Additive Manufacturing Stage Offset for Residual Resin Removal
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in efficiently removing residual resin from components, which can lead to the need for subsequent cleaning processes that may alter the structure of the component.
Innovation Solution
An additive manufacturing apparatus that includes a stage for curing resin layers and a removal position offset from the build zone, allowing for the separation of residual resin using radiant energy, thereby reducing the need for subsequent cleaning processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If cleaning processes are used to remove residual resin from components, then the residual resin is removed, but the structure of the component may be altered
Solution Approach 1:
The patent applies preliminary action by removing residual resin through a controlled separation process before subsequent cleaning operations are needed. The resin support is separated from the component at an offset position, allowing residual resin to be removed preliminarily without requiring aggressive cleaning that could alter the component structure.
Solution Approach 2:
The resin support acts as an intermediary element that facilitates the removal of residual resin. By separating the resin support from the component at an offset position, the resin support mediates the removal process, allowing residual resin to be removed without direct contact between cleaning mechanisms and the component structure.
2Manufacturing precision
If the stage is positioned at the curing position for layer formation, then resin layers are cured effectively, but residual resin remains on the component
Solution Approach 1:
The patent introduces a dimensional change by moving the separation process to an offset position rather than at the curing position. This spatial dimensionality change allows the component to be separated from the resin support at a different location, enabling residual resin removal without compromising the curing process quality.
Solution Approach 2:
The patent segments the build process into distinct curing and separation operations. The curing operation occurs at the curing position with high precision, while the separation and residual resin removal occur at an offset position, dividing the functions to achieve both precise layer formation and effective residual resin removal.
3Object-generated harmful factors
If multiple cleaning processes are applied to remove all residual resin, then residual resin is completely removed, but the component undergoes structural alterations
Solution Approach 1:
The patent extracts the residual resin removal function from the main curing process by implementing separation at an offset position. This extraction allows residual resin to be removed through a dedicated separation mechanism rather than requiring multiple cleaning processes, simplifying the overall system while achieving effective residual resin removal.
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 apparatus effectively minimizes residual resin on components, eliminating the need for subsequent cleaning processes that could weaken the structure, thus enhancing the integrity of the manufacturing process.
Implementation Method 1
Stereolithography (SLA) is a type of additive manufacturing process, which employs a tank of radiant-energy curable photopolymer 'resin' and a curing energy source such as a laser.
Implementation Method 2
The viscosity modification assembly can be configured to apply a mechanical stress to a resin to modify a viscosity of the resin
Data Source
AI summary
An additive manufacturing apparatus includes a support plate including a window. A stage is configured to hold one or more cured layers of the resin to form a component. A radiant energy device positioned on an opposite side of the support plate from the stage and operable to generate and project radiant energy in a patterned image through the window. An actuator is operably coupled with the stage and is configured to move the stage between a curing position and a removal position. The curing position can be offset from the removal position.