Resin Conditioning Unit for Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing devices face inefficiencies in curable resin usage, leading to waste and layer irregularities during the buildup of three-dimensional objects, due to uncontrolled resin characteristics such as viscosity, humidity, and particle size, which result in lower quality final products.
Innovation Solution
The implementation of a resin conditioning unit that maintains and modifies the chemical composition, viscosity, humidity, and temperature of the curable resin, combined with a filter system to ensure particle sizes do not exceed a predetermined size, and a scraper for resin reuse, along with a variable height blade for precise layer deposition, enhances resin efficiency and layer quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If curable resin is applied directly without conditioning, then the process is simple, but resin characteristics such as viscosity, humidity, and particle size are uncontrolled, leading to layer irregularities and waste
Solution Approach 1:
The resin conditioning unit performs preliminary conditioning of the curable resin before it is applied to the build platform. The unit controls viscosity, humidity, and particle size of the resin in advance, ensuring optimal characteristics for layer deposition. This preliminary action prevents layer irregularities and reduces waste during the manufacturing process.
Solution Approach 2:
The resin conditioning unit actively adjusts and controls key parameters of the curable resin including viscosity, humidity, and particle size. By modifying these parameters to optimal ranges before application, the system ensures consistent layer quality and prevents defects during additive manufacturing.
2Loss of substance
If resin is reused without conditioning, then material waste is reduced, but resin characteristics deteriorate leading to layer irregularities
Solution Approach 1:
The system recovers curable resin that would otherwise be wasted during the additive manufacturing process. The resin collection mechanism gathers excess or partially used resin and returns it to the resin conditioning unit for reconditioning. This recovery process maintains material efficiency while preventing contamination and degradation through proper conditioning before reuse.
Solution Approach 2:
The resin conditioning unit implements a feedback loop where resin characteristics are continuously monitored and adjusted. When resin is collected for reuse, the unit assesses its current state and applies necessary conditioning adjustments to restore optimal viscosity, humidity, and particle size characteristics, ensuring consistent layer quality upon reuse.
3Manufacturing precision
If resin viscosity is not controlled, then application is easier, but layer thickness uniformity and quality are compromised
Solution Approach 1:
The resin conditioning unit precisely controls the viscosity parameter of the curable resin within optimal ranges for additive manufacturing. By maintaining viscosity within specified tolerances, the system achieves uniform layer thickness and high quality surfaces while ensuring the resin remains sufficiently fluid for smooth application through the dispensing 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 solution ensures higher quality three-dimensional objects by maintaining optimal resin characteristics, reducing waste, and preventing layer irregularities, thereby improving the overall efficiency and consistency of the additive manufacturing process.
Implementation Method 1
a radiation source (10) for radiation curing of the resin layer (6)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Additive manufacturing device for manufacturing a three dimensional object, having a foil substrate (2) and a resin depositor (4) for depositing a layer of curable resin (6) on a first side (2a) of the foil substrate (2), wherein the resin depositor (4) comprises an input side resin storage unit (5). A radiation source (10) is present for radiation curing the resin layer (6) on the first side (2a) of the foil substrate (2), wherein a cured resin layer (6) represents a cross sectional slice of a three dimensional object (12). A stage (9) is configured to hold a stacked arrangement of one or more cured resin layers representing at least in part the three dimensional object (12), and a positioning system is provided for relative positioning the foil substrate (2) and the stage (9). A resin conditioning unit (16) is provided upstream from the input resin storage unit (5).