Solid Imaging Cartridge With Flexible Film Transport
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Solution Overview
Problem
Solid imaging systems face challenges with complex and costly setups, excessive maintenance, and inefficiencies due to complex alignment steps and contamination issues with large resin vats, leading to tacky and incompletely cured products.
Innovation Solution
A redesigned solid imaging apparatus featuring a replaceable cartridge assembly with a transport surface and integrated cleaning system, a fixed imager alignment fixture, and high-intensity UV curing, which includes a flexible film for transporting and cleaning build material, reducing maintenance and alignment complexities while ensuring fully cured products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional solid imaging systems use large resin vats and complex alignment mechanisms, then imaging functionality is achieved, but device complexity and maintenance requirements increase significantly
Solution Approach 1:
The system is divided into modular components: a replaceable cartridge containing build material and a transport surface, a fixed imager assembly with alignment fixture, and a build platform. This segmentation allows the imager to remain stationary while only the cartridge needs replacement, dramatically reducing maintenance complexity
Solution Approach 2:
The cartridge is designed as a disposable or replaceable component containing the build material and transport surface. Instead of maintaining and cleaning large resin vats and transport surfaces, users simply replace the entire cartridge when material is depleted, eliminating complex cleaning and alignment maintenance
2Manufacturing precision
If complex alignment steps are implemented for positioning the radiation source and image plane, then imaging precision is achieved, but operational efficiency decreases
Solution Approach 1:
The imager assembly is pre-aligned to the build platform using a fixed alignment fixture with precision mechanical features (parallel sides, perpendicular ends). This preliminary alignment is performed during assembly rather than during each operation, eliminating the need for complex alignment steps during use
Solution Approach 2:
The complex mechanical alignment system is replaced with a fixed alignment fixture that provides automatic mechanical positioning. The fixture's geometric features (parallel sides, perpendicular ends) ensure precise alignment without requiring operator intervention or complex adjustment mechanisms
3Productivity
If uncured build material is allowed to wet the build surface, then layer-by-layer construction is achieved, but product quality deteriorates due to tackiness and incomplete curing
Solution Approach 1:
The cleaning assembly is integrated into the cartridge system and automatically removes uncured build material from the transport surface between layers. This extraction of excess material prevents it from wetting and contaminating the build surface, ensuring complete curing and eliminating tackiness while maintaining rapid layer-by-layer construction
Solution Approach 2:
The cleaning assembly provides automatic self-cleaning of the transport surface between layers without requiring operator intervention. The system self-manages the removal of uncured material, ensuring consistent build quality and preventing contamination while maintaining high productivity
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 solution simplifies operation, reduces maintenance, and produces fully cured, tack-free builds with reduced material waste, enhancing efficiency and cost-effectiveness.
Implementation Method 1
a high-intensity UV lamp, in the range of approximately 600 Watts, and associated cooling channels for air flow, the UV lamp illuminating the build from the bottom for curing operations for each layer of the part after imaging and cleaning
Implementation Method 2
A layer of photopolymer build material is formed on the transport surface and the imager cures the layer from the other side of the transport surface to complete the layer
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
A solid imaging apparatus is provided that includes a replaceable cartridge containing a source of build material and an extendable and retractable flexible transport film for transporting the build material layer-by-layer from the cartridge to the surface of a build in an image plane. An operator using the device needs merely to remove a spent cartridge and replace it with a fresh cartridge to continue solid imaging virtually uninterrupted. The apparatus also includes the capability of withdrawing and inserting an imager without the operator having to perform a separate alignment step. A brush attached to the transport film and forming part of the cartridge provides for intra-layer removal of excess uncured build material. If desired, the apparatus can produce a fully reacted build. A high intensity UV source cures the build between layers. An injection molded build pad is designed to hold a build in an inverted position for improving the build. The invention also provides for tilting the build elevator to reduce air entrainment and for releasing the build from the image plane.