action principle by pre-calculating and storing optimal pixel grid positions and orientations for different component features before the actual printing process. This allows the system to quickly retrieve and execute pre-determined positioning instructions during printing, minimizing the time required for grid repositioning while still achieving alignment with component features for improved edge sharpness.
4Adaptability or versatility
If a fixed grid of pixels is used for additive manufacturing, then the apparatus structure is simple, but the adaptability deteriorates due to inability to print diverse part geometries with high fidelity
Solution Approach 1:
The patent applies the dynamics principle by making the pixel grid movable rather than fixed. The pixel array can be shifted to different positions and orientations to align with the features of the component being printed. This dynamic repositioning capability allows the same pixel grid to adapt to different component geometries, improving edge sharpness and reducing pixelization effects without requiring a completely different apparatus for each component type.
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 enhances the precision and efficiency of additive manufacturing, allowing for the creation of complex shapes with improved resolution at edges and surfaces, and reduces the overall complexity of the manufacturing apparatus, enabling the production of larger components with maintained or improved fidelity.
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 and joins it to a previously-cured layer.
Data Source
AI summary
An additive manufacturing apparatus includes a support plate defining a window and a resin support configured to support an uncured layer of resin. A stage is configured to hold one or more cured layers of the resin to form a component positioned opposite a support plate. A radiant energy device is positioned on an opposite side of the resin support from the stage and is operable to project radiant energy in a grid through the window. The grid and/or pixels thereof are intelligently shifted to efficiently print one or more layers of a component.