3D Printer Resin Containment with Rotating Hinge and Tensioning Ring
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Solution Overview
Problem
Existing large area stereolithography-based 3D printers face challenges in forming articles with a large lateral area due to limitations in the optical path and resin containment systems.
Innovation Solution
A three-dimensional printing system with a support plate, resin containment structure, actuator, light engine, and controller, featuring a rotating lower substructure and tensioning ring to maintain a transparent sheet and provide a stable optical path for layer-by-layer fabrication, allowing for larger build areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a flexible transparent sheet is used to define the build plane, then the system can accommodate large lateral areas, but the optical path stability and resin containment become difficult to maintain
Solution Approach 1:
The support structure is divided into multiple rigid components (support plate, upper substructure, lower substructure) connected by a hinge, with the transparent sheet positioned between them. This segmentation allows the system to maintain large lateral area while providing rigid optical paths through the separate structural elements that guide and stabilize the radiation.
Solution Approach 2:
The transparent sheet acts as an intermediary element between the light engine and the resin, while the rigid support structures serve as intermediaries to stabilize the optical path. The hinge mechanism provides an intermediary connection that allows controlled movement while maintaining structural integrity for optical stability.
2Area of stationary object
If the transparent sheet is made flexible to allow large area coverage, then the build area increases, but the sheet becomes difficult to tension and contain resin
Solution Approach 1:
The resin containment is achieved through segmented rigid structures (upper substructure with clamping mechanism, lower substructure with support plate) that work together to secure the flexible transparent sheet. These segmented rigid elements provide the necessary tensioning and containment functions without requiring the sheet itself to be rigid.
Solution Approach 2:
The transparent sheet is designed as a flexible thin film that can be tensioned between rigid support structures. The flexibility of the sheet allows it to conform to the build plane and accommodate large areas, while the rigid clamping mechanisms provide the necessary tensioning and resin containment.
3Reliability
If rigid structures are used to maintain optical path stability, then the optical path is stable, but the system complexity increases
Solution Approach 1:
Multiple functions are merged into the rigid support structures: the support plate provides both structural support and optical path stability, the upper substructure with clamping mechanism provides both sheet tensioning and resin containment, and the lower substructure provides both support and hinge connection. This merging reduces the number of separate components and simplifies the overall system.
Solution Approach 2:
The rigid support structures serve multiple functions simultaneously: the support plate provides structural support, optical path stability, and positioning reference; the upper substructure provides sheet tensioning, resin containment, and optical path guidance; the lower substructure provides support, hinge connection, and movement mechanism integration. This multi-functionality reduces system complexity.
4Measurement precision
If a hinge mechanism is introduced to enable movement and positioning, then the system achieves precise positioning, but the mechanical complexity increases
Solution Approach 1:
The positioning system is segmented into discrete components (hinge joint, actuator, cam mechanism, follower) that work together to achieve precise positioning. The hinge provides a simple rotational degree of freedom, while the cam-follower mechanism provides controlled motion, and the actuator provides actuation. This segmentation makes the complex positioning function modular and manageable.
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 precise and efficient fabrication of large area three-dimensional articles by maintaining a stable optical path and tensioning the transparent sheet, enhancing the printer's ability to form larger lateral dimensions.
Implementation Method 1
The light engine is configured to project radiation up through the transparent plate and the transparent sheet to a build plane above and proximate to the transparent sheet
Implementation Method 2
The actuator is affixed to the support plate and configured to rotate the lower substructure about the hinge between a (1) a raised position in which the transparent plate contacts and supports the transparent sheet and (2) a lowered position in which the transparent plate is out of contact with the transparent sheet
Implementation Method 3
The tensioning ring impinges upon the transparent sheet in a downward direction. The tensioning ring provides a dual function of tensioning the transparent sheet and providing a peripheral surface for laterally containing the resin above the transparent sheet
Implementation Method 4
The lower substructure includes a cam follower. The actuator includes a cam that engages the follower. The actuator is configured to rotate the cam to move the follower to selectively raise and lower the second end of the lower substructure
Data Source
AI summary
A three-dimensional printing system for fabricating or manufacturing a three-dimensional article includes a support plate, a resin containment structure, an actuator, a light engine, a support tray coupled to a movement mechanism, and a controller. The resin containment structure is supported by the support plate and includes a lower substructure that is moveably coupled to an upper substructure. The upper substructure defines an upper central opening that is closed by a transparent sheet. The lower substructure defines a lower central opening that is closed by a transparent plate. The actuator is affixed to the support plate and configured to rotate the upper substrate about the hinge between a (1) a raised position in which the transparent plate contacts and supports the transparent sheet and (2) a lowered position in which the transparent plate is out of contact with the transparent sheet.