Replaceable Optical Module for Tool-Free 3D Printer Calibration
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Solution Overview
Problem
The process of replacing and calibrating UV projectors in 3D printers is complex, time-consuming, and requires specialized tools and expertise due to the need for precise alignment and adjustment of optical components, which is exacerbated by variations between different projectors.
Innovation Solution
A replaceable optical module design for 3D printers that includes a detachable and pre-calibrated unit containing key components like the light valve and control circuit board, allowing for easy installation and alignment during manufacturing, eliminating the need for further calibration post-installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the UV projector is replaced as a whole unit, then the image performance and projection area can be maintained, but the replacement process becomes complex and time-consuming due to the need for specialized jigs and programs to adjust the optical engine position
Solution Approach 1:
The patent divides the UV projector into two main segments: a standardized optical engine module and a printer chassis. The optical engine module is designed as a replaceable unit that can be detached and replaced without requiring adjustment of the printer chassis or specialized alignment tools. This segmentation allows the optical engine to be replaced as a complete pre-assembled unit, eliminating the need for complex adjustment procedures while maintaining image performance and projection area specifications.
2Reliability
If the light valve component is replaced, then the damaged component can be renewed, but the replacement process becomes complex requiring disassembly of casing, heat dissipation module, circuit boards, and other components
Solution Approach 1:
The patent merges the light valve component with the optical engine module, assembling them into a single integrated replaceable unit. This combination includes the light valve, its mounting structure, and associated components all pre-assembled together. When replacement is needed, the entire optical engine module is replaced as one unit rather than disassembling individual components like the light valve, casing, heat dissipation module, and circuit boards separately. This merging dramatically simplifies the repair process while ensuring component functionality.
3Manufacturing precision
If the lens is adjusted after DMD replacement, then image center alignment and resolution can be maintained, but the replacement process becomes more time-consuming
Solution Approach 1:
The patent implements preliminary action by pre-assembling and pre-aligning the optical engine module during manufacturing. The lens and light valve are positioned and aligned precisely before the module is sealed and delivered to the customer. This pre-performed alignment eliminates the need for time-consuming post-installation adjustment of the lens to maintain image center alignment and resolution. The module is designed to be replaced as a complete pre-aligned unit, significantly reducing replacement time while maintaining manufacturing precision.
4Reliability
If specialized jigs and programs are used for projector replacement, then the replacement projector can achieve specified image performance, but the maintenance process requires substantial manpower and technical expertise
Solution Approach 1:
The patent enables self-service maintenance by designing the optical engine module as a standardized, plug-and-play replacement unit. The module includes integrated mounting structures and connection interfaces that allow customers to replace the optical engine themselves without requiring specialized jigs, programs, or technical expertise. The standardized design ensures that replacement modules from different manufacturers can be directly installed while maintaining specified image performance, eliminating the need for complex adjustment procedures and reducing maintenance complexity.
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
Simplifies maintenance by enabling direct replacement of pre-calibrated optical modules, reducing maintenance time and labor, and allowing users to perform self-replacement without specialized tools or expertise.
Implementation Method 1
a light valve (325) that modulates the image beam
Implementation Method 2
an optical projection engine (328) that projects the image beam onto a photosensitive material
Implementation Method 3
a tank (21) for accommodating a photosensitive material... the optical projection engine (328) projects the image beam onto the photosensitive material
Data Source
AI summary
A three-dimensional printer includes a printer main body, a printer chassis and an optical module. The printer main body includes a tank for accommodating a photosensitive material, a light-transmissive plate located at a bottom of the tank, and a printing platform adjacent to the tank. The printer chassis includes at least one base plate and defines a storage space outwardly connected to an external environment. The optical module is capable of being detached from the printer main body, the optical module is capable of being fixed in the storage space, and the optical module is capable of being entirely withdrawn from the storage space to the external environment in a single motion.