Stationary Build Platform 3D Printing Resin Control

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Solution Overview

Problem

3D printing technologies face challenges such as surface rippling and slow print speed due to the attachment and release of printed portions from the membrane, which affect the quality and efficiency of the process.

Innovation Solution

A 3D printing system using a stationary build platform with a dosing pump to transport photo-sensitive resin to a vat and an image projector to cure each layer, reducing the need for moving parts and minimizing surface disturbances, allowing for precise control of resin delivery and curing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a membrane is used to support the printed portion during 3D printing, then the printed portion can be attached and released, but surface rippling occurs and print quality deteriorates

Engineering Contradiction:

Improveattachment and release of printed portionVSAvoidsurface rippling

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent removes the membrane component entirely from the 3D printing system. Instead of using a membrane to support and release printed portions, the invention employs a stationary build platform that directly supports the printed object, eliminating the source of surface rippling while maintaining reliable attachment and release capabilities through direct contact between the printed portion and build platform

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent inverts the traditional approach by making the build platform stationary rather than movable. Conventional systems move the build platform to achieve layer-by-layer printing, but this invention keeps the build platform fixed and uses a movable print head to deposit material, thereby eliminating membrane-related rippling while maintaining printing functionality

Inventive Principle:

Principle #13The other way round (Inversion)

2Adaptability or versatility

If moving parts are present in the 3D printing system, then flexibility and adaptability are improved, but surface disturbances increase and print speed decreases

Engineering Contradiction:

Improveflexibility of printing systemVSAvoidsurface disturbances

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent inverts the traditional motion scheme by making the build platform stationary and the print head movable. This reversal eliminates surface disturbances caused by membrane movement and platform acceleration, while the movable print head provides the necessary flexibility and adaptability for different printing configurations and material deposition patterns

Inventive Principle:

Principle #13The other way round (Inversion)

3Quantity of substance

If resin is transported to the vat using conventional methods, then resin delivery is achieved, but surface rippling occurs and print quality decreases

Engineering Contradiction:

Improveresin deliveryVSAvoidsurface rippling

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent replaces conventional mechanical resin transport methods that cause surface disturbance with a dosing pump system that delivers resin in a controlled manner. The dosing pump transports the exact amount of resin needed to the stationary build platform, eliminating the splashing and rippling associated with traditional resin delivery mechanisms while maintaining precise quantity control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enhances print speed and quality by reducing unwanted ripples and eliminating the need for a membrane, resulting in more robust and stable printing with improved precision and reduced risk of detachment issues.

Implementation Method 1

A device or combination of devices capable of volumetric dosing and delivery, such as a dosing pump, may be used to transport an amount of photo-sensitive resin necessary to create one layer of a 3D object to a vat

Methodology Applied

Scientific EffectPumping: Pump

Implementation Method 2

an image projector may cure the resin one layer at a time over the stationary build platform

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS20240116240A13D Printing with Stationary Build Platform

Publication Date: 2024.04.11 COMCAST CABLE COMM LLC

AI summary

Systems, apparatuses, and methods are described for 3D printing using a stationary build platform. Resin (e.g., a photopolymer) may be dosed into a vat in volumes required to create one layer at a time. An image projector may cure the top-most layer of the resin in the vat to create one layer at a time to fabricate a three-dimensional (3D) object from the bottom up, right side up, and/or layer-by-layer over the build plate.