Automated Resin Handling Module for Stereolithography
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Stereolithography systems face challenges with high costs and variability due to human labor, necessitating automation to improve fabrication repeatability and productivity for manufacturing applications.
Innovation Solution
A three-dimensional printing system incorporating a vertical support, support plate, resin vessel, resin handling module, latch, and interface mechanism, which includes a fluid outlet and fluid level sensor, to automate the resin dispensing and leveling process, ensuring consistent resin flow and reducing human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual resin handling is used in stereolithography systems, then the system is simpler and easier to operate, but human labor costs increase and variability in fabrication quality occurs
Solution Approach 1:
The resin handling module performs automated resin dispensing and the interface mechanism automatically levels the resin surface, enabling the system to service itself without human intervention. This self-service capability eliminates human variability while maintaining consistent fabrication quality across multiple builds.
Solution Approach 2:
The interface mechanism pre-levels the resin surface before each stereolithography build begins, and the resin handling module pre-positioned resin in the vessel. These preliminary actions ensure consistent starting conditions for each fabrication run, improving repeatability without requiring complex real-time adjustments during building.
2Productivity
If automated resin handling is implemented, then productivity and consistency improve, but the device complexity and initial cost increase
Solution Approach 1:
The interface mechanism serves multiple functions: it levels the resin surface, positions the resin handling module, and ensures proper alignment of the resin vessel. The resin handling module both dispenses resin and monitors resin levels. This multi-functionality increases productivity while limiting the growth of system complexity by having components perform multiple tasks.
Solution Approach 2:
The patent combines the resin dispensing function and resin leveling function into an integrated resin handling module and interface mechanism assembly. This merging of functions improves productivity by automating multiple operations simultaneously while managing system complexity through integrated design rather than separate independent systems.
3Manufacturing precision
If manual operation is used, then device complexity is lower, but human error and variability in resin dispensing and leveling increase
Solution Approach 1:
The interface mechanism replaces manual mechanical leveling operations with an automated mechanical system that uses actuators and sensors to precisely control resin surface level. This substitution eliminates human error in judging and achieving proper resin leveling, improving manufacturing precision while introducing controlled mechanical complexity that is more reliable than manual operations.
Solution Approach 2:
The resin handling module incorporates sensors that monitor resin levels and provide feedback to the control system. This feedback mechanism enables automated adjustment of resin dispensing and leveling operations, ensuring consistent precision without requiring complex manual measurement and adjustment procedures.
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
The system enhances fabrication repeatability and productivity by minimizing human error and variability, enabling more efficient and consistent production of three-dimensional articles through automated resin handling and curing processes.
Implementation Method 1
stereolithography printers having a general principle of operation including the selective curing and hardening of radiation curable (photocurable) liquid resins
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A three dimensional printing system includes a vertical support (4), a support plate (10), a resin vessel (20), a resin handling module (150), a latch (152), and an interface mechanism (60). The support plate has a proximal end affixed to the vertical support and extends along a first lateral axis to a distal end. The resin vessel is supported by the support plate and includes a vessel body (82) and a transparent sheet (55). The vessel body has a latch feature (92) formed therein. The resin handling module includes a fluid outlet (30) for dispensing resin into the resin vessel. The interface mechanism is configured to move the latch into engagement with the latch feature and to move the resin handling module from a non-operating position to an operating position whereby the fluid outlet is operably positioned over a portion of the resin vessel.