Tilting Solidification Substrate for 3D Printing Resin Management
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Solution Overview
Problem
Existing three-dimensional rapid prototyping methods require a planar exposed surface for solidification, leading to bond formation between the object and substrate, which necessitates separation methods that introduce delays and increase damage susceptibility.
Innovation Solution
A tiltable solidification substrate assembly that tilts away from the build platform after each layer formation, allowing for the introduction of fresh resin without direct contact, reducing the need for peeling mechanisms and minimizing production delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a planar exposed surface is created using a solidification substrate, then the depth of solidification energy penetration is regulated and manufacturing precision is improved, but bond formation occurs between the object and substrate requiring separation mechanisms that increase device complexity and production time
Solution Approach 1:
Instead of moving the substrate away from the build platform to introduce fresh resin, the build platform is moved downward while the substrate remains stationary. This inverted approach eliminates the need for complex peeling mechanisms while maintaining the ability to regulate solidification depth through the stationary substrate.
Solution Approach 2:
The substrate is extracted from the moving components and kept stationary, separating the functions of depth regulation (substrate) from layer introduction (build platform movement). This simplifies the system by removing the need for substrate manipulation mechanisms.
2Manufacturing precision
If a solidification substrate is used to create a planar surface, then manufacturing precision is improved, but production time increases due to separation and repositioning operations
Solution Approach 1:
The process inverts the conventional approach by keeping the substrate stationary and moving the build platform instead. This eliminates time-consuming separation and repositioning operations while maintaining planar surface quality through the stationary substrate's consistent positioning.
Solution Approach 2:
The stationary substrate enables continuous operation where the build platform can move downward without interruption to introduce fresh resin layers. The solidification process continues uninterrupted through the always-present planar surface, eliminating idle time for separation and repositioning.
3Ease of operation
If the build platform moves away from the solidification substrate to introduce fresh resin, then new material can be supplied, but the part becomes susceptible to damage from resin forces
Solution Approach 1:
Instead of moving the substrate away from the part, the build platform is moved downward while the substrate remains in place. This inverted approach maintains continuous support for the part during resin introduction, preventing damage from unbalanced resin forces while still enabling fresh material supply.
Solution Approach 2:
The stationary substrate provides preliminary counter-action to the forces exerted by incoming resin during platform movement. This pre-established support prevents part damage before it can occur, maintaining reliability during the resin introduction process.
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 the speed and integrity of three-dimensional object manufacturing by eliminating the need for peeling mechanisms and reducing the risk of damage from resin forces, while maintaining a stable layer of solidifiable material.
Implementation Method 1
In many known techniques of making a three-dimensional object from a solidifiable resin, such as a photocurable or photopolymerizable material, it is necessary to create a substantially planar exposed surface of the solidifiable resin in order to regulate the depth to which the solidification energy penetrates and solidifies the resin
Data Source
AI summary
An apparatus and method for making a three-dimensional object from a solidifiable material using a linear solidification device is shown and described. The apparatus includes a solidification substrate that is tiltable relative to a film about a tilting axis. Layers of the solidifiable material solidify in contact with a film located between the most recently solidified object layer and a solidification substrate that comprises the solidification substrate assembly. The tilting of the solidification substrate relative to the film allows the substrate to be used to squeeze excess solidifiable material from between the film and the most recently solidified object surface while minimizing or eliminating the formation of bubbles in the solidifiable material which can prolong object build times. In addition, tilting the solidification substrate before separating an adhered object surface from the film breaks any vacuum formed between the substrate and the film which reduces the forces involved in separating the object form the film.