Photocurable Resin Recirculation in Vat 3D Printing
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Solution Overview
Problem
Existing additive manufacturing apparatuses lack a suitable resin circuit for implementing internal resin recirculation and recycling of photocurable resin, which is essential for practical handling and efficient operation.
Innovation Solution
The apparatus incorporates a resin supply system with a resin container, conveying device, and agitating device, along with a closed resin supply cycle, enabling internal resin recirculation and recycling, and includes features like a flexible membrane, build platform, and irradiation devices for precise resin handling and curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional vat device is used without a resin supply system, then the apparatus structure is simple, but resin recirculation and recycling cannot be implemented
Solution Approach 1:
The vat device is segmented into a vat body and a separate flexible membrane component. The membrane can be detached and replaced, allowing the resin supply system to be integrated modularly without complicating the entire apparatus structure. This segmentation enables resin recirculation functionality while maintaining structural simplicity.
Solution Approach 2:
The flexible membrane serves multiple functions: it acts as a barrier between resin and the irradiation device, enables resin recirculation through its permeability properties, and can be replaced for cleaning or maintenance. This multi-functionality allows resin recirculation capability to be added without proportionally increasing device complexity.
2Reliability
If photocurable resin is processed without an agitating device, then the apparatus structure is simple, but resin quality deteriorates during processing
Solution Approach 1:
The agitating device is designed to automatically agitate the resin during the additive manufacturing process without requiring manual intervention. The device integrates with the existing apparatus structure, allowing resin quality maintenance through self-agitation while minimizing additional complexity.
Solution Approach 2:
The agitating device is merged with the resin supply system and vat device structure. The agitation mechanism is integrated into the existing apparatus components, allowing resin quality maintenance without adding separate, complex external systems.
3Productivity
If manual resin handling is used, then the apparatus structure is simple, but operational efficiency is low
Solution Approach 1:
Manual resin handling operations are replaced with an automated resin supply system that uses conveying devices and controlled flow mechanisms. This substitution eliminates manual intervention, improving operational efficiency while the system is designed to integrate smoothly with the existing apparatus.
Solution Approach 2:
The resin supply system enables continuous resin delivery and recirculation throughout the additive manufacturing process. Resin is continuously supplied to the vat, circulated through the membrane, and replenished as needed, eliminating interruptions and improving productivity without requiring overly complex batch processing systems.
4Loss of substance
If resin is not recirculated, then the apparatus structure is simple, but resin waste increases
Solution Approach 1:
Instead of discarding used resin, the system recovers and recirculates it through the flexible membrane and resin supply line. The membrane allows selective passage of resin components, and the recirculation system continuously replenishes the vat, significantly reducing resin waste while the circuit design remains relatively simple.
Solution Approach 2:
The resin recirculation system operates continuously during the additive manufacturing process, constantly circulating and replenishing resin in the vat. This continuous action maximizes resin utilization and minimizes waste without requiring complex intermittent processing systems.
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 configuration allows for efficient handling and recycling of photocurable resin, maintaining resin quality and facilitating automated cleaning, thereby enhancing the operational efficiency and versatility of the additive manufacturing process.
Implementation Method 1
The membrane is typically, transmissive to electromagnetic radiation (light) emitted from the at least one irradiation device of the apparatus
Implementation Method 2
an irradiation device, e.g. a digital light projector device, configured to emit electromagnetic radiation to selectively and successively cure the photocurable resin provided in the vat volume
Data Source
AI summary
An additive manufacturing apparatus for additively manufacturing a three-dimensional object by curing a photocurable resin, comprising:a vat device delimiting a vat volume for receiving a photocurable resin;a build platform device comprising a build platform being moveably supported relative to the vat device in at least one degree of freedom of motion;at least one irradiation device configured to emit electromagnetic radiation to selectively and successively cure the or a resin provided in the vat volume to additively manufacture a three-dimensional object;a resin supply device, the resin supply device configured to supply photocurable resin from at least one resin container to the vat device, the resin supply device comprising:at least one resin container delimiting a container volume for receiving a photocurable resin, andat least one resin conveying device configured to convey photocurable resin from the container volume to the vat device.