Resin-Supported Additive Manufacturing for Consistent Layer Adhesion
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in efficiently forming complex three-dimensional components with precise control over layer formation and material composition, particularly in tape casting methods where resin support separation and layer adhesion can be inconsistent.
Innovation Solution
The apparatus employs a movable stage with actuator assemblies for precise movement in multiple axes, combined with a radiant energy device and a transparent resin support, allowing for the controlled deposition and curing of multiple resin layers with non-stick properties and selective use of fillers to enhance component integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tape casting process is used to form components layer-by-layer, then additive manufacturing capability is achieved, but inconsistent layer adhesion and resin support separation occur
Solution Approach 1:
The patent extracts the resin support from the final component structure by providing mechanisms for clean separation. The resin support is used temporarily during manufacturing to enable layer-by-layer construction, then systematically removed or separated from the cured layers, solving the adhesion inconsistency problem while maintaining manufacturing capability.
Solution Approach 2:
The patent applies preliminary actions by pre-coating the resin support with release agents or applying specific surface treatments before resin deposition. This preliminary preparation ensures consistent separation later while maintaining proper layer adhesion during the build process, resolving the contradiction between manufacturability and reliability.
2Manufacturing precision
If multiple resin layers are deposited and cured sequentially, then complex three-dimensional components are formed, but manufacturing time increases
Solution Approach 1:
The patent implements periodic action through automated cycles of resin deposition, curing, and resin support advancement. This rhythmic, repeating process sequence enables complex multi-layer components to be manufactured efficiently by optimizing the timing and coordination of each operation, balancing precision and productivity.
Solution Approach 2:
The patent maintains continuity of useful action by ensuring the resin support is continuously advanced and repositioned during the build process, with minimal idle time between layers. The automated coordination of deposition, curing, and support movement creates a continuous manufacturing flow, reducing total build time while maintaining component complexity.
3Manufacturing precision
If radiant energy is applied to cure resin through a transparent support, then layer-by-layer solidification is achieved, but control over curing depth and uniformity is difficult
Solution Approach 1:
The patent implements feedback control by monitoring the curing process and adjusting radiant energy parameters accordingly. Sensors detect the state of resin solidification and provide feedback to the control system, which then modulates the energy source to achieve precise curing depth and uniformity, managing complexity through intelligent control.
Solution Approach 2:
The patent controls curing characteristics by changing parameters of the radiant energy source, such as intensity, wavelength, or exposure duration. By systematically adjusting these parameters, the system achieves precise control over curing depth and uniformity without requiring overly complex device architecture, balancing precision and simplicity.
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 the formation of complex, monolithic three-dimensional components with improved layer adhesion and material consistency, facilitating the creation of components with enhanced structural integrity and material properties.
Implementation Method 1
Radiant energy is produced from a radiant energy device and directed through a window to cure the resin to a component that is supported by a stage in the build zone
Data Source
AI summary
An additive manufacturing apparatus includes a resin support configured to support a first resin and a second resin. A support plate includes a window. A stage is configured to hold one or more cured layers of the resin to form a component positioned opposite the support plate. A radiant energy device is positioned on an opposite side of the resin support from the stage and is operable to generate and project radiant energy in a patterned image through the window. An actuator assembly is configured to move the stage in a Z-axis direction and in a Y-axis direction.