Method and apparatus for 3D printing using controlled UV laser-assisted polymerization
View Patent ↗A method and apparatus for forming a three-dimensional object using UV-sensitive liquid resin is disclosed herein. The apparatus employs UV lasers to manipulate intensity, position, and movement, thereby initiating resin polymerization within a transparent container. The apparatus controls premature polymerization by chilling the resin, thereby enhancing UV light penetration. The apparatus can include multiple synchronized laser beams, thereby strengthening internal polymerization. The apparatus incorporates UV-emitting devices within the resin and adjusts laser operations in real-time, using a specialized stage in the container for depth regulation. The approach ensures resin temperature consistency and replaces surrounding air with inert gas, thereby averting oxidation. After polymerization, the method separates the object from residual resin, guiding it from a flexible to a solid state. This separation leverages density differences, temperature management, and chemical assistance, thereby securing the object's structural precision after detachment.
1 . A method for forming a three-dimensional object, the method comprising the steps of:
a. providing a UV-sensitive liquid resin within a transparent container;
b. irradiating said UV-sensitive liquid resin with at least one beam of UV light from at least one UV laser to induce polymerization and form the three-dimensional object;
c. controlling the operation of the at least one UV laser by independently adjusting locations of the at least one UV laser, movements of the at least one UV laser, intensities, and angles of incidence of the beam or beams emitted by said at least one UV laser within the UV-sensitive liquid resin;
d. chilling the UV-sensitive liquid resin to prevent premature polymerization before the UV light penetrates deeper into the UV-sensitive liquid resin; and
e. wherein the irradiating step includes using the at least one UV laser emitting light within a wavelength range of 200 to 450 nm, and further wherein the controlling the operation step includes controlling a precession maneuver, wherein controlling the laser's position and precession of the emitted laser beam such that the precession maneuver orients the beam to continuously pass through a single point.