Stereolithography Apparatus with Movable Radiation Source
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Solution Overview
Problem
Current methods for producing plastic parts, such as injection molding and stereolithography, face challenges with high design and tooling costs, limited precision, and inefficiencies in producing small batches, making them impractical for low-volume production and requiring repetitive design optimization.
Innovation Solution
A stereolithography system with a frame, build platform, and movable radiation source, capable of movement along the x and y axes, and a vat with a radiation-permeable bottom, utilizing stepper motors and a microcontroller to control the curing of photo-curable polymers based on 3D drawing files, allowing for precise and efficient creation of three-dimensional objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used for plastic part production, then production efficiency and part quality are improved, but design and tooling costs increase significantly
Solution Approach 1:
The patent segments the manufacturing process into digital design and physical production phases, eliminating the need for physical tooling. The build platform divides the object into thin horizontal layers that are cured sequentially, allowing complex 3D shapes to be produced without complex molds.
Solution Approach 2:
The patent uses digital 3D models as copies of the desired final product to guide the manufacturing process. The radiation source creates a digital light pattern that matches the cross-section of the desired object, copying the digital design directly into physical form through selective curing of photopolymer layers.
2Adaptability or versatility
If stereolithography is used for producing plastic parts, then design iterations are reduced and production flexibility is improved, but manufacturing precision and reliability deteriorate
Solution Approach 1:
The patent replaces mechanical contact-based manufacturing methods with radiation-based selective curing. The radiation source can be precisely positioned and controlled to cure only the intended areas of each layer, achieving high precision without mechanical tool wear or positioning errors.
Solution Approach 2:
The patent implements a controlled process where each layer is cured, then the build platform lowers to allow fresh photopolymer to flow into position. This sequential layer-by-layer approach with controlled material replenishment ensures consistent precision and reliability across multiple layers and production runs.
3Ease of manufacture
If traditional stereolithography systems are used, then three-dimensional objects can be produced from liquid plastic, but production speed increases and energy consumption increases
Solution Approach 1:
The patent uses periodic action by curing the photopolymer in thin sequential layers rather than attempting to cure thick sections at once. Each layer is cured, the platform lowers to replenish material, and the process repeats. This periodic layer-by-layer approach maintains production speed while ensuring complete and uniform curing of each layer.
Solution Approach 2:
The patent employs a movable build platform that dynamically adjusts its position to lower into the photopolymer reservoir as layers are completed. This dynamic movement allows continuous material replenishment and maintains optimal working conditions, enabling sustained high-speed production without compromising curing quality.
4Ease of manufacture
If traditional stereolithography systems are used, then three-dimensional objects can be produced, but system cost and energy consumption increase
Solution Approach 1:
The patent extracts only the essential function of stereolithography - selective radiation curing of photopolymer - while removing unnecessary components and processes. The system uses a simple movable radiation source and build platform without complex mechanical arms or robotic systems, reducing both cost and energy consumption while maintaining production capability.
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 system enables cost-effective and precise production of plastic parts with reduced design iterations, improving efficiency and quality, particularly suitable for low-volume production by directly forming objects from photopolymer layers.
Implementation Method 1
cure the photo-curable polymer and form an object in accordance with the data file
Data Source
AI summary
A system for making three dimensional objects. The system may have a frame, a build platform movably coupled to the frame, a vat removably secured so that the build platform may be lowered within the vat, and a movable radiation source capable of movement along an x and y-axis. The vat may have a radiation permeable flat bottom. The build platform may have a work surface disposed thereon. There may be at least one stepper motor capable of moving the radiation source, the build platform, or both the radiation source and the build platform. There may also be a power source, a data reader device and or computer communication device, and a microcontroller in communication with the at least one stepper motor and at least one of the data reader device or computer communication device.