Stereolithographic 3D Printer Resilient Vat Base
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Solution Overview
Problem
Large format 3D printers using visual display screens for stereolithographic 3D printing face challenges with print failure due to excessive forces at the build interface as the polymer is detached from the vat film, leading to delamination issues.
Innovation Solution
Incorporating a gulley in the screen support assembly for air reservoirs adjacent to the vat base, inflatable chambers, and resiliently deformable vat bases to facilitate gentle peeling of the 3D printed object from the vat, reducing the risk of delamination and improving print reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If visual display screens are used for stereolithographic 3D printing, then manufacturing cost is reduced and image resolution is improved, but excessive forces at the build interface cause print failure and delamination
Solution Approach 1:
A release film is introduced as an intermediary layer between the cured polymer layer and the vat base. This release film has controlled adhesion properties that allow the cured polymer to release cleanly during the peeling process, preventing delamination while maintaining the benefits of visual display screen-based printing
Solution Approach 2:
The release film is a thin, flexible film that can conform to the build interface and facilitate controlled peeling. The film's flexibility allows it to bend and separate cleanly from the cured polymer, reducing excessive forces at the build interface
2Stability of the object's composition
If the vat base is made rigid for stable printing, then printing stability is improved, but excessive forces during peeling cause delamination
Solution Approach 1:
The system is segmented into distinct functional layers: the rigid vat base provides printing stability, while a separate release film layer handles the peeling function. This segmentation allows each component to optimize its specific function without compromise
Solution Approach 2:
The release film acts as an intermediary between the rigid vat base and the cured polymer, absorbing and distributing the peeling forces to prevent delamination while allowing the rigid vat base to maintain printing stability
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
The solution effectively reduces the forces required for peeling, minimizing delamination and ensuring reliable print completion by using a gulley for air reservoirs and inflatable chambers to assist in the detachment process, enhancing the reliability of large format 3D printing.
Implementation Method 1
The liquid photopolymer is polymerised (hardened) by an electromagnetic radiation exposure of an appropriate wavelength, e.g. visible light or near ultraviolet light
Implementation Method 2
an inflatable chamber, wherein the inflatable chamber is in fluid communication with a pump
Implementation Method 3
resiliently deformable vat bases to facilitate gentle peeling of the 3D printed object from the vat
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3A~3B
AI summary
A stereolithographic 3D printer comprising: a vat for liquid photopolymer; a print platform; a screen assembly having a screen support assembly supporting a screen for providing selective exposure of electromagnetic radiation for polymerising successive layers of photopolymer to build a 3D printed object on the print platform; and a control system for controlling the separation of the print platform and screen assembly parallel to a build direction, wherein the vat has a vat base that is resiliently deformable or has a resiliently deformable portion.