3D Printer Resin Replenishment via Dynamic Pumping
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Solution Overview
Problem
Three-dimensional (3D) printers using photocurable resins face issues with 'fouling' of transparent sheets and resin depletion, leading to operational interference and quality degradation due to stress imparted by up and down motion during large cross-sectional builds, necessitating a system that maintains high speed without compromising quality.
Innovation Solution
Incorporating a spatial light modulator, pressure-sensitive transducer, and controller to dynamically adjust translation velocity and pump cycle parameters based on real-time sensor feedback, ensuring optimal resin flow and minimizing stress on the 3D article, while maintaining laminar flow and avoiding turbulent flow regimes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the support surface moves up and down rapidly to replenish resin, then resin replenishment speed is improved, but stress on the 3D article increases causing quality degradation
Solution Approach 1:
The patent replaces the mechanical up-and-down motion of the support surface with a pumping system that uses fluid pressure to replenish resin. The pump delivers resin directly to the build plane through the transparent sheet, eliminating the need for mechanical motion and the associated stresses on the 3D article while maintaining high resin replenishment speed
Solution Approach 2:
The patent employs a pumping system that uses hydraulic principles to deliver resin through the transparent sheet to the build plane. The pump creates pressure differential to move resin against gravity and through the sheet, enabling rapid resin replenishment without mechanical motion of the support surface
2Quantity of substance
If the support surface moves up and down to replenish resin, then resin supply is improved, but processing time increases due to slower motion
Solution Approach 1:
The patent replaces the mechanical up-and-down motion system with a direct pumping system that can deliver resin rapidly to the build plane. The pump can maintain continuous resin supply at high speed without the cycle time constraints of mechanical motion, reducing processing time while ensuring adequate resin supply
Solution Approach 2:
The pumping system enables continuous resin delivery to the build plane, eliminating the intermittent nature of up-and-down motion. The pump can operate continuously to replenish resin as it is consumed by the light engine, maintaining uninterrupted printing operation and reducing total processing time
3Object-affected harmful factors
If chemical inhibitors are used to prevent fouling, then transparent sheet cleanliness is improved, but resin curing effectiveness may be reduced
Solution Approach 1:
The patent extracts and removes the chemical inhibitors from the system by using a pumping mechanism to actively replenish resin through the transparent sheet. This prevents chemical residue buildup that causes fouling while maintaining full resin curing effectiveness, as no inhibitors are present to interfere with the photopolymerization process
Solution Approach 2:
The patent replaces chemical inhibition methods with a mechanical pumping system that prevents fouling through active resin renewal. The pump continuously delivers fresh resin to the build plane, preventing polymer accumulation on the transparent sheet without using chemical inhibitors that would compromise curing effectiveness
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 enables high-speed 3D printing with improved quality by reducing stress on the 3D article and maintaining optimal resin flow, preventing fouling and resin depletion, thus enhancing operational efficiency and product quality.
Implementation Method 1
The light engine transmits pixelated light up through the transparent sheet to selectively cure a layer of the photocurable resin onto the support surface
Data Source
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AI summary
A three dimensional printer includes a vessel, a light engine, a fixture, a movement mechanism, a sensor, and a controller. The vessel is for containing a liquid photocurable resin and includes a transparent sheet defining a lower surface through which the resin can be illuminated. The light engine is disposed and configured to selectively illuminate the resin through the transparent sheet. The fixture is for supporting a three dimensional article of manufacture having a lower face immersed in the resin in facing relation with the transparent sheet. The movement mechanism is configured for controllably translating the fixture to adjust a vertical height of the lower face above the transparent sheet. The sensor is configured to monitor a dynamic vertical drag force of the resin upon the three dimensional article of manufacture.