Pixel Shifting Grid for Additive Manufacturing Resolution
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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 rounder features, sharper edges, and larger components without loss of resolution, using a radiant energy device to project energy through a transparent window and support plate, with a computing system controlling the grid positioning and flashing.
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 pixelization is prominent and edge resolution is poor
Solution Approach 1:
The patent implements a movable grid system where pixels can be dynamically repositioned along the X and Y axes to align with component features. The grid transitions from a static fixed structure to a dynamic adjustable structure, allowing pixels to move to optimal positions for printing different geometries, thereby improving edge resolution without requiring complete redesign of the apparatus
Solution Approach 2:
The movable grid system serves multiple functions: it can print various component sizes, maintain different resolutions, and adapt to different geometries using the same apparatus. The grid's ability to reposition pixels allows a single device to handle diverse manufacturing requirements that would traditionally require multiple specialized systems
2Area of stationary object
If the grid size is increased to print larger components, then the printing area is expanded, but the resolution is lost
Solution Approach 1:
The grid is divided into multiple independently movable pixel units rather than a single fixed array. This segmentation allows the system to maintain high resolution by concentrating pixels on the actual component features while expanding the overall printing area through strategic pixel distribution and repositioning across a larger workspace
3Manufacturing precision
If traditional additive manufacturing is used for fidelity-critical features, then the process is simple, but pixelization reduces feature accuracy
Solution Approach 1:
The system applies different pixel densities and positions locally according to feature requirements. Critical features receive concentrated pixel attention with optimized positioning, while less critical areas use standard pixel distribution. This local optimization improves feature accuracy without complicating the overall 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
Enables diverse part creation with improved edge resolution and reduced apparatus complexity by minimizing pixelization and maintaining high resolution across larger components, enhancing printing efficiency and accuracy.
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
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.