Method and apparatus for uniform UV curing of resin parts having irregular surfaces

1 . A method of curing a part formed of a photopolymer resin and having an irregular surface, comprising:

moving a UV lamp having a plurality of UV light sources over the irregular surface;

arranging the plurality of UV light sources in a pattern to irradiate the part with UV light having a uniform intensity;

irradiating the part uniformly throughout the irregular surface using UV light from the plurality of UV light sources;

interposing an electrochromatic filter between at least some of the plurality of the UV light sources and the part,

selectively energizing the electrochromatic filter between a clear state allowing the UV light to pass through the electrochromatic filter and an opaque state blocking the UV light from passing though the electrochromatic filter; and

adjusting a distance between the UV lamp and the irregular surface based on irregularities in the irregular surface as the UV lamp moves over the irregular surface.

2 . The method of claim 1 , wherein the pattern has a shape complementary to the irregular surface of the part.

3 . The method of claim 1 , wherein the arranging includes spacing the UV light sources uniform distances away from the irregular surface of the part.

4 . The method of claim 1 , wherein the arranging includes spacing the UV light sources different distances away from the irregular surface of the part.

5 . The method of claim 1 , wherein filtering includes interposing a shutter between the at least some of the UV light sources and the part.

6 . The method of claim 1 wherein irradiating the part uniformly includes:

mounting the UV lamp on a manipulator, and

moving the UV lamp along a path complementary to the irregular surface of the part.

7 . The method of claim 6 , wherein moving the UV lamp along the path includes adjusting a distance between the UV lamp and the part such that an intensity of the UV light incident on the irregular surface is substantially constant.

8 . The method of claim 1 , wherein:

adjusting the distance includes individually adjusting a position of at least some of the plurality of UV light sources based on irregularities in the irregular surface.

9 . The method of claim 1 , wherein the plurality of UV light sources are mounted on supports capable of shifting linearly to adjust a distance between the plurality of UV light sources and the part.

10 . A method of curing a part formed of a photopolymer resin and having an irregular surface, comprising:

arranging a plurality of UV light sources in a pattern configured to irradiate the part with UV light having a uniform intensity;

irradiating the part uniformly throughout the irregular surface using the UV light from the plurality of UV light sources;

filtering out the UV light irradiated by at least some of the UV light sources by interposing an electrochromatic filter between the at least some of the UV light sources and the part; and

selectively energizing the electrochromatic filter between a clear state allowing the UV light to pass through the electrochromatic filter and an opaque state blocking the UV light from passing though the electrochromatic filter.

11 . The method of claim 10 , wherein the pattern has a shape complementary to the irregular surface of the part.

12 . The method of claim 10 , wherein the arranging includes spacing the plurality of UV light sources uniform distances away from the irregular surface of the part.

13 . The method of claim 10 , wherein the arranging includes spacing the plurality of UV light sources different distances away from the irregular surface of the part.

14 . The method of claim 10 , wherein the filtering includes interposing a shutter between the at least some of the UV light sources and the part.

15 . The method of claim 10 wherein irradiating the part uniformly includes:

mounting the plurality of UV light sources on a manipulator, and

moving the plurality of UV light sources along a path complementary to the irregular surface of the part.

16 . The method of claim 15 , wherein moving the plurality of UV light sources along the path includes adjusting a distance between the plurality of UV light sources and the part such that an intensity of the UV light incident on the irregular surface is substantially constant.

17 . The method of claim 10 , wherein irradiating the part includes:

moving the plurality of UV light sources over the irregular surface, and

adjusting a distance between the plurality of UV light sources and the irregular surface based on irregularities in the irregular surface.

18 . The method of claim 17 wherein:

adjusting the distance includes individually adjusting a position of at least some of the plurality of UV light sources based on a distance between the plurality of UV light sources and the irregular surface.

19 . The method of claim 10 , wherein the plurality of UV light sources are mounted on supports capable of shifting linearly to adjust a distance between the plurality of UV light sources and the part.

20 . The method of claim 9 , a linear position of the UV light sources may be adjusted manually or automatically using air or pneumatic cylinders.