3D Shaping Light Intensity Control for Overhang Precision
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Solution Overview
Problem
Existing shaping methods, such as those using stereolithography or digital light processing, often result in excess shaped portions on overhangs due to uniform light intensity, leading to reduced dimensional precision and increased post-processing needs.
Innovation Solution
An information processing apparatus generates setting information for a shaping apparatus to adjust light intensity selectively across layers, with higher intensity for base portions and lower intensity for overhang regions, using a liquid crystal display to control light transmittance and reduce excess curing on overhangs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If uniform light intensity is used for shaping all regions, then the shaping process is simple and fast, but excess shaped portions are formed on overhang regions reducing dimensional precision
Solution Approach 1:
The patent applies local quality by setting different light intensities for different regions of the workpiece. Specifically, the light intensity for the overhang region is set lower than that for the base region, allowing precise control of curing depth in each area. This resolves the contradiction by achieving high dimensional precision through region-specific parameter optimization without requiring complex additional hardware.
Solution Approach 2:
The patent changes the light intensity parameter selectively for different regions and layers. By adjusting the light intensity based on the geometric characteristics (overhang vs. base regions) and layer position, the curing depth is precisely controlled to prevent excess shaping while maintaining manufacturing efficiency. This parameter-based approach achieves precision without increasing device complexity.
2Productivity
If higher light intensity is used to improve shaping speed, then productivity increases, but excess curing occurs on overhang portions
Solution Approach 1:
The patent implements local quality by differentiating light intensity between overhang regions and base regions. The overhang regions receive lower light intensity to prevent excess curing, while base regions receive higher intensity for efficient shaping. This spatial differentiation maintains overall productivity while ensuring shape accuracy in critical overhang areas.
Solution Approach 2:
The patent applies partial action by providing sufficient (not excessive) light intensity specifically where needed. For overhang regions, the light intensity is carefully controlled to be just enough for proper curing without excess, while base regions receive higher intensity. This selective application of energy maintains productivity while preventing defects.
3Ease of manufacture
If uniform energy radiation is applied to all regions, then the processing is efficient, but the excess shaped portion increases post-processing requirements
Solution Approach 1:
The patent applies local quality by setting different energy radiation levels for different regions. Overhang regions receive lower energy radiation to prevent excess shaping, eliminating the need for post-processing removal. Base regions receive standard energy levels for efficient shaping. This region-specific energy control reduces post-processing requirements while maintaining reasonable energy usage.
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 minimizes excess shaped portions on overhangs, enhancing the precision of the final product and reducing post-processing requirements, thereby lowering manufacturing costs.
Implementation Method 1
using a liquid crystal display to control light transmittance and reduce excess curing on overhangs
Implementation Method 2
a shaping apparatus that forms a shaped object by laminating a plurality of cured layers obtained by curing a photocurable resin composition
Data Source
AI summary
An information processing apparatus includes an information processing portion configured to obtain setting information set for a shaping apparatus for causing the shaping apparatus to form a plurality of layers. The plurality of layers include an (n−1)-th layer, and an n-th layer formed subsequently to the (n−1)-th layer. The n-th layer includes a first region overlapping with the (n−1)-th layer in a lamination direction, and a second region that is continuous with the first region and that does not overlap with the (n−1)-th layer in the lamination direction. The setting information includes information for setting an energy radiated by an irradiation portion of the shaping apparatus in formation of the first region to first intensity, and information for setting the energy radiated by the irradiation portion in formation of the second region to second intensity lower than the first intensity.