UV Laser 3D Printing Resin Temperature Control
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Solution Overview
Problem
Current additive manufacturing techniques face challenges such as time-consuming processes, structural weaknesses, difficulties in creating complex geometries, and limitations in material properties, particularly with photopolymerization methods.
Innovation Solution
The apparatus uses a UV-sensitive liquid resin and a UV laser system with adjustable intensity and movement to cure the resin, allowing for precise control over the polymerization process. Additional features include temperature control, inert gas systems, and support structures to enhance structural integrity and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If layer-by-layer photopolymerization is used, then 3D objects can be created from liquid resin, but the process becomes time-consuming and building speed is restricted
Solution Approach 1:
The patent employs periodic pulsed UV laser irradiation instead of continuous exposure. The laser is activated in controlled pulses that initiate polymerization at specific locations, allowing the resin to remain liquid in other areas. This periodic action enables faster building speeds by selectively curing only the necessary portions at each moment, rather than exposing entire layers sequentially.
Solution Approach 2:
The patent changes the physical state parameter of the resin by controlling temperature. The resin is maintained at elevated temperatures (e.g., 60-80°C or higher) to keep it in a liquid state during printing, enabling freeform construction without layer-by-layer constraints. Temperature parameter control allows the resin to remain pourable and flowable throughout the printing process.
2Ease of manufacture
If layer-by-layer construction is used, then objects can be built, but structural weaknesses occur due to layer adhesion variability
Solution Approach 1:
The patent changes the construction approach from discrete layers to continuous volumetric formation. By maintaining the resin in a liquid state and using focused UV laser pulses, the system creates continuous polymerized structures without distinct layer boundaries. This eliminates inter-layer adhesion issues and produces uniform structural integrity throughout the object.
3Ease of manufacture
If conventional photopolymerization is used, then objects can be created, but difficulties arise in creating hollow, intricate, or overhanging features without support structures
Solution Approach 1:
The patent changes the resin state parameter to liquid through temperature control, enabling freeform construction. The liquid resin can flow into and fill complex geometries, hollow spaces, and overhanging regions without requiring support structures. The UV laser selectively polymerizes the resin in these complex regions while the bulk remains liquid, allowing intricate features to be created directly.
Solution Approach 2:
The patent uses temperature control as an intermediary mechanism to maintain the resin in a liquid state. This thermal intermediary allows the resin to exhibit liquid properties (flowability, fillability) during printing, eliminating the need for support structures while still enabling precise UV laser-induced polymerization where needed.
4Manufacturing precision
If UV light is applied to cure resin, then polymerization occurs, but depth of light penetration limits the aspect ratio of products
Solution Approach 1:
The patent changes the resin's physical state by maintaining it at elevated temperatures in a liquid form. This allows UV light to penetrate deeper into the resin without premature surface polymerization blocking further penetration. The liquid state reduces light scattering and absorption at the surface, enabling curing of deeper regions and taller structures with improved aspect ratios.
5Adaptability or versatility
If resin is kept in liquid form for freeform building, then complex geometries can be created, but maintaining equilibrium between solidification and liquid state is challenging
Solution Approach 1:
The patent systematically controls the temperature parameter to maintain the resin in a liquid state during printing. By heating the resin to specific temperature ranges (60-80°C or higher), the system ensures the resin remains fluid and pourable throughout the printing process, enabling freeform construction of complex geometries without premature solidification.
Solution Approach 2:
The patent introduces temperature control as an intermediary system that mediates between the need for liquid resin (for freeform building) and the need for solidified structure (for structural integrity). The thermal control system maintains the resin in a liquid state during printing, while the UV laser selectively induces solidification only where needed, balancing both requirements.
6Ease of manufacture
If conventional 3D printing equipment is used, then objects can be printed, but scaling up for larger products is difficult due to equipment size limitations
Solution Approach 1:
The patent changes the resin state to liquid through temperature control, which fundamentally alters the printing approach. Instead of moving the build platform layer by layer through a confined space, the liquid resin can be contained in larger vessels and the UV laser can selectively polymerize regions throughout a much larger volume. This enables scaling to larger product sizes without proportionally increasing equipment 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
This approach enables the efficient production of complex geometries with improved structural integrity and material properties, offering enhanced flexibility, efficiency, and customization in 3D object creation.
Implementation Method 1
a process where light causes chains of molecules in the resin to link, forming polymers
Implementation Method 2
a temperature control unit configured to facilitate the chilling or freezing of the UV-sensitive liquid resin to allow for deeper penetration of the UV light without initiating polymerization
Data Source
AI summary
A method and apparatus for forming a three-dimensional object using UV-sensitive liquid resin is disclosed herein. The apparatus employs UV lasers to manipulate intensity, position, and movement, thereby initiating resin polymerization within a transparent container. The apparatus controls premature polymerization by chilling the resin, thereby enhancing UV light penetration. The apparatus can include multiple synchronized laser beams, thereby strengthening internal polymerization. The apparatus incorporates UV-emitting devices within the resin and adjusts laser operations in real-time, using a specialized stage in the container for depth regulation. The approach ensures resin temperature consistency and replaces surrounding air with inert gas, thereby averting oxidation. After polymerization, the method separates the object from residual resin, guiding it from a flexible to a solid state. This separation leverages density differences, temperature management, and chemical assistance, thereby securing the object's structural precision after detachment.