3D Printing Voxel Segmentation for Resolution and Time Trade-off
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Solution Overview
Problem
Current two-photon absorption 3D printing processes are limited by insufficient Z-resolution, leading to long printing times for objects requiring both high and low resolution parts, as the dimensions of voxels must be significantly smaller than the object, resulting in inefficient manufacturing.
Innovation Solution
The process involves decomposing object volumes into identical blocks with hollow portions, using a network of irradiation beams focused at multiple points, and shifting these points between successive irradiations, allowing for the creation of voxels with dimensions much larger than the focal volume, and simultaneously printing multiple voxels to reduce overall printing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If voxel dimensions are reduced to achieve high resolution, then manufacturing precision is improved, but productivity deteriorates due to extremely long printing times
Solution Approach 1:
The patent divides the object volume into multiple identical blocks, each block being further divided into a grid of voxels. This segmentation allows parallel processing of multiple blocks simultaneously, reducing overall printing time while maintaining high resolution within each block. The decomposition into standardized blocks enables the printing system to process multiple regions in parallel rather than sequentially.
Solution Approach 2:
The patent combines multiple focal volumes into a single irradiation step by positioning multiple focal points within the material simultaneously. The beam magnifier and focusing lens system creates multiple focal points that can transform multiple voxels in parallel during a single irradiation cycle, significantly reducing the number of sequential printing operations required.
2Productivity
If voxel dimensions are increased to reduce printing time, then productivity is improved, but manufacturing precision deteriorates due to insufficient Z-resolution
Solution Approach 1:
By dividing the object into multiple identical blocks with internal voxel grids, the system can use larger effective voxel dimensions for each block while maintaining overall object resolution through the block decomposition. Each block contains a manageable number of voxels that can be processed efficiently.
Solution Approach 2:
The patent introduces a new dimension of parallelism by processing multiple blocks and multiple focal points simultaneously. Instead of increasing voxel size in three dimensions at the cost of resolution, the system adds a temporal and spatial parallelism dimension, allowing multiple smaller voxels to be processed at the same time, thus maintaining resolution while improving productivity.
3Productivity
If the number of voxels is reduced to shorten printing time, then productivity is improved, but manufacturing precision deteriorates due to inability to print fine features
Solution Approach 1:
The patent segments the object into identical blocks, each containing a standardized voxel grid. This allows the system to maintain fine feature resolution within each block while reducing the total number of printing operations by processing multiple blocks in parallel. The segmentation creates a hierarchy where fine details are preserved at the block level while overall productivity improves through parallel block processing.
Solution Approach 2:
Each block is treated as an independent unit with its own voxel grid, allowing local optimization of printing parameters. The system can maintain high resolution locally within each block while using larger, faster printing steps between blocks, achieving a balance between feature detail and overall printing efficiency.
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 significantly reduces printing times by allowing for the creation of objects with high-resolution features and larger, lower-resolution components using voxels that are 100 to 1000 times larger than those required for high-resolution parts, thereby decreasing the total printing time by a substantial factor.
Implementation Method 1
A well-known 3D printing process based on successive transformations of elementary volumes of a material by irradiation uses a photochemical reaction induced by multiphoton absorption of at least two photons
Implementation Method 2
a photochemical reaction induced by multiphoton absorption of at least two photons
Implementation Method 3
the laser beam 21 is focused by the lens 13 onto a point 23 located in the material 17
Data Source
Figure 1~3B
Figure 4~6
Figure 7A~7E
AI summary
The invention relates to a method for 3D printing, wherein elementary volumes, or voxels, of a material are sequentially transformed by irradiation, comprising the following steps: breaking down, into identical blocks (39), the volume of part (35) of an object (31) to be printed that does not require a maximum resolution; for printing, associating with each block a brick having the same contour and comprising hollow portions; and irradiating in order to print the voxels of the bricks.