Stereolithography Apparatus Multi-Material Precision Control
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Solution Overview
Problem
Existing stereolithography methods face challenges in precisely controlling the deposition of materials, particularly in forming complex shapes with fused deposition modeling (FDM) and stereolithography, due to the viscosity of the materials used, leading to difficulties in achieving precise control over the formation of three-dimensional objects with multiple materials.
Innovation Solution
A stereolithography apparatus and method that includes a manufacturing table, suppliers for photocurable materials, a spreading member to form pre-exposure layers, an exposer to create exposed and unexposed portions, a remover to convert unexposed portions into cured ones, and a controller to simplify the control process, allowing for the precise formation of three-dimensional objects with multiple materials by forming and curing layers of different materials in a predetermined shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a nozzle is used to deposit photocurable composition in each concave portion (Patent Document 1), then material can be precisely deposited, but complicated control of the nozzle is required
Solution Approach 1:
The patent replaces the mechanical nozzle-based deposition system with a light-based exposure system. Instead of using a nozzle to physically deposit material in specific locations, the invention uses a spreading member to uniformly spread photocurable composition and then uses a mask and light source to selectively cure the material in desired patterns. This substitution of mechanical deposition with optical patterning resolves the contradiction by achieving precise material formation without complex nozzle positioning control.
2Ease of manufacture
If fused material is discharged from nozzle in FDM method (Patent Document 2), then fabrication layer can be formed, but it is difficult to finely and highly precisely control the fused material due to its viscosity
Solution Approach 1:
The patent changes the physical state and properties of the fabrication material by using photocurable compositions that transition from a spreadable liquid state to a solidified cured state upon light exposure. This parameter change allows the material to be easily spread uniformly across the build surface and then precisely controlled in its final shape through selective photopolymerization, resolving the contradiction between ease of manufacture and manufacturing precision.
Solution Approach 2:
The invention utilizes the phase transition of photocurable material from liquid (uncured) to solid (cured) state through photopolymerization. The material is applied in a liquid state for easy spreading and then transformed to solid state through light exposure to achieve precise shape control. This phase transition approach resolves the contradiction by allowing easy material deposition followed by precise shape definition.
3Adaptability or versatility
If multiple materials are used to form three-dimensional object, then object complexity and functionality are improved, but control process becomes complicated
Solution Approach 1:
The patent employs segmentation by using separate masks for different materials (first mask for first photocurable composition, second mask for second photocurable composition). Each mask independently defines the pattern for a specific material, allowing multiple materials to be precisely deposited and cured without interfering with each other. This segmented approach to multi-material fabrication resolves the contradiction by enabling material versatility while maintaining simple, independent control for each material layer.
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 enables the highly precise manufacturing of three-dimensional objects with multiple materials without complicating the control process, reducing the complexity of the apparatus structure, and preventing material mixing, while allowing for the formation of objects with varying thicknesses and materials like insulating and conductive components.
Implementation Method 1
an exposer that forms a first post-exposure material layer including one or a plurality of first exposed portions and one or a plurality of first unexposed portions by exposing the first pre-exposure material layer that has been drawn and spread by the spreading member, and forms a second post-exposure material layer including one or a plurality of second exposed portions and one or a plurality of second unexposed portions by exposing the second pre-exposure material layer that has been drawn and spread by the spreading member
Implementation Method 2
a remover that removes the one or plurality of first unexposed portions and the one or plurality of second unexposed portions from the first and second post-exposure material layers
Data Source
AI summary
A first pre-exposure material layer is formed by drawing and spreading of a first material, a first post-exposure material layer including one or a plurality of first exposed portions is formed by exposure of the first pre-exposure material layer, and one or a plurality of first cured portions remain by removal of one or a plurality of first unexposed portions from the first post-exposure material layer. Next, a second pre-exposure material layer that is in contact with the one or plurality of first cured portions is formed by drawing and spreading of a second material, a second post-exposure material layer including one or a plurality of exposed portions is formed by exposure of the second pre-exposure material layer, and one or a plurality of second cured portions remain by removal of one or a plurality of second unexposed portions from the second post-exposure material layer.