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WO2018203867A1 - Photopolymérisation de cuve de balayage - Google Patents

Photopolymérisation de cuve de balayage Download PDF

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Publication number
WO2018203867A1
WO2018203867A1 PCT/US2017/030316 US2017030316W WO2018203867A1 WO 2018203867 A1 WO2018203867 A1 WO 2018203867A1 US 2017030316 W US2017030316 W US 2017030316W WO 2018203867 A1 WO2018203867 A1 WO 2018203867A1
Authority
WO
WIPO (PCT)
Prior art keywords
build layer
velocity profile
scanning
dimensional shape
pixel
Prior art date
Application number
PCT/US2017/030316
Other languages
English (en)
Inventor
Viswanath MEENAKSHISUNDARAM
Christopher B. Williams
Original Assignee
Virginia Tech Intellectual Properties, Inc.
Compagnie Générale Des Etablissements Michelin
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Virginia Tech Intellectual Properties, Inc., Compagnie Générale Des Etablissements Michelin filed Critical Virginia Tech Intellectual Properties, Inc.
Priority to PCT/US2017/030316 priority Critical patent/WO2018203867A1/fr
Priority to PCT/US2018/040481 priority patent/WO2018204938A2/fr
Publication of WO2018203867A1 publication Critical patent/WO2018203867A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/277—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

