3D Printer Light Engine Scanning Array for High Resolution
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Solution Overview
Problem
Current 3D printing systems face challenges in achieving high resolution and speed in selectively curing or fusing materials, particularly in the application of energy using imaging systems like lasers.
Innovation Solution
A 3D printing system with a light engine that scans an array of light spots across a build plane using a parallel beam generator and spatial light modulator, which includes a columnar array of controllable elements, beam expanders, and micro-lenses to generate and direct modulated light beams, allowing for precise imaging and efficient material processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser beam is used to selectively cure or fuse material, then the system is simple to operate, but the imaging speed and productivity are limited
Solution Approach 1:
The patent divides a single laser beam into multiple parallel beams using beam splitting optics. Each beam can independently image different regions of the build plane simultaneously, effectively segmenting the imaging task across multiple parallel processing channels to increase overall productivity without requiring multiple separate laser sources
Solution Approach 2:
The patent transitions from sequential single-point imaging to parallel multi-point imaging by introducing a spatial dimension of parallelism. Multiple beams are arranged in arrays and scanned across the build plane in parallel, adding a dimensional aspect of simultaneous multi-location processing that dramatically increases imaging speed
2Manufacturing precision
If the laser beam is focused to a small spot for high resolution, then the manufacturing precision is improved, but the area covered per scan is reduced
Solution Approach 1:
The patent segments the build plane into multiple regions that can be imaged simultaneously by different beams in the parallel array. Each beam maintains a small focused spot size for high resolution while the collective array of beams covers the entire build plane in parallel, thus resolving the contradiction between spot size and coverage area
Solution Approach 2:
The patent combines multiple small focused beams into a parallel array system where each beam maintains its high-resolution capability while the merged system achieves comprehensive coverage. The individual high-resolution beams work together in unison to image the entire build plane, merging their collective capability to overcome the limitation of single-beam coverage
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 resolution and speed in the 3D printing process, enabling the formation of high-quality three-dimensional articles by selectively imaging and fusing build material layers with improved precision and efficiency.
Implementation Method 1
a spatial light modulator that includes a columnar array of controllable elements that each receive light from a light source and output a modulated light beam
Implementation Method 2
a beam expander that expands the columnar array of light beams along the second axis
Implementation Method 3
a columnar array of micro-lenses that each shrink one of the light beams
Implementation Method 4
Some of these three dimensional printing systems utilize the application of energy to selectively cure or fuse materials
Implementation Method 5
The energy is applied using imaging systems such as lasers
Data Source
Figure 1
Figure 2~3
Figure 4A
AI summary
A three dimensional printing system for manufacturing a three dimensional article includes a build platform (4), a light engine, and a controller. The build platform (4) is coupled to a vertical positioning apparatus. The light engine is configured to generate and scan a columnar array of light spots (24) across a build plane (10). The columnar array of light spots are arranged along a second axis. The light spots are scanned along a first axis. The build plane is laterally defined by mutually perpendicular X and Y axes. In the build plane, the first axis is parallel to the X-axis. The light engine is operated to scan the light spots (24) over the build plane (10), the scanning light spots image the build material along stripes (26) that are parallel to the X-axis and are separated from each other along the Y-axis leaving unimaged stripes (28) between the imaged stripes. This is repeated one or more times with the light spots shifted in Y in order to image the unimaged stripes. These steps are repeated until the three dimensional article is formed.