3D Printing Transparent Dental Parts with Reconfigurable Light Diffusion
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Solution Overview
Problem
Current 3D printing systems for transparent dental appliances often produce surface defects that affect transparency due to uneven light curing, and existing solutions are limited in their ability to diffuse light effectively and are not easily reconfigurable.
Innovation Solution
A multi-layered optical diffusion structure comprising a separation film, light diffusing film, and rigid substrate is used to evenly distribute light intensity across the resin layer, combined with a method of reorienting the digital model to improve transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a light diffusing element is provided between the light source and the resin layer, then surface defects are reduced and transparency is improved, but the device complexity increases and reconfigurability is limited
Solution Approach 1:
The optical diffusion structure is divided into multiple independent layers including a separation film, light diffusing film, and rigid substrate. Each layer can be independently manufactured and assembled, allowing the system to achieve effective light diffusion while maintaining modularity and reducing overall complexity through segmented design.
Solution Approach 2:
The patent implements reconfigurability by allowing the separation film and light diffusing film to be independently replaced and adjusted. The separation film can be removed or repositioned, and the light diffusing film can be swapped with different materials, enabling dynamic adaptation to different printing requirements without redesigning the entire optical assembly.
2Manufacturing precision
If a light diffusing element is provided between the light source and the resin layer, then surface defects are reduced and transparency is improved, but the ease of operation decreases due to limited reconfigurability
Solution Approach 1:
The optical assembly is segmented into independently replaceable components including the separation film and light diffusing film. This segmentation allows users to easily access, remove, and replace individual components without affecting the entire assembly, significantly improving ease of operation and reconfigurability while maintaining surface quality improvements.
Solution Approach 2:
The system is designed with dynamic reconfigurability where the separation film and light diffusing film can be independently adjusted or replaced based on different printing requirements. This dynamic design enables users to adapt the optical assembly to various applications while maintaining the benefit of reduced surface defects and improved transparency.
3Ease of manufacture
If conventional LCD-based 3D printing is used, then manufacturing is simple, but surface imperfections occur that affect transparency
Solution Approach 1:
The optical diffusion structure is positioned between the light source and the resin layer to perform preliminary light diffusion before the curing process. This preliminary action ensures uniform light distribution and prevents surface imperfections from forming during printing, while the modular design keeps the manufacturing process simple and accessible.
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 system achieves improved transparency and surface quality by minimizing surface defects, reducing the need for post-print polishing, and enhancing the overall appearance of 3D printed objects.
Implementation Method 1
a light diffusing film (402) having a diffusing film upper surface (404) and a diffusing film lower surface (406)... wherein light emitted from the light emitting system passes through the rigid substrate and the second interface and through the light diffusing film and the first interface and through the separation film to cure a layer of resin at the print surface; and wherein the light is diffused by passing through the first interface and through the second interface
Data Source
AI summary
A system and method of producing transparent dental appliances. The system includes a reservoir tank assembly with a reconfigurable multi-layer light diffusing assembly. The light diffusing assembly diffuses the curing light thereby reducing defects within the printed part. The light diffusing assembly is easily reconfigurable to provide various levels of light diffusion. The system and method also includes a method for reorienting the build model to a specific offset angle for the three-dimensional printing process to improve the printed part's overall transparency.