Vatless Additive Manufacturing Using Transparent Build Table
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Solution Overview
Problem
Existing additive manufacturing methods, such as vat-based and tape casting, face issues with contamination and material wastage, leading to undesirable geometry and inefficiency in the build process due to the reuse of contaminated resin and wasteful tape usage.
Innovation Solution
An additive manufacturing method and apparatus that deposits and cures material on a rigid, transparent build table, which is moved to expose a fresh surface for each layer, using a radiant energy source and a material remover to ensure clean and efficient material handling, reducing contamination and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vat-based additive manufacturing is used, then material can be built up layer-by-layer, but contamination from old resin cures into the component resulting in undesirable geometry
Solution Approach 1:
The build surface is divided into multiple sections that can be independently advanced. After a layer is cured, the build surface is advanced to expose a fresh, clean section for the next layer, separating the cured component from the remaining resin and preventing contamination.
Solution Approach 2:
The build surface is made movable rather than stationary. It can be advanced between layers to continuously expose fresh material, transforming a static vat-based system into a dynamic process that prevents contamination by constantly moving to new clean areas.
2Ease of manufacture
If tape casting process is used, then resin can be deposited onto flexible tape, but the tape is often not reusable resulting in material wastage
Solution Approach 1:
Instead of using expensive, non-reusable flexible tape, the invention employs a rigid build surface that is advanced and reused. The build surface maintains its structural integrity across multiple layers and can be cleaned and reused, eliminating the need for disposable tape.
Solution Approach 2:
The system recovers and reuses the build surface after each layer is cured. The build surface is advanced to expose fresh material, and the process is repeated, recovering the utility of the build surface for multiple layers rather than discarding it like the tape.
3Manufacturing precision
If the build surface is advanced to expose fresh material, then contamination is minimized, but additional actuators and drive mechanisms are required
Solution Approach 1:
The build surface serves multiple functions: it provides the curing surface, stores the resin material, and acts as the platform that is advanced between layers. This multi-functionality reduces the need for separate actuators and drive mechanisms compared to dedicated component 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
This approach enhances the build process by minimizing contamination, reducing material waste, and improving the accuracy and efficiency of component production, offering a more cost-effective and faster method compared to prior art techniques.
Implementation Method 1
a radiant energy apparatus positioned adjacent to the build table opposite to the stage, and operable to generate and project radiant energy on the resin through the build table in a predetermined pattern
Implementation Method 2
a material applicator operable to deposit a radio-energy-curable resin on the build surface
Data Source
AI summary
An additive manufacturing apparatus includes: a build table, at least a portion of which is transparent, the build table defining a build surface; a material applicator operable to deposit a radio-energy-curable resin on the build surface; a stage positioned facing the build surface of the build table and configured to hold a one or more cured layers of the resin; one or more actuators operable to change the relative positions of the build table and the stage; a radiant energy apparatus positioned adjacent to the build table opposite to the stage, and operable to generate and project radiant energy on the resin through the build table in a predetermined pattern; a drive mechanism operable to move the build table so as to expose a new portion thereof for each layer; and material remover operable to remove remnants from the build surface. A method for using the apparatus is provided.