3D Printed Resin Post-Curing for Surface Crack and Pore Repair
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Solution Overview
Problem
Existing 3-D printing methods using light-curing resin formulations face issues such as time-consuming curing, surface distortions, and the presence of uncured residues and filler particles that affect the final shape and strength of the printed objects, necessitating complex and potentially damaging aftertreatments.
Innovation Solution
A method involving exposure of the 3-D object to an aftertreatment fluid with a light-curing resin formulation that penetrates into surface fissures and pores due to capillarity, followed by removal and post-curing to enhance surface quality and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional stereolithography with focused laser beam scanning is used, then 3-D objects can be printed layer-by-layer, but the process becomes time-consuming and causes edge region distortions in larger objects
Solution Approach 1:
The patent uses a micromirror unit that copies the light source pattern across multiple points simultaneously, rather than scanning a single focused beam point-by-point. This allows parallel curing of multiple resin points, dramatically increasing printing speed while maintaining curing accuracy through precise micromirror positioning.
Solution Approach 2:
The patent transitions from one-dimensional laser scanning to two-dimensional parallel curing by using an array of micromirrors that can independently direct light to different spatial coordinates, enabling simultaneous multi-point curing across the resin surface.
2Manufacturing precision
If manual grinding, jet-blasting and polishing are performed to achieve high surface quality, then surface fissures and pores can be removed, but the object may no longer conform accurately to the originally desired shape
Solution Approach 1:
The patent changes the physical state of uncured resin from liquid to solid through post-curing, causing it to shrink and pull away from surface fissures and pores. This parameter change (curing state) automatically removes surface defects without mechanical intervention that could alter the object's shape.
Solution Approach 2:
The patent replaces mechanical surface treatment methods (grinding, jet-blasting, polishing) with a chemical/optical process (post-curing) that achieves surface defect removal through resin shrinkage, eliminating the need for contact-based mechanical operations that risk shape distortion.
3Strength
If filler particles are added to increase strength under high stress, then the 3-D object becomes stronger, but filler particles remain on the surface after cleaning and adversely affect surface shape and properties
Solution Approach 1:
The patent applies a release agent to the mold cavity before printing, creating a preliminary protective layer that prevents uncured resin and filler particles from adhering to the object surface. This preliminary action ensures that even with filler-containing resin, the surface remains clean and defect-free.
Solution Approach 2:
The patent introduces a release agent as an intermediary substance between the mold cavity and the resin formulation. This mediator prevents direct contact and adhesion between uncured resin/filler particles and the object surface, allowing clean separation after printing while maintaining surface quality.
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 method improves surface quality and increases the strength of 3-D objects by effectively removing uncured residues and filler particles, ensuring accurate shape retention and enhanced mechanical properties.
Implementation Method 1
the aftertreatment fluid can penetrate into a fissure or a pore on the surface of the 3-D object within the contact time owing to capillarity
Implementation Method 2
irradiating the 3-D object with light for post-curing of the light-curing resin formulation used to print the 3-D object and curing the aftertreatment fluid that has penetrated into fissures and/or pores
Data Source
AI summary
The invention relates to a method for the post-treatment of 3D objects (10) printed from a light-curing resin formulation. A 3D object (10) removed from a 3D printer is post-treated according to the following steps: a) exposing the surface (11) of the 3D object (10) to a post-treatment liquid (16) comprising a light-curing resin formulation for a prescribed exposure time, wherein the post-treatment liquid (16) and the exposure time are chosen such that the post-treatment liquid (16) can penetrate into a crack (12) or a pore (13) on the surface (11) of the 3D object within the exposure time as a result of capillarity; b) removing the post-treatment liquid (16) remaining on the surface of the 3D object (10); and c) irradiating the 3D object (10) with light for post-curing the light-curing resin formulation used for the printing of the 3D object (10) and curing the post-treatment liquid (16) that has penetrated into cracks (12) and/or pores (13) on the surface (11) of the 3D object (10).