Replaceable Cartridge for Solid Imaging Apparatus
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Solution Overview
Problem
Solid imaging systems face challenges such as complex and costly maintenance, inefficient alignment processes, and the production of tacky, uncured products due to excessive uncured build material, which increases operational costs and reduces efficiency.
Innovation Solution
The redesign of solid imaging apparatus with a replaceable cartridge assembly, a flexible transport surface, and a cleaning assembly that removes excess uncured material, along with a fixed imager alignment fixture and high-intensity UV lamp for improved curing, results in a more efficient and cost-effective system that produces fully cured, tack-free builds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional solid imaging systems are used with large vats of liquid resin, then build material is available for continuous production, but the system becomes expensive and the resin becomes contaminated with cured pieces requiring maintenance
Solution Approach 1:
The build material supply system is segmented into individual cartridges that can be independently replaced. Each cartridge contains a limited amount of build material in a sealed container, eliminating the need for large continuous vats. This segmentation allows contamination to be isolated to individual cartridges rather than affecting the entire resin supply system.
Solution Approach 2:
The patent employs disposable cartridges containing build material that are replaced when contaminated or depleted. These cartridges are designed as single-use or limited-use components that eliminate the need for cleaning and maintenance of the resin supply system. The cartridge housing, pump, and associated components are discarded with the spent build material.
2Manufacturing precision
If laser imaging systems are used for solid imaging, then precise layer-by-layer curing is achieved, but the systems become costly and complex requiring extensive alignment steps
Solution Approach 1:
The cartridge assembly is designed with self-aligning features that automatically position the build material and transport surface relative to the imaging system. The cartridge housing includes registration features and the transport surface is pre-aligned during cartridge manufacturing, eliminating the need for complex operator alignment procedures. The system self-adjusts to ensure proper positioning of each layer.
3Productivity
If excessive uncured build material remains on the build surface, then the build can be continuously produced, but the product becomes tacky and requires cleaning prior to full curing
Solution Approach 1:
The cleaning assembly extracts and removes excess uncured build material from the build surface between layers. A scraper or wiper mechanism physically removes the harmful uncured material that would otherwise remain tacky on the finished product. This extraction function is integrated into the cartridge system, allowing continuous operation without manual intervention.
Solution Approach 2:
A transport surface or build pad acts as an intermediary between the build material and the final product. This intermediate surface allows the build material to be applied and then easily removed, preventing direct contamination of the finished part. The transport surface can be cleaned or replaced independently of the build product.
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 significantly reduces maintenance efforts, eliminates tackiness, and enhances production efficiency by enabling fully cured products with minimal post-build cleaning, making the system more accessible and cost-effective.
Implementation Method 1
A laser or other source of radiation suitable for solid imaging sequentially irradiates individual thin layers of the build material in response to which the material transforms into a solid
Implementation Method 2
a pump for supplying the build material to the film
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.