3D Printing UV LED Curing System for Complex Geometries
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Solution Overview
Problem
Existing 3D printing material curing processes are unable to achieve high-performance large-scale printing due to inadequate curing energy distribution and flexibility, particularly with UV light sources like LEDs, which result in inefficient curing and limited complexity in printed objects.
Innovation Solution
A 3D printing system with a compact and movable curing system that combines multiple UV LEDs focused onto a focal region, allowing for adjustable intensity and orientation to efficiently cure printed material, enabling the rapid creation of complex geometries and structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple UV LEDs are used to provide sufficient curing energy, then the curing intensity is improved, but the device complexity and space consumption increase
Solution Approach 1:
The curing system is divided into multiple independent UV LED modules, each capable of being individually positioned and angled. This segmentation allows the curing energy to be distributed across multiple sources while maintaining manageable complexity through modular design, where each module can be independently optimized and replaced.
Solution Approach 2:
The patent positions UV LEDs in three-dimensional space around the printing head, utilizing vertical, horizontal, and angular dimensions to distribute light paths. This spatial arrangement allows multiple LEDs to provide cumulative curing energy without requiring a bulky planar arrangement, as the LEDs are distributed in multiple dimensions around the focal printing area.
2Illumination intensity
If multiple UV LEDs are arranged to distribute light, then the light distribution is improved, but the curing efficiency decreases
Solution Approach 1:
Each UV LED is individually positioned and angled to target specific regions of the printed material, with adjustable orientation to concentrate light paths at the focal region. This local optimization ensures that each LED contributes maximally to the curing process, maintaining high curing efficiency while achieving comprehensive light distribution across the print area.
Solution Approach 2:
The system incorporates sensors to detect the position of the curing system relative to the 3D printed object, enabling real-time adjustment of LED orientations and positions. This feedback mechanism ensures optimal light distribution and curing efficiency by dynamically adapting the LED arrangement to match the actual geometry and position of the printed material.
3Ease of operation
If the curing system is made compact for mobility, then the ease of operation is improved, but the curing energy delivery is limited
Solution Approach 1:
Multiple UV LED modules are nested within a compact housing structure, with each module containing its own optical elements and positioning mechanisms. This nested arrangement allows a high density of curing sources to be packed into a small volume, maintaining compactness and mobility while delivering sufficient cumulative curing energy through the coordinated output of multiple nested modules.
Solution Approach 2:
The compact curing system utilizes three-dimensional LED arrangement around the printing head, with LEDs positioned at various heights, angles, and radial distances. This multi-dimensional configuration allows the system to deliver high curing energy within a compact footprint, as the light paths converge in three-dimensional space rather than requiring extended linear or planar arrangements.
4Volume of moving object
If UV LEDs are used instead of gas discharge lamps, then the size is reduced, but the curing energy is insufficient
Solution Approach 1:
Multiple UV LED modules are combined in a coordinated array, with their individual curing energies accumulating to match or exceed the total output of traditional gas discharge lamps. This merging of multiple lower-power LED sources achieves the required total curing energy while maintaining the compact size advantage of LEDs, as the modular combination allows scalable energy delivery without the bulk of lamp-based systems.
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 faster and more controlled curing of 3D printed materials, allowing for the production of complex and high-quality objects with increased printing speed and flexibility, reducing labor costs and improving automation precision.
Implementation Method 1
a plurality of curing sources (e.g., UV LEDs) that can be coordinated to focus their combined curing energies (e.g., UV light) upon a relatively small focal region
Data Source
AI summary
A 3D printing system can include an extruding system, curing system and feedback system. The extruding system can include a feed pipe coupled to a printing material source and a nozzle that extrudes a printed material. The feedback system can include a processor and sensors and can detect the temperature and location of the curing system during the printing process. The curing system cures the printed material after extrusion and includes curing sources coupled to a mounting arrangement, which can be a curved surface. The curing sources can each be directed toward a focal region located proximate the nozzle outlet and can combine to emit a combined curing energy to the focal region. The curing sources can be LEDs and the curing energy can be UV light. The curing system can rotate about an axis during printing and curing to facilitate rapid movement and printing of complex 3D objects.