Electronic Light Projector Edge Pattern Superimposition
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Solution Overview
Problem
Existing methods for exposing photo polymerizable materials in 3D printing and 2D lithography often result in undesired non-continuous effects at the edges of adjacent exposure stripes due to variations in image positioning and brightness uniformity, leading to discontinuities and non-exposed areas.
Innovation Solution
A system comprising an electronic light projector and an exposure table that moves relative to each other, with a projector control unit superimposing a static image pattern of narrower width onto the edges of images to be exposed, ensuring smooth transitions and uniformity between adjacent exposure stripes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If exposure stripes are placed close together to improve productivity, then exposure efficiency is improved, but discontinuities and non-continuous effects occur at the edges due to positioning variations and brightness non-uniformity
Solution Approach 1:
A static image pattern is pre-calculated and superimposed onto the edge sections of the images to be exposed. This preliminary action compensates for the expected brightness variations and positioning deviations before exposure occurs, ensuring continuous power transitions at the edges of adjacent exposure stripes while maintaining high productivity
Solution Approach 2:
The static image pattern is applied specifically to the edge sections of the images rather than the entire image area. This local application targets the problematic edge regions where discontinuities occur, leaving the central regions unchanged and maintaining overall exposure quality while ensuring continuity at stripe boundaries
2Manufacturing precision
If strict brightness uniformity and image positioning precision are required to eliminate edge effects, then exposure quality is improved, but machine complexity and cost increase
Solution Approach 1:
The patent replaces the need for precise mechanical positioning and brightness uniformity control with a computational approach. By calculating and superimposing a static image pattern that compensates for expected variations, the system achieves high exposure quality without requiring expensive precision mechanics or complex brightness uniformity control systems
3Reliability
If overlap zones are applied between adjacent exposure stripes to ensure coverage, then completeness of exposure is improved, but overexposure occurs in the overlap regions
Solution Approach 1:
The static image pattern is applied specifically to the edge sections where overlap zones occur, with a width that is slimmer than the full image width. This local application ensures that the compensation is targeted at the overlap regions, maintaining complete coverage while preventing overexposure through controlled power distribution in these specific zones
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 ensures continuous power and position transitions between adjacent exposure stripes, improving the quality of the exposure result by eliminating discontinuities and non-exposed areas, thereby reducing the need for expensive machine components and enhancing brightness uniformity.
Implementation Method 1
exposing a photo polymerizable material for solidification of material layer by layer to build a 3D object
Data Source
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AI summary
A system for exposing a material with images comprises an exposure table (12) and an electronic light projector (13) arranged above the exposure table (12) and being adapted to project images towards a material arranged at the exposure table (12). The electronic light projector and the exposure table are configured to be moved relative each other and the electronic light projector (13) is connected to a projector control unit. The projector control unit is configured to provide a sequence of images to be exposed represented by image data, superimpose a static image pattern onto the edge sections of the images to be exposed, resulting in a sequence of combined images, and the electronic light projector (13) is configured to expose the combined images sequentially onto the material.