Volumetric 3D Printing with Multi-Color Light Sheet Polymerization
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Solution Overview
Problem
Existing volumetric 3D printing methods using multi-color photopolymerization of photocurable resins face inefficiencies and quality issues due to homogeneous light intensity distribution, leading to unnecessary polymerization of non-object volume elements and difficulty in recycling partially polymerized resin.
Innovation Solution
A method that controls the intensity distribution of light sheets by irradiating photocurable resin with light of different wavelengths, creating an inhomogeneous intensity distribution to selectively polymerize only the desired object volume elements, using a controller to manage the overlap and angles of individual light sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a homogeneous light intensity distribution is used in volumetric 3D printing, then the light intensity is uniformly distributed throughout the working volume, but this causes unnecessary polymerization of non-object volume elements and reduces printing efficiency
Solution Approach 1:
The patent applies local quality by creating an inhomogeneous light intensity distribution where the light intensity varies spatially according to the geometry of the target object. The irradiation device generates light sheets with different intensities at different positions and depths, ensuring that only the volume elements corresponding to the object receive sufficient intensity for polymerization, while non-object regions receive insufficient intensity to trigger polymerization. This resolves the contradiction by achieving precise polymerization control without wasting energy on unnecessary regions.
2Manufacturing precision
If a homogeneous light intensity distribution is used, then the light intensity is uniformly distributed, but this leads to partial polymerization of resin in non-object regions making recycling difficult
Solution Approach 1:
The patent implements local quality by spatially varying the light intensity so that only specific regions experience sufficient intensity for polymerization. The irradiation device controls the light sheet intensity to match the object's geometric requirements, ensuring that resin in non-object regions remains unpolymerized and in its original liquid state, thereby maintaining ease of recycling and reprocessing.
3Illumination intensity
If light of the first wavelength is used to form individual light sheets, then the light can penetrate through the photocurable resin, but light absorption causes inhomogeneous light intensity distribution
Solution Approach 1:
The patent applies dynamics by making the light sheet intensity distribution adaptive rather than static. The irradiation device dynamically adjusts the light intensity at different positions and depths based on the object's geometry and the light absorption characteristics of the resin. This dynamic control compensates for the inhomogeneous distribution caused by light absorption, ensuring that the effective light intensity matches the required polymerization patterns.
4Area of stationary object
If multiple individual light sheets are used to form a resulting light sheet, then the light can cover the entire working volume, but this increases the complexity of the irradiation device
Solution Approach 1:
The patent applies merging by combining multiple individual light sheets into a single resulting light sheet that covers the entire working volume. The irradiation device integrates multiple light sources or multiple beams into a unified light sheet structure, where the individual light sheets are merged in space and time to create a comprehensive coverage pattern. This merging approach expands coverage area while managing device complexity through integrated control.
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 efficiency and quality of 3D printing by ensuring precise polymerization only where needed, improving the resolution and properties of the printed object while allowing for easier recycling of unused resin.
Implementation Method 1
volumetric 3d-printing a three-dimensional object by multi-color photopolymerization of a photocurable resin
Implementation Method 2
Due to the light absorption of the photocurable resin the light intensity decreases the further the light penetrates into the volume
Data Source
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AI summary
A method for volumetric 3d-printing a three-dimensional object by multi-color photopolymerization of a photocurable resin.