UV Projector Beam Splitter 3D Printing System
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Solution Overview
Problem
Conventional projection-based 3D printers face limitations in production speed and output area due to fixed focal length UV projectors and a large number of pixels, leading to reduced resolution and increased manufacturing costs for mass production.
Innovation Solution
A 3D printing system utilizing a single UV projector, beam splitters, and mirrors, with a workstation that adjusts gray scale levels and shutter control to simultaneously output multiple patterns, allowing for high-resolution, large-area printing by dispersing UV light and optimizing light distribution across the output area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of UV projectors is increased to achieve mass production and large-area output, then productivity is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent divides a single UV light source into multiple independent light paths using beam splitters. Each beam splitter separates the light into different directions, creating multiple projection channels from one source. This segmentation allows simultaneous multi-area printing without requiring multiple UV projectors, thereby improving productivity while avoiding the high cost of deploying multiple projectors.
2Area of stationary object
If the output area is expanded by combining with appropriate lenses, then area is improved, but resolution is lowered due to fixed pixel count
Solution Approach 1:
The patent transitions from a single 2D projection plane to multiple 2D projection planes by introducing beam splitters that create separate light paths. Each beam splitter directs light to a different output area, effectively adding a spatial dimension to the projection system. This allows the system to maintain high resolution in each individual projection area while simultaneously expanding the total output area across multiple regions.
3Adaptability or versatility
If movement is given to optical components such as UV projector to achieve flexibility, then adaptability is improved, but accuracy is deteriorated in high-resolution output and output speed is reduced
Solution Approach 1:
The patent segments the optical system into multiple fixed beam splitters that create separate, stable light paths. By dividing the projection function across multiple fixed components rather than moving a single projector, the system achieves flexibility in terms of simultaneous multi-area output while maintaining the stability and precision required for high-resolution printing in each area.
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 customized mass production with high resolution and large-area output while maintaining image quality, as UV light is evenly distributed and adjusted through gray scale levels and shutter control, overcoming the limitations of conventional systems.
Implementation Method 1
a plurality of beam splitters for dispersing the irradiated UV light
Implementation Method 2
a plurality of mirrors for reflecting the dispersed UV light
Implementation Method 3
projection-based 3D printers, which cure photocurable materials one layer by one through UV light from a UV projector
Data Source
AI summary
The present invention relates to a 3D printing system and method for controlling the same, the method comprising a 3D printer comprising a single UV projector for irradiating UV light, a plurality of beam splitters for dispersing the irradiated UV light, a plurality of mirrors for reflecting the dispersed UV light, and a shutter that is open or closed according to the number of outputs that are to be simultaneously output, and a workstation for performing pre-processing and control for 3D printing, the method comprises receiving, by the workstation, the number of outputs that are to be simultaneously output in parallel, opening, by the 3D printer, the shutter according to the number of outputs, setting, by the workstation, a pattern image, adjusting, by the workstation, a gray scale level for each pixel with respect to the set pattern image and 3D printing, by the 3D printer, the pattern image of which the amount of light is adjusted through the gray scale level.