Definitions

  • Vat-Photopolymerization is an Additive Manufacturing process where light of a particular wavelength is used to cure a liquid resin or photopolymer to a solid part.
  • Mask Projection Vat-Photopolymerization is a modification to the traditional VP technique, where a digital masking device is used to generate and project patterns on the surface of a photocurable resin.
  • Digital masks such as Digital Micro-Mirror Devices (DMD), Liquid Crystal Devices (LCD) and Liquid Crystal on Silicon (LCOS) can be used to generate and reflect patterns.
  • the present invention provides a VP system and method wherein the pattern mask is scanned at non-uniform speeds to create three-dimensional objects, patterns as well as shapes of varying or graded thickness profiles through an area of film.
  • the present invention provides a VP system and method wherein the pattern mask is scanned with different light intensities to create three- dimensional objects, patterns as well as shapes of varying or graded thickness profiles through an area of film.
  • the present invention provides a VP system and method wherein the pattern mask is scanned at non-uniform speeds and varying light intensities to create three-dimensional objects, patterns as well as shapes of varying or graded thickness profiles through an area of film.
  • the present invention provides a VP system and method that can produce smooth cavities in a single pass.
  • the present invention can create curved, arcuate and other surface features that very in height in a single pass.
  • the present invention provides a VP system and method wherein the frame rate of the moving mask is matched with a velocity profile to achieve a predetermined profile on the film.
  • the present invention provides a VP system and method that can make textures on the resin, without having to make multiple passes. Textures may be printed on existing parts such as shoes, gloves and tires. Also, complex patterns can be generated for creating new and unique tread patterns. Moreover, monolayer patterns can be printed on test specimens for preliminary evaluation.
  • the present invention provides a VP system and method that can manufacture large area and high resolution parts.
  • the present invention provides a process to make parts and objects with varying thickness without having multiple layers and intermediate recoating steps used in the VP process. With the elimination of the recoating step, the manufacturing speed is increased significantly.
  • the present invention provides a VP system and method that overcomes the effects of stair-stepping by using appropriate velocity profiles and pixel blending.
  • the present invention provides a VP system and method for use in the automobile industry. Complex patterns can be created, with high temperature polymers and ceramic printing technologies, for heat exchangers and catalytic converters at a fraction of the cost by eliminating need to use micromachining.
  • the present invention provides a VP system and method for use in making apparel.
  • the embodiments of the present invention allow for the rapid manufacturing of custom shoe grips, glove grips and other textured sports apparel. Due to the large manufacturing area, multiple custom components can be built at the same time.
  • the present invention provides a VP system and method that may be used to produce complex shapes in a single layer using a single pass.
  • the embodiments of the present invention may be used to produce structures having little to no interlayer interfaces which reduces cracks propagation sites in a build layer.
  • the present invention provides a VP system and method for use in making implants and planar cell scaffolds.
  • the embodiments of the present invention may be used to manufacture planar scaffolds for cell growth and for making implants like partial dental crowns.
  • the embodiments of the present invention may also be used to manufacture intricate single layer stents and sheaths for nerve repair.
  • the thin films can also be used for controlled drug delivery through differential -dissolution.
  • the present invention provides a VP system and method for use in making films that may be used to manufacture purification membranes for water treatment apparatus. Also, gas separation membranes may be made by controlling the feature sizes in the nanometer scale.
  • the present invention provides a VP system and method for producing a three-dimensional shape on a build layer in a single scan by variably exposing one or more scanned units and/or voxels of the build layer in a single scan.
  • the scanning is a continuous movement which may have a variable scanning speed, a variable intensity, or both.
  • the present invention provides a scanning vat- photopolymerization system and method for producing a three-dimensional shape on a build layer in a single scan by varying the thickness in one or more scanned units by varying the energy applied to each scanned unit.
  • the present invention provides a system and method wherein the thickness is varied by changing the exposure depth of the scanned units and/or voxels.
  • the scan may be a continuous movement having a variable scanning speed, a variable intensity, or both.
  • the present invention provides a system and method wherein further including the steps of determining the active-pixel density from the bitmap image of the geometry; determining the required number of pixel translations to create a mask for the required geometry; and determining the frame rate for each pixel transition to achive the energy for creating a predetermined thickness on a specific region of the build layer.
  • Figure 1 is a schematic of a mask projection vat-photopolymerization.
  • Figure 2 is a schematic of a Scanning Mask Projection Vat-Photopolymerization machine.
  • Figure 3 provides a working schematic for scanning vat-photopolymerization.
  • Figure 4A is a schematic of a variable exposure scanning vat-photopolymerization machine for one embodiment of the present invention.
  • Figure 4B provides an example velocity profile used in connection with the embodiment shown in Figure 4A.
  • Figure 5 illustrates a generated pixel pattern (left) and an effective pixel pattern (right).
  • Figure 6A provides a general process flow for one embodiment of the present invention.
  • Figure 6B provides a slice generation algorithm.
  • Figure 6 is a flowchart showing gray-scaling to obtain patterns with varying thickness.
  • Figure 7 illustrates an example pattern to be printed (left) and a velocity profile required for printing the pattern (right).
  • Figure 9 illustrates the different thicknesses observed in a single layer for an embodiment of the present invention.
  • FIG. 1 shows a schematic of a Mask Projection VP system 100. Light emitted from source 102 is collimated, clipped and transmitted by optics 104-105 and mirror 106 to and from DMD 108. A computer 110 is used to generate and relay a bitmap
  • White pixels representing the desired pattern
  • Black pixels representing the voids or uncured areas
  • the ON' pixels reflect the light perpendicular to the surface of the resin, projecting a pattern
  • the OFF' pixels reflect the light away from the projection optics.
  • the irradiated part of the resin surface undergoes photopolymerization and cures in the shape of the projected pattern.
  • the build platform is lowered into the resin by a depth of one-layer thickness. The process is repeated until the entire 3D part is built layer-by- layer in a time-consuming manner.
  • Figure 2 shows a typical setup of a Scanning Mask Projection Vat-
  • Photopolymerization machine 200 A common light source 202 such as a laser, Light Emitting Diode (LED) or a broad-spectrum Ultra Violet (UV) light source is focused into projector 204, which may be a DLP® projector, with the help of imaging optics 206, which may be a collimator or a light guide respectively. Appropriate imaging and projection optics are attached to the projector depending on the requirements such as projected pixel size, projection area, projected pixel intensity and manufacturing time.
