Shifting Curing Location in Stereolithography 3D Printing
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Solution Overview
Problem
During stereolithography 3D printing, repeated exposure of liquid resin to UV radiation at the same location leads to degradation, resulting in material waste, increased costs, and nonuniformity of layers due to the formation of a 'skin' layer and uneven resin degradation.
Innovation Solution
Shifting the curing location within the resin container by moving the resin container relative to the base plate after each layer is formed, thereby avoiding repeated curing at the same spot and agitating the resin to prevent skin layer formation and uniform degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the resin container remains stationary during 3D printing, then the curing process is simple and fast, but the resin degrades at the same location repeatedly causing material waste and nonuniform layers
Solution Approach 1:
The resin container is made movable relative to the UV light source, transitioning from a static to a dynamic system. The container can be shifted horizontally or rotated between curing steps to change the curing location, preventing repeated degradation at the same spot while maintaining process simplicity
Solution Approach 2:
The invention introduces spatial movement in the horizontal plane (x-y dimensions) in addition to the vertical curing direction (z-dimension). By moving the container in lateral directions or rotating it, the system utilizes additional spatial dimensions to distribute curing across different resin areas, solving the uniformity problem without complicating the vertical curing process
2Loss of substance
If the resin container is moved to shift curing location, then resin degradation is reduced and material waste minimized, but the printing process time increases
Solution Approach 1:
The resin container undergoes periodic movement (shifting or rotation) at intervals between layer formations. This periodic action allows the system to maintain efficient curing for each layer while periodically redistributing the resin exposure, preventing cumulative degradation without requiring continuous movement that would slow down the overall process
Solution Approach 2:
The resin container is repositioned in advance between layer formations, before the next curing operation begins. This preliminary movement ensures that the resin is already in the optimal position for the next layer, eliminating the need for time-consuming adjustments during curing and maintaining process efficiency
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 reduces resin degradation, minimizes material waste, and enhances the uniformity of layers by distributing degradation evenly throughout the resin container, without the need for additional mechanical agitation methods like scrapers.
Implementation Method 1
a 3D structure is built up one layer at a time, with each layer being formed by exposing a photo-reactive resin to an ultraviolet (UV) light source that cures the resin
Data Source
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AI summary
Example implementations may relate to shifting a curing location during a three-dimensional printing procedure. A system may control components of a 3D printer (100) to form a first layer of the 3D structure (112) from resin in a first area of a resin container (102). The components may include: (i) a base plate (108) and (ii) light source(s) (104) operable to emit radiation that cures resin (105). After formation of the first layer, the system may move the resin container (102) with respect to the base plate (108) such that a second layer of the 3D structure (112) can be formed in a second area of the resin container (102). The second area and the first area may be at least partially non-overlapping. The system may then control the components of the 3D printer (100) to form the second layer of the 3D structure (112) from resin (105) in the second area of the resin container (102).