3D Printer Tank With Mobile Oxygen Layer
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Solution Overview
Problem
The adhesion of photopolymer to the transparent substrate in 3-D printers slows down the printing process, reducing productivity, as existing technologies fail to effectively prevent this adhesion during the curing process.
Innovation Solution
A 3-D printer tank is designed with a first mobile layer of oxygen-filled gas permeable liquid that separates the photopolymer from the bottom wall and maintains a continuous flow to prevent adhesion, and a second mobile layer of inhibition liquid that overlays the first layer, preventing the photopolymer from curing and adhering to the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If photopolymer is used directly on the transparent substrate for curing, then printing quality is maintained, but adhesion occurs which slows down the printing process and reduces productivity
Solution Approach 1:
The patent introduces an inhibition liquid layer as an intermediary between the photopolymer and the transparent substrate. This inhibition liquid prevents direct contact and adhesion between the photopolymer and substrate, while still allowing the printing process to proceed efficiently. The mediator layer solves the adhesion problem without compromising printing quality or speed.
Solution Approach 2:
The patent segments the liquid medium into two distinct layers: a photopolymer layer for printing and an inhibition liquid layer for preventing adhesion. This segmentation allows each layer to perform its specific function independently - the photopolymer layer maintains printing quality while the inhibition liquid layer prevents unwanted adhesion to the substrate.
2Reliability
If a single liquid layer is used in the tank, then device complexity is low, but it cannot simultaneously prevent adhesion and enable proper curing
Solution Approach 1:
The tank structure is segmented into functional layers with the inhibition liquid layer positioned between the photopolymer and the substrate. This segmentation enables the system to achieve reliable adhesion prevention while maintaining a relatively simple overall tank structure that follows the basic stereolithography configuration.
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 configuration prevents photopolymer adhesion to the substrate, ensuring a continuous and efficient printing process by maintaining a laminar flow of the gas permeable liquid and inhibiting the curing of the inhibition liquid, thereby enhancing productivity and reducing delays.
Implementation Method 1
a first mobile layer defined by an oxygen filled liquid that separates the photopolymer from an upper surface of a bottom wall of the tank
Implementation Method 2
maintain a continuous flow of the liquid of the first mobile layer along the upper surface of the bottom wall
Implementation Method 3
a second mobile layer defined by an inhibition liquid that overlays the first mobile layer, the second mobile layer being located beneath a printing area
Implementation Method 4
maintain a continuous flow of the liquid of the first mobile layer along the upper surface of the bottom wall in order to further limit and/or prevent adhesion of the photopolymer to the bottom wall and to draw heat out of the tank
Implementation Method 5
operation of a resin curing device is controlled to provide light to the printing area thereby polymerizing predetermined portions of the polymerizable resin forming an object
Data Source
AI summary
A method of operating a 3-D printer apparatus includes a tank structure with a bottom wall with a printing area defined above and spaced apart from the bottom wall. A gas permeable liquid within the tank overlays the bottom wall of the tank structure defining a first mobile layer below the printing area. An inhibition liquid within the tank overlays the gas permeable liquid defining a second mobile layer below the printing area. A polymerizable resin overlays the inhibition liquid and flows into the printing area. Positioning of an object carrier controlled such that a lower surface of the object carrier is initially located within the polymerizable resin and within the printing area. Operation of a resin curing device beneath the bottom wall provides light to the printing area polymerizing predetermined portions of the polymerizable resin forming an object attached to the lower surface of the object carrier.