  • a computer 210 is used for the generation of the dynamic moving mask and the synchronous control commands for the projector, and the X, Y and Z linear stages.
  • Figure 3 shows the working schematic of the scanning Mask Projection Vat- Photopolymerization machine 200.
  • the build platform is lowered to one-layer thickness below the resin surface.
  • position 1 only the first pixel is 'Switched On' to cure a square on the resin surface.
  • position 2 the first pixel is maintained in the ON' position, curing another square.
  • the projector scans the surface of the resin at a predetermined speed from position 1 through 5, a line of uniform layer thickness is cured on the resin surface.
  • a layer of required thickness is obtained by moving the projector at a scan speed that exposes every pixel with a predetermined constant irradiance. For example, if curing square 300 shown in Figure 3, required 2 seconds, then the moving mask and the scan speed are synchronized such that every pixel is consecutively exposed for 2 seconds over the entire scanning time.
  • a single pixel model is illustrated in Figure 3 to reduce the complexity of the concept.
  • any complex 2D pattern i.e. multiple pixels
  • the achievable part size is determined by the length of the linear stages and not the optics, as in traditional VP machines.
  • a complete 3D part can be obtained by lowering the build platform and repeating the steps discussed above.
  • 3D parts are created by a continuous scanning process wherein the scan speed is maintained constant throughout the scan. This results in cured layers having uniform thicknesses because they are exposed to equal UV radiation throughout the scan.
  • the scan speed during the printing of a single layer is varied depending on the thickness desired for a predetermined area of a layer. This enables the embodiments of the present invention to facilitate the manufacturing of large area, high resolution textured films at high speeds.
  • the pattern mask is scanned at non-uniform or variable speeds to create a graded thickness profile through the area of the film.
  • Figure 4A and 4B provide an exemplary velocity profile that may be used to generate the pattern shown.
  • the effective UV irradiation on the resin reduces and thus lowers the layer thickness of the cure part.
  • the frame rate of the moving mask is matched with the velocity profile to achieve the required profile on the film at a predetermined location.
  • Figure 5 shows an exemplary layer 500 having a surface 502 that may be obtained in a single pass using the embodiments of the present invention.
  • layer 500 has a non-uniform thickness and is comprised of sections, printed units, scanned units and/or voxels 510-514 each of which has discrete exposure values and corresponding depths of exposure.
  • Section 512 was made by applying the least amount of energy as compared to the other sections shown. This may be accomplished by using the highest value velocity profile, the lowest intensity, or a combination of both.
  • 512 has a depth of exposure (x) in this instance as compared with sections, scanned units and/or voxels 510, 511, 513 and 514.
  • Scanned sections 510 and 514 were made using the highest applied energy levels, such as the lowest velocity profile or highest intensity level. Sections 510 and 514 have a depth of exposure in this instance of twice (2x) that of 512. Sections 511 and 513 were made using applied energy levels in between the other profiles and have a depth of exposure of in this instance of one point five (1.5x) that of 512.
  • a wide variety of surface profiles may be obtained. These surface features include curved, arcuate, concave, convex, ramped, peaked, valley-like as well as other three-dimensional shapes.
  • the staircase effect may be eliminated from the cured part - which is typical in a layer-by-layer manufacturing approach.
  • the embodiments of the present invention can produce parts/features with improved surface finish compared to current printed parts.
  • the improvements include, smooth transitions in layer thickness.
  • FIG. 6A The general process flow for the proposed process is shown in Figure 6A.
  • the .STL file of the part is sliced into a bitmap image - that represents the required pattern.
  • the bitmap image is formatted such that the resolution matches that of the projector (1024x768 pixels as in the above case).
  • the corrected image is sliced one-pixel row at a time using a slicing algorithm.
  • the generated slices are stitched together as a movie using the movie generation algorithm.
  • a velocity profile is created depending on the required pattern.
  • the generated movie is projected and the required velocity profile is applied to the stages. This cures a pattern on the surface of the resin with varying thicknesses.
  • the slice generation algorithm is shown in Figure 6B.
  • the algorithm translates the required number of pixels and creates a static mask.
  • the algorithm combines the static masks and creates a movie with a varying framerate.
  • machine learning algorithms can be used to tune the frame-rate of the movie, depending on the location and density of active-pixels on the DMD, to achieve the desired exposure profile.
  • the required velocity profile is provided as a waveform to the actuator such that the framerate of the movie and the velocity profile of the actuator are synchronous.
  • Table 1 table showing the various combinations for the scanning vat photopolymerization machine
  • Table 1 shows the various subsystems that may be used to generate the high- resolution patterns described above for the various embodiments of the present invention.
  • Combinations that may be used with the various embodiments of the present invention include a 365 nm LED source with a LCD mask can be used to project patterns on pre-existing substrates using rotary actuators.
  • the material could be a photopolymer+ solvent system placed in an inert atmosphere of nitrogen.
  • the thickness of the desired patterned film can be varied by altering the layer thickness - when a platform is used, or can be directly lifted off the surface of the resin.
  • the high resolution three and two dimensional patterns may also be
  • the intensity of the light used As the intensity increases, the effective UV irradiation on the resin increases and thus increases the layer thickness of the cure part. The reverse happens when intensity is lowered.
  • the intensity is matched with the velocity profile to achieve the required profile on the film at a predetermined location as the film is scanned.
  • both the intensity and velocity may be varied.
  • the intensity and velocity may be alternately varied as desired as the film is scanned.
  • intensity may also be varied by selective gray-scaling of the input image.
  • the pixel grayscale can be set such that the overall intensity reflected by the pixel is just enough to cure the photocuring resin to the required thickness. This process can again be used with any of the elements shown in Table 1.
  • Figure 8 shows an example pattern with varying thickness and pattern along its area. Initially, the moving mask containing the pixel pattern throughout the area is generated. Next, the scan speed and/or intensity as well as the frame rate of the mask movie are adjusted and synchronized as shown in the velocity profile in Figure 8.
  • Figure 9 shows a part printed using the concept proposed in the document.
  • a thin film was printed using a commercial resin and a linearly increasing velocity profile.
  • the printed film thickness was varied from 137 ⁇ to 76 ⁇ .

