UV Cure Level Determination via Thermal Rayleigh Wave Measurement
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Solution Overview
Problem
Current 3D printing methods lack an efficient method to determine whether materials are fully cured, leading to potential issues with finish quality, adhesion, and the need for inefficient offline analysis and reprocessing.
Innovation Solution
A method and apparatus that apply heat to induce Rayleigh waves in UV-cured materials, measuring storage and loss modulus values to determine the cure level by comparing them to predefined values, and generating a signal to display the cure status, allowing for in-line evaluation within a 3D printing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If offline analysis methods are used to determine cure level, then measurement accuracy may be adequate, but productivity is reduced due to reprocessing and loss of time
Solution Approach 1:
The patent applies preliminary action by implementing real-time cure level monitoring during the 3D printing process rather than performing offline analysis after printing. The system continuously measures cure levels using optical sensors and provides immediate feedback, allowing the printing process to be adjusted on-the-fly without stopping for offline analysis or reprocessing.
Solution Approach 2:
The patent replaces mechanical/offline analysis methods with an optical measurement system. Instead of physically extracting samples for laboratory analysis, the system uses optical sensors to non-contact, real-time measure the cure level of materials during printing, substituting mechanical intervention with optical field-based measurement.
2Productivity
If no cure level determination is performed, then productivity is maintained, but manufacturing precision deteriorates due to improper finish and adhesion
Solution Approach 1:
The patent implements feedback control by continuously monitoring cure levels during the printing process and using this information to adjust printing parameters in real-time. The system measures the actual cure level achieved and compares it to the target cure level, then modifies subsequent printing or curing operations to compensate for deviations, ensuring consistent finish quality and adhesion.
Solution Approach 2:
The system performs preliminary cure level verification during the printing process itself, allowing detection of insufficient curing before the printing is complete. This prevents the need for reprocessing while maintaining quality, as issues are addressed during rather than after printing.
3Manufacturing precision
If real-time monitoring is implemented, then productivity and manufacturing precision are improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a monitoring system that can evaluate cure levels across different materials and printing conditions using the same fundamental optical measurement approach. The system is configured to work with various photopolymerizable materials and printing technologies, reducing the need for multiple specialized devices while maintaining measurement accuracy.
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
Enables a non-destructive, efficient evaluation of UV cure levels, ensuring proper completion of the curing process and reducing the need for offline analysis and reprocessing, thereby improving the quality and efficiency of 3D printing.
Implementation Method 1
material that is cured via a UV light source
Implementation Method 2
controls a heat source to heat the material
Implementation Method 3
determines the UV cure level of the material based on the parameter that is measured and a predefined response of the material at a temperature associated with the heat
Data Source
AI summary
A method for determining an ultraviolet (UV) cure level of a material is disclosed. For example, the method includes receiving an object with the material that is cured via a UV light source, controlling a heat source to heat the material, measuring a parameter of the material in response to the heat, determining the UV cure level of the material based on the parameter that is measured and a predefined response of the material at a temperature associated with the heat, and generating a signal to display the UV cure level in response to the determining.