Stereolithography Apparatus Splitting Coupling Unit
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Solution Overview
Problem
Conventional stereolithography apparatuses require multiple light irradiations to form a single cured layer, leading to decreased throughput.
Innovation Solution
A stereolithography apparatus that includes a splitting/coupling unit to split and couple light beams in multiple directions, and spatial light modulation units to generate patterned light beams for rapid curing of photocurable resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If one cured layer is formed by a plurality of times of irradiation with light, then the curing is performed with a single light source, but the throughput decreases
Solution Approach 1:
The patent divides a single light beam into multiple beams using optical elements such as beam splitters or diffraction gratings. These multiple beams are then directed to different regions of the photocurable resin simultaneously, enabling parallel curing of multiple areas. This segmentation of the light beam allows one cured layer to be formed in a single irradiation step, significantly improving throughput without requiring sequential multiple irradiation processes.
Solution Approach 2:
The patent utilizes spatial light modulation devices such as liquid crystal on silicon (LCOS) or digital micromirror devices (DMD) to modulate the light beams in the spatial domain. By controlling the phase, amplitude, or direction of multiple light beams in different spatial positions, the system can selectively cure multiple regions simultaneously. This spatial dimensionality approach transforms a single-point or single-line curing process into a multi-point parallel curing process, resolving the throughput limitation.
2Productivity
If multiple light beams are used to form multiple cured layers simultaneously, then the throughput improves, but the device complexity increases
Solution Approach 1:
The patent employs spatial light modulation devices that can perform multiple functions: beam splitting, beam steering, pattern generation, and focal point control. A single LCOS or DMD device can simultaneously modulate multiple light beams to create multiple cured layers at different depths or positions. This multi-functionality reduces the need for separate optical systems for each curing operation, thereby improving throughput while limiting the increase in device complexity.
Solution Approach 2:
The patent introduces optical elements such as lenses, mirrors, or beam combining optics as intermediaries to manage multiple light beams. These intermediary components facilitate the precise control and combination of multiple beams without requiring direct complex interactions between all beam paths. The intermediary optical elements simplify the overall system architecture by providing standardized interfaces for beam manipulation, thus enabling multi-layer simultaneous curing with controlled device complexity.
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
The apparatus enables the formation of multiple cured layers with a single light application, significantly improving throughput and efficiency in the stereolithography process.
Implementation Method 1
Stereolithography apparatuses have been used to form a fabricated object by piling up layers of a cured portion formed by applying laser light to a photocurable resin for curing
Implementation Method 2
a splitting/coupling unit that splits incident light applied to a photocurable resin to form a cured portion, in a first direction and a second direction, couples light beams obtained by splitting incident light
Data Source
AI summary
To form a cured portion quickly. A stereolithography apparatus includes a splitting/coupling unit, a first spatial light modulation unit, and a second spatial light modulation unit. The splitting/coupling unit splits incident light applied to a photocurable resin to form a cured portion, in a first direction and a second direction, couples light incident from the first direction and light incident from the second direction, and emits the coupled light in a third direction. The first spatial light modulation unit is arranged in the first direction to modulate a light beam from the splitting/coupling unit into a light beam having a first pattern that is a pattern of the cured portion and emits the light beam having the first pattern to the splitting/coupling unit, for coupling. The second spatial light modulation unit is arranged in the second direction to modulate a light beam from the splitting/coupling unit to a light beam having a second pattern in the vicinity of the first pattern and emits the light beam having the second pattern to the splitting/coupling unit, for coupling.