Static Optics SLA Printing for Large-Scale High Resolution

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Solution Overview

Problem

Current 3D printing technologies, such as SLA and DLP-based stereolithography, face challenges in achieving high resolution for large dimension parts due to mechanical noise and limited printing volume, with existing methods like scanning-projection stereolithography being inefficient and CLIP having small printing volumes.

Innovation Solution

A static optic setup for 3D printing devices featuring a light engine, collimation lenses, a microlens array, microdiaphragm array, and a movable stage with piezoelectric translation, allowing for high-resolution printing of large structures by subdividing pixels into sub-pixels and reducing noise, combined with a procedural modeling application for efficient visualization and manipulation of crystallographic structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If scanning-projection stereolithography is used to print large dimension parts, then printing volume is increased, but mechanical noise and resolution deteriorate

Engineering Contradiction:

Improveprinting volumeVSAvoidresolution

Core Design Contradiction:

Volume of stationary objectVSManufacturing precision

Solution Approach 1:

The patent divides the projection system into multiple fixed projectors arranged in an array, each projector handling a specific region. This segmentation allows large volume printing without the mechanical noise and resolution loss associated with scanning systems, as each projector remains stationary while collectively covering the entire printing volume.

Inventive Principle:

Principle #1Segmentation

2Productivity

If CLIP technology is used, then printing speed is improved, but printing volume is limited to small dimensions

Engineering Contradiction:

Improveprinting speedVSAvoidprinting volume

Core Design Contradiction:

ProductivityVSVolume of stationary object

Solution Approach 1:

The patent merges the advantages of CLIP (continuous printing speed) with extended printing volume by using multiple fixed projectors working in parallel. The oxygen permeable membrane maintains continuous printing operation while the array of projectors expands the printable volume beyond what a single projector could achieve.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If traditional geometric-based modeling tools are used for crystallographic structures, then modeling functionality is provided, but computational cost and time increase significantly

Engineering Contradiction:

Improvemodeling functionalityVSAvoidmodeling time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent replaces traditional geometric-based modeling approaches with procedural modeling using signed distance functions and ray marching algorithms. This substitution transforms the modeling process from computationally expensive mesh-based operations to efficient function-based evaluations, dramatically reducing modeling time while maintaining full functionality for crystallographic structures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If mesh-based renderers are used to visualize crystallographic scenes, then visualization is achieved, but storage space requirements become extremely large

Engineering Contradiction:

Improvevisualization capabilityVSAvoidstorage space

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The patent extracts the essential geometric information from complex mesh representations and stores only the procedural functions (signed distance functions) that define the crystallographic structures. This extraction allows visualization to be performed on-demand through ray marching, reducing storage requirements from terabytes to kilobytes while preserving full visualization capability.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Enables high-resolution, large-scale 3D printing with reduced noise and increased efficiency, allowing for the creation of complex structures like bioreactors with precise control over layer thickness and pixel resolution, while also providing a compact data representation of geometry for storage and visualization.

Implementation Method 1

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

Methodology Applied

Scientific EffectOptical focusing and subdivision: Lens

Implementation Method 2

The piezoelectric stage translates the movable lens in the X-Y plane with nanometer resolution

Methodology Applied

Scientific EffectPiezoelectric translation: Piezoelectric Effect

Implementation Method 3

a UV projector configured to project a luxbeam comprising a plurality of pixels along a Z axis... The projected light may enable the initiation of the polymerization reaction which may generate a cross-linked polymeric structure

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS11718020B2Platform, systems, and devices for 3D printing

Publication Date: 2023.08.08 STAMM VEGH CORP

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.