Stereolithography Auto Off-Load Cart and Elevator System
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Solution Overview
Problem
Current stereolithography systems require significant human intervention and are inefficient in producing multiple three-dimensional objects sequentially, as they need operator attendance for each build, leading to reduced productivity and precision.
Innovation Solution
The system introduces automated features such as an elevator with attachment bracket, an auto off-load cart, and a recoater assembly with RFID-tagged resin containers, allowing unattended building of multiple objects from the same location, with computer-controlled resin leveling and recoater blade positioning to correct for machine errors, enabling simultaneous builds in multiple chambers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operation is used for each build, then operational flexibility is maintained, but productivity is reduced due to operator attendance requirements between builds
Solution Approach 1:
The system enables self-service operation where the stereolithography system automatically performs builds, removes completed objects, and prepares for subsequent builds without requiring operator intervention between builds. The automated off-load cart and elevator work together to remove completed objects and install fresh platforms, allowing the system to service itself continuously.
Solution Approach 2:
Manual mechanical operations performed by operators are replaced with automated mechanical systems. The automated off-load cart with telescoping arms replaces manual object removal, while the elevator system with attachment brackets replaces manual platform handling. This substitution eliminates the need for operator attendance between builds.
2Productivity
If multiple objects are built sequentially, then productivity increases, but manufacturing precision may deteriorate due to accumulated operational variations
Solution Approach 1:
The system incorporates feedback mechanisms where sensors detect the position and status of objects and platforms, and the control system adjusts operations accordingly. The attachment bracket on the elevator provides feedback about platform positioning, and the automated off-load cart uses sensors to detect when objects need removal, ensuring precise operations throughout sequential builds.
Solution Approach 2:
The system performs preliminary actions by pre-positioning fresh platforms on the elevator and pre-preparing resin containers before builds begin. The attachment bracket is pre-configured on the elevator, and resin containers are pre-filled and positioned, eliminating the need for adjustments during sequential builds and maintaining precision.
3Productivity
If automated features are added, then productivity and continuity improve, but device complexity increases
Solution Approach 1:
The automated system is segmented into distinct functional modules: the elevator with attachment bracket for platform handling, the automated off-load cart for object removal, and the resin container system for material supply. Each module operates independently but coordinates through the control system, making the overall complexity manageable through modular design.
Solution Approach 2:
The attachment bracket on the elevator serves multiple functions: it secures platforms during builds, enables automated object removal, and facilitates platform exchange. The automated off-load cart performs both object removal and fresh platform installation. This multi-functionality reduces the total number of separate components needed.
4Manufacturing precision
If resin leveling is automated, then manufacturing precision improves, but device complexity and control requirements increase
Solution Approach 1:
The resin leveling process is automated through the recoater assembly that self-regulates resin levels using sensors and feedback control. The system automatically detects resin level and adjusts the recoater blade position to maintain precise leveling without operator intervention, enabling continuous precise builds.
Solution Approach 2:
Manual resin leveling operations are replaced with an automated recoater assembly that uses mechanical and sensor-based control. The recoater blade position is precisely controlled by a motor-driven mechanism with feedback from level sensors, substituting manual skill with automated precision control.
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 solution enables unattended sequential building of multiple three-dimensional objects with improved precision and reduced human intervention, increasing productivity by allowing continuous operation without operator attendance between builds and correcting for mechanical inaccuracies.
Implementation Method 1
Stereolithography, to which the subject matter herein is primarily addressed, builds solid images from thin layers of polymerizable liquid, commonly referred to as resin. An ultraviolet laser generates a small and intense spot of light that is moved across the liquid surface... The laser cures selected portions of liquid resin at the working surface
Implementation Method 2
Excess liquid resin runs off to level the resin by gravity to a single layer thickness
Data Source
AI summary
A stereolithography apparatus having a resin vat with resupply containers in one-way flow communication and a leveling container in two-way flow communication, an automatic offload cart to remove and replace build support platforms, an elevator assembly for supporting and releasably retaining a build platform removably attached to the stereolithography apparatus frame such that elevator forks supporting the build platform can be released into the vat and removed from the stereolithography apparatus with the vat, and a recoater assembly and recoater blade for mapping the resin surface in the vat and applying a fresh coating of resin to a cross-section being built in the vat.