Resin Batch Parameter Tuning for Accurate Additive Manufacturing

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Solution Overview

Problem

Additive manufacturing techniques, such as stereolithography, face challenges in maintaining accuracy and consistency due to batch-to-batch variations in resin characteristics, making it difficult to optimize performance across different resin types and apparatus configurations.

Innovation Solution

A method involving the blending and characterization of distinct resin batches, assigning unique identities, and modifying operating instructions based on physical characteristics to enhance performance characteristics like accuracy and speed, using a database to store and retrieve resin-specific parameters for each batch.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the speed of object production is increased in additive manufacturing, then productivity is improved, but manufacturing precision deteriorates

Engineering Contradiction:

Improvespeed of object productionVSAvoidaccuracy of object production

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent modifies operating parameters (exposure time, light intensity, layer height) based on the specific physical characteristics of each resin batch. By dynamically adjusting these parameters, the system maintains manufacturing precision even when production speed is increased, resolving the contradiction between productivity and precision.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system incorporates feedback mechanisms where resin batch characteristics are measured and used to automatically adjust operating instructions. This closed-loop control ensures that precision is maintained across varying production speeds by continuously adapting parameters based on actual resin properties.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If operating parameters are tuned for specific resin types to improve manufacturing precision, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improveaccuracy of object productionVSAvoidcomplexity of operating instructions

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system automatically determines resin batch characteristics and generates appropriate operating instructions without requiring manual intervention. The apparatus self-adjusts parameters based on measured resin properties, reducing the complexity burden on operators while maintaining high manufacturing precision.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Resin batch characteristics are determined in advance before manufacturing begins. Operating instructions are pre-configured based on these characteristics, allowing the system to maintain precision without requiring complex real-time adjustments during the manufacturing process.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If resin batches are customized for specific applications to improve manufacturing precision, then manufacturing precision is improved, but ease of operation deteriorates

Engineering Contradiction:

Improveaccuracy of object productionVSAvoidease of using different resin batches

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The system is designed to universally handle multiple resin batches with different characteristics through a single automated process. The apparatus can determine characteristics and adjust parameters for any resin type, making it easy to operate across diverse materials while maintaining precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Manual parameter adjustment and resin selection processes are replaced with automated optical and electronic characterization systems. The apparatus automatically measures resin properties and configures operating parameters, eliminating the need for manual intervention and simplifying operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 allows for optimized performance by adapting operating parameters to specific resin batches, improving accuracy and reliability in additive manufacturing processes, even with varying resin types and properties.

Implementation Method 1

create a three-dimensional object by the sequential polymerization of a light polymerizable resin

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS20240009933A1Performance optimization in additive manufacturing

Publication Date: 2024.01.11 CARBON INC

AI summary

A method of enhancing a performance characteristic of an additive manufacturing apparatus, the method including:(a) dispensing a batch of a light polymerizable resin into the additive manufacturing apparatus, the batch characterized by at least one physical characteristic;(b) determining the unique identity of the batch;(c) sending the unique identity of the batch to a database; then(d) either: (i) receiving on the controller from the database modified operating instructions for the resin batch, which modified operating instructions have been modified based on the at least one physical characteristic, or (ii) receiving on the controller from the database the at least one physical characteristic for the specific resin batch and modifying the operating instructions based on the at least one physical characteristic; and then(e) producing the object from the batch of light polymerizable resin on the additive manufacturing apparatus with the modified operating instructions.