Static Optical Assembly for High-Resolution Large-Area 3D Printing
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Solution Overview
Problem
Existing 3D printing technologies, particularly SLA and DLP-based SLA, struggle to achieve high resolution for micrometer-sized structures and large dimension parts, and scanning-projection stereolithography is limited by mechanical noise and slow printing speed.
Innovation Solution
A static optical assembly with a light engine, collimation lens, microlens array, microdiaphragm array, and projection lens, combined with a movable stage and control circuitry, enables high-resolution 3D printing of large structures using pixel-based modulation and management, and a procedural modeling suite for visualizing and manipulating crystallographic structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If scanning-projection stereolithography is used to print large structures, then printing area is increased, but mechanical noise increases and printing speed decreases
Solution Approach 1:
The patent divides the large printing area into multiple smaller DLP projection zones that can be independently controlled. Instead of moving a single large projector, the system uses multiple fixed projectors to cover different regions simultaneously, eliminating mechanical movement while maintaining large-area printing capability and high speed
Solution Approach 2:
The patent transitions from a single-plane projection approach to a multi-plane, multi-angle projection system. By projecting light from multiple angles and combining the exposures, the system achieves large-area coverage without mechanical scanning, resolving the contradiction between printing area and printing speed
2Adaptability or versatility
If traditional geometric-based modeling tools are used to model complex crystallographic structures, then modeling functionality is provided, but computational cost and time increase significantly
Solution Approach 1:
The patent replaces traditional geometric-based modeling approaches with procedural modeling algorithms. Instead of manually constructing complex crystallographic structures using geometric primitives, the system uses procedural generation methods that automatically create accurate models based on crystallographic parameters, dramatically reducing modeling time while maintaining full functionality
Solution Approach 2:
The patent transforms the modeling approach from geometry-based construction to parameter-based definition. By defining crystallographic structures through parameters (lattice types, unit cell dimensions, atomic positions) rather than explicit geometric operations, the system achieves both versatility and computational efficiency
3Manufacturing precision
If DLP-based SLA is used for high-resolution printing of micrometer-sized structures, then resolution is improved, but printing speed decreases
Solution Approach 1:
The patent segments the high-resolution printing task across multiple DLP projectors operating in parallel. Each projector handles a portion of the total area at full resolution, and the combined effect achieves both high resolution and high speed by distributing the computational and optical workload
Solution Approach 2:
The patent eliminates the need for mechanical scanning by using multiple fixed projectors that simultaneously project onto different regions of the printing vat. This continuous parallel operation maintains high resolution while achieving high printing speed, as all projectors work continuously without sequential movement
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 allows for the high-resolution printing of large structures with reduced mechanical noise and increased printing speed, utilizing a static optical assembly and procedural modeling to efficiently visualize and manipulate complex crystallographic scenes.
Implementation Method 1
a light engine configured to project a luxbeam comprising a plurality of pixels
Implementation Method 2
stereolithography (SLA) works by light projection on a photosensitive resin contained in a printing vat. The projected light may enable the initiation of the polymerization reaction
Implementation Method 3
at least one collimation lens configured to collimate the luxbeam
Implementation Method 4
a microlens array (MLA) configured to focus the collimated luxbeam to a final beam of smaller diameter, wherein each pixel of the luxbeam is subdivided into a plurality of sub-pixels to multiply resolution of the final beam
Implementation Method 5
a microdiaphragm array (MDA) configured to reduce noise and cross-talk between lenses of the MLA
Data Source
AI summary
Described are 3D printing platforms comprising stereolithographic 3D printing devices utilizing a static optical assembly and procedural modeling applications representing 3D scenes as signed distance function. Described are also structures such as bioreactors that can be printed using such platforms, as well as characteristics and used thereof.