Solid Imaging Apparatus with Multiple Imagers for Large Object Fabrication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Solid imaging devices face limitations in producing larger objects with high resolution and efficiency, as they require longer exposure times and reduced detail due to the spread of radiation energy over larger areas, and are restricted by the size of the radiation source and scanning speed.
Innovation Solution
The solution involves a solid imaging apparatus with multiple reciprocating transport surfaces and radiation sources that allow for simultaneous imaging and efficient layer-by-layer build-up of build material, using a combination of inkjet print heads and gravure rolls to apply and cure build material, and multiple imagers aligned for larger image areas without reducing resolution or increasing exposure time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If radiation energy is spread over larger areas to produce larger objects, then object size increases, but exposure time increases and resolution decreases
Solution Approach 1:
The radiation source is divided into multiple independent imagers (e.g., three 1024x768 pixel imagers) that simultaneously illuminate different regions of the build platform. This segmentation allows the total illumination area to be much larger than what a single imager could provide, thereby increasing object size capability without increasing exposure time, as all regions are exposed in parallel rather than sequentially
Solution Approach 2:
Multiple imagers are merged into a coordinated system where each imager contributes to a portion of the overall image. The imagers work together simultaneously to illuminate the entire build area, combining their individual capabilities to achieve high-resolution imaging of large objects without the exposure time penalties associated with sequential scanning or single-imager approaches
2Volume of moving object
If radiation energy is spread over larger areas to produce larger objects, then object size increases, but manufacturing precision decreases
Solution Approach 1:
The build platform and radiation field are segmented into multiple zones, each covered by a dedicated imager. Each imager maintains its native high resolution (e.g., 1024x768 pixels) for its assigned region, and the segmented regions are precisely aligned to form a complete high-resolution image of the entire large object, thereby maintaining manufacturing precision across the full build area
Solution Approach 2:
The system transitions from a single-point or single-area scanning approach to a multi-area simultaneous illumination approach by adding spatial distribution of imagers. This dimensional expansion allows high-resolution imaging across large areas by distributing the imaging function across multiple imagers positioned at different locations, effectively multiplying the total illuminated area while maintaining per-pixel resolution
3Productivity
If laser scanning speed is increased to improve productivity, then build time decreases, but the size limitation of the radiation source and scanning mechanism constrains object size
Solution Approach 1:
The mechanical laser scanning system is replaced with a digital light processing (DLP) imager system that uses digital mirror devices to steer light. This substitution eliminates the mechanical scanning limitations, allowing instantaneous projection of entire layer patterns across large build areas without the speed constraints of mechanical scanners, thereby enabling both high productivity and large object fabrication
Solution Approach 2:
Multiple imager systems are merged to cover larger build areas simultaneously. Instead of relying on a single scanner to traverse the entire build platform, multiple imagers are positioned to illuminate different regions at the same time, effectively multiplying the build area capability while maintaining high scanning speeds through parallel operation rather than sequential mechanical movement
4Manufacturing precision
If batch production is used to maintain quality, then manufacturing precision is preserved, but productivity decreases due to inability to produce continuously
Solution Approach 1:
The system enables continuous production by eliminating the need for batch processing and intermediate handling. Multiple imagers and build platforms operate in a coordinated continuous sequence, allowing uninterrupted layer-by-layer fabrication. The useful action of imaging and curing continues without interruption across multiple platforms, maintaining manufacturing precision through consistent process parameters while achieving continuous high-volume output
5Manufacturing precision
If uncured build material is removed from green products, then surface quality improves, but additional processing time and complexity are required
Solution Approach 1:
The system performs preliminary removal of uncured build material during the build process itself, before the product is considered complete. By integrating the removal action into the layer-by-layer fabrication process, the surface is prepared in advance, eliminating the need for separate post-processing removal steps and reducing overall processing complexity while maintaining high surface quality
Solution Approach 2:
The build system performs self-cleaning by automatically removing uncured build material from the build surface during the imaging process. This self-service capability eliminates the need for external post-processing operations, reducing device complexity and processing steps while ensuring consistent surface quality through integrated real-time removal rather than separate batch cleaning operations
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 production of larger, tack-free, fully cured three-dimensional objects with improved feature detail and reduced post-build processing, allowing for semi-continuous operation and the use of multiple build materials, while maintaining high resolution and efficiency.
Implementation Method 1
A laser or other source of radiation sequentially irradiates individual thin layers of the build material in response to which the material transforms to a solid
Data Source
AI summary
Solid imaging apparatus and methods for use are disclosed that reduce the amount of uncured solid imaging build material remaining on a completed build object following the completion of the solid imaging build process. The amount of uncured build material is reduced through the use of either an uncoating web that removes excess build material from the build object during the course of the building process or an ink jet source of build material that uses only as much build material as is necessary for the fabrication of the build part. Also disclosed is an imager assembly for use with such a solid imaging apparatus that incorporates two or more individual imagers in an array and accounts for variations in the intensity and alignment of adjacent imagers. The apparatus can be modified for semi-continuous operation and for integrating into a manufacturing operation, if desired.