Addressable UV Curing for 3D Printed Parts
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Solution Overview
Problem
3D printing with UV-curable inks faces challenges in achieving proper curing without over-curing, which affects the physical and aesthetic properties of the printed objects, including strength, hardness, and color consistency, and poses health hazards due to incomplete curing of non-biologically neutral inks.
Innovation Solution
Implementing addressable UV curing systems that use controllable UV light to irradiate specific pixels or areas of the 3D printed object based on a multi-layer history, adjusting curing intensity layer-by-layer to ensure complete curing without over-curing, by employing LED-based exposure arrays that account for the varying penetration of UV light through different ink layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If UV light is applied to cure UV-curable inks in 3D printed parts, then the ink layers are cured and structural integrity is improved, but over-curing occurs which degrades physical and aesthetic properties
Solution Approach 1:
The curing process is segmented by applying UV light layer-by-layer through the build plate, with each layer cured individually before the next layer is deposited. This segmentation prevents over-curing of underlying layers while ensuring complete curing of each layer, resolving the contradiction between curing completeness and physical property preservation
Solution Approach 2:
The system performs preliminary curing of each ink layer immediately after deposition before proceeding to the next layer. This preliminary action ensures each layer is fully cured without exposing underlying layers to excessive UV light, thereby preventing over-curing damage while maintaining curing completeness
2Reliability
If UV light penetration is increased to cure deeper layers, then complete curing is achieved, but surface layers become over-cured and discolored
Solution Approach 1:
The curing process is divided into discrete layer-by-layer steps where UV light is applied to each layer individually. This segmentation ensures that only the current layer receives UV exposure, preventing surface layers from becoming over-cured and discolored while still achieving complete curing of deeper layers
Solution Approach 2:
The system applies different curing conditions to different layers based on their depth and ink composition. Each layer receives customized UV exposure parameters appropriate for its specific requirements, ensuring uniform color consistency across all layers while maintaining complete curing
3Device complexity
If standard UV curing is applied to all layers uniformly, then the process is simple, but incomplete curing occurs in deeper layers posing health hazards
Solution Approach 1:
The curing process is segmented into sequential layer-by-layer curing steps. Each layer is cured completely before the next layer is deposited, ensuring that even deep layers receive adequate UV exposure. This segmentation eliminates health hazards from incomplete curing while adding minimal complexity to the printing process
Solution Approach 2:
The UV curing action is applied continuously and uniformly to each layer as it is deposited, with no interruption between layer curing. This continuous action ensures complete curing of all layers including deep ones, eliminating health hazards while maintaining process simplicity through automated sequential operation
4Productivity
If higher UV intensity is used to cure thick parts, then curing speed increases, but over-curing damage occurs to the parts
Solution Approach 1:
The curing process is segmented by thickness, with UV light applied in controlled increments to each layer. This segmentation allows high curing speed for thin layers while preventing over-curing damage in thick parts, as each layer is cured completely before the next layer is added, distributing the total curing intensity across many smaller exposure events
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
Ensures thorough and uniform curing of 3D printed parts, enhancing their structural and surface integrity, minimizing defects and health risks associated with incomplete curing, while maintaining optimal physical and aesthetic properties across a range of UV ink colors.
Implementation Method 1
curing of ultraviolet (UV) light curable inks
Implementation Method 2
employing LED-based exposure arrays that account for the varying penetration of UV light through different ink layers
Data Source
AI summary
A system and method are provided for implementing adjustable curing of layers of deposition materials, including ultraviolet (UV) light or photo curable ink layers, used in the formation and/or manufacture of three-dimensional (3D) printed parts, objects and components, particularly those parts, objects and components formed in 3D printers and additive material manufacturing systems such as 3D jetted ink printing systems. A multi-layer (or layer-by-layer) history of the deposited materials is developed by which to adjust an intensity of an addressable curing unit to provide complete curing to a particular layer without introducing damaging effects that may be caused by over curing the particular layer. The applied curing energy will differently penetrate a number of layers based on constitutions and/or colors of the individual layers in the number of layers to be penetrated. Discrete addressable curing of the individual layered components provides correct curing to the individual layers.