Consistent Resin Curing Techniques in 3D Printing

Controlling temperature at the resin interface in an additive manufacturing process improves 3D printing quality and avoids issues like warping and delamination. The process involves independently heating the bulk resin, building chamber, and resin-interface layer to specific target temperatures. This allows selective curing of layers without disrupting the bulk resin temperature or building chamber environment.

Source

3D printing of parts with improved mechanical properties and reduced warping. The method involves using a photopolymer composite ink with a dual-cure system that enables complete curing of each layer in a 3D printed object. The composite consists of a polymer matrix, inorganic fillers, and a combination of photo and thermal initiators. The dual-cure initiators allow the composite to be partially cured by UV light after each layer is printed and then fully cured by heat. This prevents uncured resin from accumulating stress and warping the part.

Source

Apparatus for dispensing and curing liquid media like resins for 3D printing and other applications. The apparatus has a nozzle to dispense the media, a microwave source to cure it, and a displacement assembly to move the nozzle relative to the workpiece. The microwave irradiation zone is between the nozzle and the reservoir, so curing happens before the media enters the workpiece. This allows moving the nozzle to fill complex molds without viscosity changes during curing. The media properties are also controlled by mixing and metering devices upstream of the irradiation zone. Moving the nozzle, dispensing, and curing simultaneously allows it to fill large molds with precise control for quality 3D printing.

Source

Optimizing exposure light distribution and intensity improves stereolithographic 3D printing efficiency and LED light source service life. The method uses a spatial light modulator like a micromirror array to expose the 3D printer's build area selectively. The modulator's mirror tilt angles are adjusted to even out exposure intensity across the build area. This way, all parts of the build area receive the same average intensity for optimal curing. Before each layer exposure, the modulator is brightened to ensure at least one mirror uses the full intensity range. This allows full utilization of the LED light source's power across the build area.

Source

A method for three-dimensional lamination molding of objects using resin material that allows for flattening the resin before curing. The method involves iterative steps of discharging, flattening, and curing resin layers. The key aspect is using a roller to partially transfer and flatten the resin off the previous layer before curing. This helps prevent the build-up of droplets and unevenness that can occur when just discharging and curing resin on top of the resin.

Source

System and method for removing uncured resin from 3D printed parts prior to final curing to avoid unevenly cured areas. The system uses a rotating device to move the printed part within an enclosed space shielded from UV light. The rotation allows uncured resin trapped in cavities to drain out. After draining, the part can be safely and fully cured without the risk of uneven curing due to trapped resin.

Source

Optimizing additive manufacturing processes improves 3D printing quality and prevents damage to parts during fabrication. The optimization involves implementing several operations, including tailored separation forces based on layer overhangs, reducing adhesion forces as resin containers wear, waiting after squishing to prevent deformation, and using controlled curing to avoid partially cured resin. This helps produce higher-quality parts with fewer defects.

Source

Resin handling improvements for a resin-based additive manufacturing device like a 3D printer that deposits and cures resin layers to build objects. The improvements include a resin conditioning system to optimize resin quality, a scraper system to collect unused resin for reuse, and a foil flattening device to keep the build substrate flat. The conditioning system controls resin properties like viscosity and humidity. The scraper system collects unused resin after each layer. The foil flattening device keeps the flexible substrate flat during printing.

Source

A thermosetting resin composition for use in 3D printing or sealing applications that can be uniformly cured using a magnetic field. The composition contains thermosetting resin and magnetic particles with multiple magnetic domains that can be magnetized. When a magnetic field is applied, the particles heat up due to vibration and cure the resin. This allows the entire composition to be uniformly and stably cured compared to conventional methods.

Source

Building objects using inkjet 3D printing that require UV curing of the ink. It allows for an inkjet build method that uses UV LEDs in a pulsed driving scheme to cure the ink layers. The pulsed UV curing prevents overheating while increasing curing intensity and avoiding creasing. The UV LEDs are driven with pulses of electric power instead of continuously on, which raises peak luminous intensity. This improves uniform curing and prevents creasing compared to continuous UV exposure.

Source