Homogenizing Radiation Field in 3D Printing via Spatial Filtering
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Solution Overview
Problem
In three-dimensional article production by layer-by-layer solidification, existing technologies face challenges in achieving a homogeneous intensity distribution of the radiation field due to inhomogeneities caused by the optical system, leading to inconsistent material curing.
Innovation Solution
A correcting or filtering device is introduced between the radiation source and the build plane, featuring a substrate with a correcting or filtering coating that attenuates or deflects radiation inhomogeneities, ensuring a homogeneous intensity distribution by adapting to the specific inhomogeneities of the radiation field, thereby compensating for intensity variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an optical system including a radiation source and optical projection system is used for layer-by-layer solidification, then three-dimensional articles can be produced efficiently, but an inhomogeneous intensity distribution results in the build plane
Solution Approach 1:
The patent applies local quality by introducing a correcting device with spatially varying optical properties into the radiation path. The correcting device has different transmission or reflection characteristics at different locations to compensate for the inhomogeneous intensity distribution, ensuring uniform energy input across the build plane while maintaining high production efficiency
Solution Approach 2:
The correcting device serves as an intermediary element between the radiation source and the build plane. It mediates the inhomogeneous radiation field by selectively attenuating or redirecting radiation in specific regions, thereby producing a homogeneous intensity distribution without compromising the overall production efficiency
2Manufacturing precision
If computer-processed intensity corrections are continuously applied to homogenize the radiation field, then intensity distribution uniformity is improved, but device complexity and operational costs increase
Solution Approach 1:
The patent implements preliminary action by pre-configuring the correcting device with fixed optical properties that are designed to compensate for known inhomogeneities in the radiation field. This eliminates the need for continuous computer-processed corrections during operation, reducing device complexity while maintaining intensity distribution uniformity
Solution Approach 2:
The correcting device can be implemented as a simple, inexpensive optical element (such as a filtered glass plate or simple lens array) that replaces complex active correction systems. This static correcting element provides durable, maintenance-free operation without requiring continuous computational adjustments
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 homogenizes the radiation field, ensuring consistent material curing and reducing manufacturing costs by minimizing the need for continuous intensity corrections, allowing for the production of high-quality three-dimensional articles without constant computer-processed adjustments.
Implementation Method 1
A correcting or filtering device is introduced between the radiation source and the build plane, featuring a substrate with a correcting or filtering coating that attenuates or deflects radiation inhomogeneities
Implementation Method 2
A correcting or filtering device is introduced between the radiation source and the build plane, featuring a substrate with a correcting or filtering coating that attenuates or deflects radiation inhomogeneities
Data Source
AI summary
The invention relates to a device for correcting an inhomogeneous intensity distribution of a radiation field generated by a radiation source, in particular a radiation source for a device for producing three-dimensional articles by the layer-by-layer solidifying, in a build plane, of a material that is solidifiable under the action of radiation. The device comprises a correcting or filtering device that is to be introduced, between the radiation source and the build plane, into a radiation path of a device for producing three-dimensional articles by the layer-by-layer solidifying of a material that is solidifiable under the action of radiation. Further, improved methods for producing a device for correcting an inhomogeneous intensity distribution of a radiation field generated by a radiation source, and methods and devices for producing a three-dimensional article are proposed.