3D Printing Pulse Imaging With Mirror Redundancy for Resolution
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Solution Overview
Problem
Current three-dimensional printing systems face challenges in achieving high resolution and speed in the imaging process, particularly in selectively curing or fusing materials using energy sources like lasers.
Innovation Solution
A three-dimensional printing system incorporating a motorized build platform, a pulsed light source, a two-dimensional mirror array, and a controller that scans the imaging module over the build plane, utilizing a redundancy mechanism to ensure high resolution and reliability by controlling individual mirrors between ON and OFF states during the dark state of the pulsed light source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a laser imaging system is used to selectively cure or fuse materials in 3D printing, then the manufacturing capability is improved, but the resolution and speed are insufficient
Solution Approach 1:
The patent employs pulsed light sources that emit radiation in periodic pulses rather than continuous illumination. This periodic action allows the system to achieve high resolution by concentrating energy in short bursts while maintaining high speed through rapid repetition of pulses, effectively resolving the contradiction between manufacturing precision and productivity in the imaging process
Solution Approach 2:
The patent implements dynamic scanning of the imaging module across the build plane during pulsed illumination. The scanning motion is synchronized with the pulsed light emission, creating a dynamic imaging approach that covers the entire build area rapidly. This dynamic operation enables both high resolution (through focused pulsed illumination) and high speed (through rapid scanning coverage)
2Measurement precision
If a mirror array is used to scan the imaging module, then the imaging capability is improved, but malfunctioning mirror elements can degrade performance
Solution Approach 1:
The patent implements a redundancy mechanism where multiple mirrors in the mirror array are assigned to address the same location on the build plane. This beforehand cushioning ensures that if one mirror malfunctions, other mirrors can compensate by taking over its imaging responsibilities, thereby maintaining system reliability without compromising imaging precision
3Area of stationary object
If continuous light illumination is used, then the imaging coverage is improved, but the resolution and contrast ratio are reduced
Solution Approach 1:
The patent uses pulsed light illumination instead of continuous light. The periodic pulsing creates high contrast ratios by providing intense illumination during pulse moments followed by complete darkness between pulses. This enables clear distinction between cured and uncured material regions while maintaining comprehensive build plane coverage through the scanning motion during the pulse cycle
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 the resolution and speed of the imaging process, allowing for more precise control over the curing of materials and reducing the impact of malfunctioning mirror elements, while also enabling the creation of detailed three-dimensional articles with improved contrast ratios.
Implementation Method 1
a pulsed light source, an imaging module, a movement mechanism, and a controller. The imaging module receives radiation from the pulsed light source
Implementation Method 2
The imaging module receives radiation from the pulsed light source and includes a two-dimensional mirror array defining N rows and M columns of mirrors
Implementation Method 3
Some of these three dimensional printing systems utilize the application of energy to selectively cure or fuse materials
Implementation Method 4
The energy is applied using imaging systems such as lasers
Data Source
AI summary
A three-dimensional printing system for fabricating a three-dimensional article includes a motorized build platform, a dispensing module, a pulsed light source, an imaging module, a movement mechanism, and a controller. The imaging module receives radiation from the pulsed light source and includes a two-dimensional mirror array. The movement mechanism imparts lateral motion between the imaging module and the build platform. The controller is configured to operate the motorized build platform and the dispensing module to form a layer of build material at a build plane, operate the movement mechanism to laterally scan the imaging module over the build plane, operate the pulsed light source to generate a sequence of radiation pulses that illuminate the mirror array, and operate the mirror array to selectively image the build material.