Resin Batch Characterization for Accurate Additive Manufacturing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

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 databases and unique identifiers for efficient data transfer and storage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If operating parameters are tuned for specific resin types to improve accuracy, then manufacturing precision is improved, but batch-to-batch variations in resin characteristics have substantial detrimental effect on performance

Engineering Contradiction:

ImproveaccuracyVSAvoidconsistency

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies parameter changes by dynamically adjusting operating parameters (exposure time, light intensity, temperature, viscosity) based on measured resin batch characteristics. Each resin batch is characterized for its specific properties, and the operating parameters are modified accordingly to maintain optimal performance across different batches, thereby resolving the contradiction between achieving high precision and maintaining consistency.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements feedback by measuring the actual characteristics of each resin batch and using this information to adjust operating parameters. The system continuously monitors resin properties such as photosensitivity and viscosity, and automatically modifies the print program based on these measurements, ensuring that accuracy is maintained despite batch-to-batch variations.

Inventive Principle:

Principle #23Feedback

2Productivity

If speed of object production is enhanced, then productivity is improved, but accuracy of object production decreases

Engineering Contradiction:

Improvespeed of object productionVSAvoidaccuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies dynamics by making the operating parameters adaptive rather than static. The system dynamically adjusts exposure times, light intensities, and other parameters based on real-time resin batch characteristics and production requirements. This allows the system to optimize for speed when appropriate while maintaining accuracy when needed, resolving the contradiction between productivity and precision.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If a greater variety of resin types are utilized to produce objects with greater variety of properties, then adaptability is improved, but optimization of manufacturing performance on each apparatus becomes more complex

Engineering Contradiction:

Improvevariety of resin typesVSAvoidoptimization complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies universality by creating a standardized characterization and parameter adjustment framework that works across multiple resin types and apparatus configurations. The system uses a universal approach to measuring resin properties (viscosity, photosensitivity, etc.) and adjusting operating parameters, making the system adaptable to various resin types without proportionally increasing complexity. The modular architecture allows the same basic process to handle different resin types efficiently.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 characteristics by tailoring 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

PatentUS11801643B2Performance optimization in additive manufacturing

Publication Date: 2023.10.31 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.