Volumetric 3D Printing with Cryogenic Cooling and Flash Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printing systems are time-consuming and limited in producing large or complex 3D objects due to the layering process, which restricts the size and quantity of objects that can be manufactured.
Innovation Solution
A system utilizing 3D volumetric display vector techniques with photonic energy emitters and UV curable materials in combination with flood and drain additive manufacturing, allowing for high-speed production of 3D objects through 'flash emitting' of photonic energy to solidify the material, and employing cryogenic cooling to prevent heat-induced distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional layer-by-layer 3D printing is used, then manufacturing precision is maintained, but production time increases significantly and productivity decreases
Solution Approach 1:
The system uses periodic flash emission of photonic energy to cure photopolymer material in volumetric sections. Instead of continuous layer-by-layer processing, the system employs periodic pulsed illumination where each pulse cures a volumetric chunk of material, significantly reducing the total number of processing steps while maintaining precision through controlled timing and intensity of each periodic action.
Solution Approach 2:
The invention transitions from two-dimensional layer-by-layer curing to three-dimensional volumetric curing by using multiple photonic energy emitters positioned at different angles. This dimensional change allows simultaneous curing of entire volumetric sections rather than processing thin layers sequentially, dramatically improving productivity while maintaining manufacturing precision through coordinated multi-angle illumination.
2Productivity
If high-power photonic energy emitters are used to speed up curing, then productivity increases, but heat accumulation causes material distortion and manufacturing precision deteriorates
Solution Approach 1:
The system segments the total photonic energy delivery into multiple lower-power pulses delivered from different angles and time periods. Instead of using one high-power emitter that causes heat accumulation, multiple emitters deliver energy in segmented pulses, each at lower intensity, preventing thermal distortion while achieving the same total curing effect and maintaining manufacturing precision.
Solution Approach 2:
The system performs preliminary cooling of the photopolymer material before each flash emission event. By pre-cooling the material and using periodic intervals between pulses, the system prevents heat accumulation that would cause distortion, allowing high-productivity curing while maintaining shape accuracy through proactive thermal management.
3Productivity
If volumetric display techniques are implemented, then production time is reduced and productivity increases, but system complexity increases due to multiple photonic energy emitters and control mechanisms
Solution Approach 1:
The multiple photonic energy emitters are designed to perform multiple functions: each emitter can independently target different volumetric sections, all emitters collectively provide cross-linking reinforcement, and the system can adaptively adjust which emitters are active based on the object geometry. This multi-functionality justifies the increased device complexity by enabling volumetric curing speeds that single-emitter systems cannot achieve.
Solution Approach 2:
The system merges multiple photonic energy emitter systems into a coordinated unified control architecture. By combining the emitters under single integrated control that synchronizes their operation, the system achieves volumetric curing productivity while managing complexity through consolidation of control functions and shared infrastructure rather than independent control of each emitter.
4Speed
If flash emitting technique is used to solidify material rapidly, then production speed increases, but heat-induced warping occurs and object integrity is compromised
Solution Approach 1:
The system applies counter-illumination from multiple angles to balance and distribute thermal stress during rapid solidification. By positioning photonic energy emitters strategically and controlling their activation sequences, the system creates counterbalancing energy distribution that prevents localized overheating and warping, maintaining object structural integrity while achieving rapid flash emitting solidification speeds.
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 rapid and high-volume production of 3D objects without the limitations of traditional layering methods, allowing for the creation of complex designs and larger objects in sections rather than thin layers, while maintaining object integrity.
Implementation Method 1
computer and software controlled photonic energy emitters such as but not limited to ultraviolet ("UV"), visible light spectrum, and/or infrared ("IR") emitting
Implementation Method 2
photonic energy reactive, curable, or solidifying material
Implementation Method 3
employing cryogenic cooling to prevent heat-induced distortion
Data Source
AI summary
Methods and systems of and for using volumetric display technology including volumetric display technology to create three-dimensional objects for various industries, including, but not limited to solar, automotive and/or other technological areas that use 3D printing or additive manufacturing.