Domain-Based Variable Exposure for Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing devices face challenges in achieving uniform curing of polymer parts due to inconsistent light energy distribution, leading to undercuring or overcuring issues, especially at edges and fine structures, caused by dispersion, reflection, and optical effects in photopolymer resins.
Innovation Solution
The system calculates the total energy received by each portion of a layer, accounting for direct light from the source and light from surrounding elements, and adjusts exposure time to ensure each element receives sufficient energy to meet a curing threshold, using a controller to manage the light source and project discrete light elements to achieve uniform curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If uniform light intensity is used to form a layer, then the light source is simple to control, but undercuring occurs at edges and fine structures
Solution Approach 1:
The patent applies local quality by varying the light intensity across different regions of the build area. Specifically, edges and fine structures receive higher light intensity compared to central regions. This is achieved by modulating the light source output based on the spatial coordinates and structural characteristics of each pixel, ensuring that each region receives appropriate curing energy for its specific geometric and optical properties.
2Reliability
If light exposure time is increased to cure edges and fine structures, then curing completeness improves, but overcuring occurs in other areas
Solution Approach 1:
The patent implements dynamics by making the light exposure parameters time-dependent and spatially variable. Instead of applying a static uniform exposure time across the entire layer, the system dynamically adjusts the exposure duration for each pixel based on its location and structural importance. Edges and fine structures receive extended exposure time while central regions receive shorter exposure, preventing overcuring while ensuring complete curing of critical areas.
3Manufacturing precision
If higher light intensity is applied to ensure sufficient curing energy, then curing threshold is met, but overcuring and bleeding occur
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting multiple light exposure parameters including intensity, duration, and spectral distribution based on the specific requirements of each pixel. The system calculates the optimal combination of these parameters for each region, taking into account factors such as pixel area, structural thickness, and expected light scattering. This precise parameter control ensures that the curing threshold is met without exceeding it, preventing overcuring and bleeding while maintaining manufacturing precision.
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 ensures consistent curing across part layers, allows for the creation of sharp and fragile structures without quality loss, minimizes overcuring and bleeding, and maintains resolution, enabling the formation of precise features like channels and openings.
Implementation Method 1
produce polymer parts solidified from a photopolymer resin which has been exposed in a layer-wise fashion to electromagnetic radiation generated by a light source
Implementation Method 2
light does not travel through the material being cured in a completely linear fashion. Among other things, there is dispersion, reflection and other optical effects
Implementation Method 3
light does not travel through the material being cured in a completely linear fashion. Among other things, there is dispersion, reflection and other optical effects
Data Source
AI summary
Devices, systems, methods and computer program products are disclosed that facilitate part layer curing by an additive manufacturing device wherein each element of the part layer is exposed to light from a light source until the element receives sufficient energy to cure. In an aspect, received energy is calculated based on both the light received directly from the light source and light received from surrounding elements due to dispersion and other effects. The present disclosure enables consistent curing across a part layer, facilitate the creation of sharp outer structures, and allow fragile structures to be built alongside larger structures without a loss of quality, clarity, or resolution.