3D Ray-Traced VAM Dose Optimization for Print Fidelity

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Solution Overview

Problem

Existing volumetric additive manufacturing (VAM) technologies face limitations in print fidelity due to non-telecentricity and etendue issues, which affect the precision and size of printed objects, and are inefficient in light delivery, leading to thermal loss and reduced build volume.

Innovation Solution

A method using three-dimensional ray tracing to model optical effects such as refraction, transmission loss, absorption, and non-telecentricity, allowing for accurate computation of light dose distribution in the print volume, enabling improved print fidelity without additional hardware.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If telecentric focusing optics with minimal etendue are used to achieve parallel rays, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improveprint fidelityVSAvoidoptical system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent transforms the optical system from a physical telecentric configuration to a computational model that simulates telecentric ray behavior through software algorithms. This parameter change allows the system to achieve equivalent manufacturing precision without the complex optical hardware, thereby resolving the contradiction between print fidelity and device complexity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical/optical telecentric system with a computational ray-tracing model. Instead of using physical optics to achieve parallel rays, the system uses software to calculate and correct for non-telecentric effects, substituting a complex mechanical system with a computational approach that achieves the same result with simpler hardware

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If system aperture is increased to increase light output, then productivity is improved, but manufacturing precision deteriorates due to compromised etendue

Engineering Contradiction:

Improvelight outputVSAvoidprint fidelity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements a feedback mechanism where the computational ray-tracing model continuously calculates the actual light delivery patterns and uses this information to adjust the projected images. This feedback loop allows the system to maintain manufacturing precision even with larger aperture by dynamically compensating for any precision losses through software correction

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts projection parameters based on the computational model's calculations, changing the projection patterns to compensate for the effects of larger aperture. This parameter adjustment allows the system to achieve both high light output and maintained print fidelity

Inventive Principle:

Principle #35Parameter changes

3Productivity

If LED current is increased to increase light output, then productivity is improved, but loss of energy increases due to thermal loss

Engineering Contradiction:

Improvelight outputVSAvoidthermal loss

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent changes the operational parameters of the LED source by using pulsed illumination patterns optimized by the computational model. Instead of continuous high-current operation that generates heat, the system uses optimized pulse sequences that deliver the required light output with lower average power consumption and reduced thermal loss

Inventive Principle:

Principle #35Parameter changes

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

Enhances print fidelity and build volume by accurately modeling non-telecentricity and etendue in three dimensions, resulting in higher quality and larger printed objects without the need for an index-matching bath.

Implementation Method 1

three-dimensional ray tracing of light rays from a pixel array through the rotating vial thereby modelling optical effects on the light rays in three dimensions as they pass through the rotating vial

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

modelling optical effects such as refraction, transmission loss, absorption, and non-telecentricity

Methodology Applied

Scientific EffectAbsorption: Absorption (EM radiation)

Implementation Method 3

photocurable resin is exposed to spatially structured (i.e. 3D) light that causes the resin to cure

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS20260102975A1Method of volumetric additive maufacturing via 3D ray-tracing dose optimization

Publication Date: 2026.04.16 NAT RES COUNCIL OF CANADA

AI summary

A method and apparatus are set forth for volumetric additive manufacturing (VAM) wherein light rays that are used to determine tomographic projections are modelled using ray tracing, in order to account for projector non-telecentricity and etendue in all three dimensions. The path of rays from each light source (e.g. pixel) are computed as they propagate through the VAM system. Optical effects such as refraction, transmission loss, absorption, etendue, and non-telecentricity are intrinsically accounted for via ray tracing. Using these rays, the required dose to solidify the photosensitive resin is computed.