Variable Voxel Stereolithography With Dynamic Apertures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current stereolithography (SL) printers face challenges in fabricating 3D macro-scale objects with micro-scale features due to tradeoffs between resolution, speed, scalability, and feature size, struggling to optimize laser beam usage across different scales.
Innovation Solution
A multi-scale stereolithography apparatus with a dynamic aperture having multiple apertures of varying sizes and shapes, controlled by a processor to adjust the laser beam's shape and size, allowing for optimized resolution and speed by switching between different apertures for different features and layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a high resolution is used in SL printing, then the fabrication resolution is improved, but the fabrication speed deteriorates
Solution Approach 1:
The patent applies a dynamic aperture system that can change the size of the laser beam in real-time during the printing process. The aperture diameter is adjusted dynamically based on the local features being printed - smaller apertures for high-resolution micro-features and larger apertures for macro-features, thereby resolving the contradiction between resolution and speed
Solution Approach 2:
The patent changes the physical parameter of the laser beam (beam diameter) by using variable apertures. This parameter change allows the system to adapt to different printing requirements - narrow beams for detailed micro-features and wide beams for large macro-features, eliminating the need to choose between resolution and speed
2Volume of moving object
If the object size is increased in SL printing, then the scalability is improved, but the fabrication speed deteriorates
Solution Approach 1:
The patent applies local quality by using different aperture sizes for different regions of the object. Micro-scale features receive focused attention with small apertures for high resolution, while macro-scale regions use large apertures for rapid fabrication. This localized approach allows large objects to be printed quickly without sacrificing detail where needed
Solution Approach 2:
The patent segments the printing process into different stages or regions based on feature size. The system divides the build volume into micro-scale zones requiring small apertures and macro-scale zones allowing large apertures, enabling simultaneous optimization of resolution for small features and speed for large features
3Volume of moving object
If the part size is increased in SL printing, then the scalability is improved, but the feature resolution deteriorates
Solution Approach 1:
The dynamic aperture system continuously adjusts the beam size based on the current printing location and feature requirements. Even when printing large parts, the system can switch to small apertures for specific detailed features, maintaining high resolution throughout the entire build volume regardless of overall part size
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 the simultaneous optimization of resolution and speed in both the XY and Z directions, allowing for high-resolution micro-features and faster fabrication of macro-features by using appropriate aperture settings, thereby overcoming the limitations of conventional SL printers.
Implementation Method 1
direct the laser beam to cure resin onto the object to be printed
Data Source
AI summary
Methods, systems, and apparatus for multi-scale stereolithography. The apparatus includes a light source for providing a laser beam having a first shape and a first size. The apparatus includes a dynamic aperture having multiple apertures that are of the same or different sizes or shapes. The dynamic aperture is configured to receive the laser beam and modify at least one of the shape or the size of the laser beam. The apparatus includes a platform for holding an object to be printed. The apparatus includes a processor connected to at least one of the light source, the dynamic aperture or the platform. The processor is configured to move the platform to direct the laser beam or direct the laser beam to cure resin onto the object to be printed using a first aperture of the multiple apertures to form the object.