3D Printing Resin Level Control via Volume Compensator
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Solution Overview
Problem
3D printing systems face challenges in maintaining a level build plate surface, leading to defective articles due to non-parallel or non-level resin surfaces, which requires excessive base layers to ensure a flat surface for fabrication, increasing material usage and processing time.
Innovation Solution
A three-dimensional printing system that includes a resin vessel, imaging system, build plate, vertical positioner, resin level sensor, and volume compensator, where a controller analyzes signals from a compensation volume position sensor to maintain the resin level within a tolerance range, allowing for the efficient formation of base layers and subsequent 3D articles by determining when the surface is level enough to start fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the build plate is not perfectly parallel to the resin surface, then the system can operate with simpler positioning, but the article quality deteriorates due to defective articles from non-parallel surfaces
Solution Approach 1:
The system employs a resin level sensor to continuously monitor the resin surface position and provides feedback to the volume compensator. This closed-loop feedback mechanism allows the system to automatically adjust the build plate positioning to maintain parallelism with the resin surface, thereby ensuring high geometric accuracy without requiring overly complex manual positioning systems
Solution Approach 2:
The volume compensator automatically adjusts the build plate position based on real-time resin level measurements, enabling the system to self-correct positioning errors without external intervention. This self-service capability maintains manufacturing precision while keeping the positioning system relatively simple
2Manufacturing precision
If excessive base layers are formed to ensure a level surface, then the surface quality improves, but the processing time and material usage increase
Solution Approach 1:
The resin level sensor and volume compensator are activated before base layer formation begins, performing preliminary leveling of the resin surface. This preliminary action ensures the surface is adequately leveled before fabrication starts, eliminating the need to form excessive base layers just to achieve levelness, thus reducing processing time while maintaining surface quality
Solution Approach 2:
The system replaces the mechanical approach of forming multiple base layers to achieve leveling with a sensor-based detection and automated compensation system. The resin level sensor detects surface variations and the volume compensator mechanically adjusts the build plate position, substituting the need for excessive material deposition and reducing processing time
3Manufacturing precision
If excessive base layers are formed to ensure a level surface, then the surface quality improves, but the material consumption increases
Solution Approach 1:
The system performs preliminary resin surface leveling using the volume compensator before base layer formation, ensuring the surface is adequately prepared without requiring excessive base layers. This preliminary action reduces resin material consumption while maintaining the necessary surface levelness for quality fabrication
Solution Approach 2:
The system replaces the material-intensive mechanical approach of forming multiple base layers with a sensor-guided volume compensation system. The resin level sensor detects surface variations and the volume compensator adjusts the build plate position, substituting resin material consumption with precise mechanical positioning to achieve surface levelness
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 minimizes the number of base layers required to achieve a level surface, reducing material usage and processing time while ensuring geometric accuracy and enabling the efficient fabrication of 3D articles.
Implementation Method 1
The CVPS may be any type of sensor suitable for sensing menisci formation
Implementation Method 2
An article is manufactured in a layer-by-layer manner by selectively imaging and solidifying layers of the resin over the build plate
Data Source
AI summary
A three-dimensional (3D) printing system includes a resin vessel containing photocurable resin, an imaging system, a build plate with a plate upper surface, a vertical positioner, a volume compensator (VC), and a controller. The controller is configured to: (a) operate the VC to maintain a resin upper surface proximate to a build plane, (b) operate the imaging system and the vertical positioner to generate a plurality of base layers upon the plate upper surface, (c) receive a first signal responsive to vertical motion of the resin upper surface, (d) analyze the first signal to determine a metric that is related to an extent of immersion of the plate upper surface below the resin upper surface during formation of the base layers, and (e) operate the imaging system and the vertical positioner to begin generation of the 3D article after the metric has reached a predefined threshold.