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Microelectronics & Electronic Packaging (AREA)

Abstract

L'invention concerne un système de photopolymérisation de cuve de balayage et une méthode de production d'une forme tridimensionnelle sur une couche de construction en un seul balayage. La forme tridimensionnelle est créée par application variable d'énergie pendant l'exposition d'une ou de plusieurs sections ou voxels balayés de la couche de construction dans un seul balayage.
PCT/US2017/030316 2017-04-30 2017-04-30 Photopolymérisation de cuve de balayage WO2018203867A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
PCT/US2017/030316 WO2018203867A1 (fr) 2017-04-30 2017-04-30 Photopolymérisation de cuve de balayage
PCT/US2018/040481 WO2018204938A2 (fr) 2017-04-30 2018-06-29 Photopolymérisation en cuve de balayage

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2017/030316 WO2018203867A1 (fr) 2017-04-30 2017-04-30 Photopolymérisation de cuve de balayage

Publications (1)

Publication Number Publication Date
WO2018203867A1 true WO2018203867A1 (fr) 2018-11-08

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PCT/US2017/030316 WO2018203867A1 (fr) 2017-04-30 2017-04-30 Photopolymérisation de cuve de balayage
PCT/US2018/040481 WO2018204938A2 (fr) 2017-04-30 2018-06-29 Photopolymérisation en cuve de balayage

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112060576A (zh) * 2019-05-24 2020-12-11 波音公司 道次型增材制造系统和方法

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Publication number Priority date Publication date Assignee Title
FI129104B (en) * 2019-04-25 2021-07-15 Planmeca Oy Stereolithography equipment and procedures for checking the temperature of resin materials

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US20150147685A1 (en) * 2013-11-22 2015-05-28 Wasatch Photonics, Inc. System and method for holography-based fabrication
US20160046072A1 (en) * 2014-08-12 2016-02-18 Carbon3D, Inc. Acceleration of stereolithography
WO2016176444A1 (fr) * 2015-04-29 2016-11-03 Northwestern University Impression 3d d'implants biomédicaux

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US9561622B2 (en) * 2008-05-05 2017-02-07 Georgia Tech Research Corporation Systems and methods for fabricating three-dimensional objects
US10308007B2 (en) * 2015-06-18 2019-06-04 University Of Southern California Mask video projection based stereolithography with continuous resin flow

Patent Citations (3)

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Publication number Priority date Publication date Assignee Title
US20150147685A1 (en) * 2013-11-22 2015-05-28 Wasatch Photonics, Inc. System and method for holography-based fabrication
US20160046072A1 (en) * 2014-08-12 2016-02-18 Carbon3D, Inc. Acceleration of stereolithography
WO2016176444A1 (fr) * 2015-04-29 2016-11-03 Northwestern University Impression 3d d'implants biomédicaux

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112060576A (zh) * 2019-05-24 2020-12-11 波音公司 道次型增材制造系统和方法
CN112060576B (zh) * 2019-05-24 2024-01-26 波音公司 道次型增材制造系统和方法

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WO2018204938A3 (fr) 2019-01-03
WO2018204938A2 (fr) 2018-11-08

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