3D Printer Resin Tank Segmentation for Waste Reduction
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Solution Overview
Problem
Current 3D printing systems face challenges in accurately determining the amount of photosensitive resin needed for a print job, leading to incomplete prints or excess resin waste, and often require resin removal alongside debris, which complicates the process and results in further waste. Additionally, many systems lack a rigid interface between the lift arm and build platform, causing inaccurate printing.
Innovation Solution
A resin tank assembly with a scraper system that moves resin between a print area, storage area, and reflux area, along with a cartridge system that dispenses the correct amount of resin based on weight measurements, and an air heating assembly to maintain resin quality, while ensuring a rigid interface between the lift arm and build platform for accurate printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If resin is removed from the tank for debris cleaning, then debris can be removed, but resin is wasted
Solution Approach 1:
The resin tank is divided into multiple compartments: a print area for active printing, a storage area for excess resin, and a reflux area for resin that needs cleaning. This segmentation allows debris removal from the print area without removing resin from the storage and reflux areas, thereby eliminating resin waste during maintenance.
Solution Approach 2:
The system recovers resin by maintaining it in the storage and reflux areas separate from the print area. When debris cleaning is needed, only the print area is affected while the resin in other areas is preserved and can be reused, implementing a discard-and-recover strategy for resin management.
2Productivity
If excess resin is kept in the tank for future prints, then printing can continue without interruption, but resin waste increases
Solution Approach 1:
The resin tank segments resin into functional areas: print area for current printing, storage area for future use, and reflux area for regeneration. This allows the system to maintain printing continuity by having reserved resin in the storage area while managing excess resin efficiently through the reflux area for future regeneration.
Solution Approach 2:
The system changes the state of resin by moving it between different areas based on its condition and usage stage. Resin transitions from the print area to the reflux area for cleaning, then to the storage area for future use, optimizing both continuity and waste reduction through state parameter changes.
3Device complexity
If a simple resin tank design is used, then device complexity is reduced, but resin management precision deteriorates
Solution Approach 1:
The tank is segmented into distinct functional areas (print area, storage area, reflux area) that can be visually distinguished and managed separately. This segmentation provides inherent resin amount control without requiring complex sensors or measurement systems, maintaining simplicity while improving management precision.
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 system effectively manages resin levels, reduces waste by dispensing only the necessary amount, and ensures accurate printing by maintaining resin quality and providing a stable platform interface, thereby improving print completion rates and reducing material waste.
Implementation Method 1
the scraper member releasably magnetically coupled to the sliding block and configured to move in a direction parallel to the track
Implementation Method 2
an air heating assembly to maintain resin quality
Implementation Method 3
a sensor configured to measure a weight of the cartridge and to provide information based on the measured weight to the controller
Data Source
AI summary
A three-dimensional (3D) printing system is provided. The printing system includes a resin tank assembly with a sliding scraper, an automatic resin dispensing system, sensors configured to measure various aspects of the system, e.g., the volume of resin within the resin tank and/or within the resin dispensing system, a rigid releasable interface between the lift arm and the build platform, a resin heating system, a magnetic interface between the resin tank and the base assembly, a resin tank locking system, and other novel aspects.