3D Printer Light Bar for High-Volume Resin Curing
Solution Overview
Problem
Current three-dimensional printers optimized for photocurable materials are limited in their ability to transition from low-volume prototyping to high-volume manufacturing, requiring advancements in precision and scalability for solid article fabrication.
Innovation Solution
A high-performance three-dimensional printing system featuring a resin vessel with a transparent sheet, a vertical movement mechanism for a support tray, and a light engine with a light bar and lateral movement mechanism, utilizing individually controllable light emitting devices to selectively harden resin layers, controlled by a processor for precise positioning and scanning, ensuring proper operating distances and efficient resin distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional three-dimensional printers optimized for photocurable materials are used, then prototyping applications are effective, but manufacturing capability and productivity are limited
Solution Approach 1:
The light engine is segmented into multiple independently controllable light emitting devices arranged in a light bar, allowing selective activation of specific regions. This enables precise control over resin curing zones, improving manufacturing precision and productivity by allowing parallel processing of multiple article regions simultaneously.
Solution Approach 2:
The system transitions from conventional single-point light sources to a distributed light bar arrangement with multiple emission points along a lateral axis. This dimensional expansion allows the light engine to address entire build planes efficiently, enabling high-volume manufacturing while maintaining precision through individual device control.
2Manufacturing precision
If the light bar is positioned close to the transparent sheet for proper operating distance, then resin curing precision is improved, but the risk of resin adhesion to the sheet increases
Solution Approach 1:
A spacing element is introduced as an intermediary component between the light bar and the transparent sheet. This element maintains the optimal operating distance for precise resin curing while preventing direct contact that would cause resin adhesion. The spacing element acts as a mediator that resolves the contradiction between proximity for precision and distance to prevent adhesion.
3Manufacturing precision
If individually controllable light emitting devices are used in the light bar, then selective hardening precision is improved, but device complexity increases
Solution Approach 1:
Multiple light emitting devices are merged into a single integrated light bar assembly that functions as one cohesive unit. While individually controllable for precision, the devices are physically combined in a compact arrangement, reducing overall system complexity compared to separate light sources. The light bar structure provides a unified platform for control and operation.
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 scalable and precise fabrication of three-dimensional articles by maintaining optimal resin curing distances and preventing resin adhesion, enhancing the printer's capability for high-volume manufacturing beyond prototyping.
Implementation Method 1
The light engine is configured to selectively harden layers of resin over a build plane above the transparent sheet
Data Source
AI summary
A system for manufacturing a three-dimensional article includes a resin vessel, a vertical movement mechanism, and a light engine. The resin vessel includes a lower opening closed by a transparent sheet. The vertical movement mechanism is for positioning a support tray which supports the three-dimensional article. The light engine is disposed below the transparent sheet and is configured to selectively harden layers of resin over a build plane above the transparent sheet. The light engine includes a light bar coupled to a lateral movement mechanism. The light bar includes an array of light emitting devices and a device for impinging upon the transparent sheet. The impingement maintains a proper operating distance H between the transparent sheet and the build plane.