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WO2025040610A1 - Système de photopolymérisation, dispositif d'éclairage et procédé de production d'un objet tridimensionnel - Google Patents

Système de photopolymérisation, dispositif d'éclairage et procédé de production d'un objet tridimensionnel Download PDF

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Publication number
WO2025040610A1
WO2025040610A1 PCT/EP2024/073182 EP2024073182W WO2025040610A1 WO 2025040610 A1 WO2025040610 A1 WO 2025040610A1 EP 2024073182 W EP2024073182 W EP 2024073182W WO 2025040610 A1 WO2025040610 A1 WO 2025040610A1
Authority
WO
WIPO (PCT)
Prior art keywords
pixels
photo
array
vat
optical elements
Prior art date
Legal status (The legal status 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 status listed.)
Pending
Application number
PCT/EP2024/073182
Other languages
English (en)
Inventor
Ralph Wirth
Peter Brick
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ams Osram International GmbH
Original Assignee
Ams Osram International GmbH
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 Ams Osram International GmbH filed Critical Ams Osram International GmbH
Publication of WO2025040610A1 publication Critical patent/WO2025040610A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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
    • B29C64/20—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
    • 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

Definitions

  • 3D printers may be based on the photo-polymeri zation of a photo- curable polymer due to irradiation with an appropriate light source .
  • layers of a predetermined thickness may be repeatedly stacked while curing the layer portions using e . g . UV irradiation .
  • ef forts are made to improve the speed and resolution of 3D printers .
  • a photo-polymeri zation system comprises a vat for housing a photo-curable polymer, an array of pixels , comprising a plurality of pixels , wherein each of the pixels comprises an LED .
  • the array is arranged so as to be facing the vat .
  • the photo-polymeri zation system further comprises an array of optical elements comprising a plurality of optical elements .
  • Each of the pixels is assigned to a corresponding one of the optical elements , respectively .
  • the array of optical elements is arranged between the array of pixels and the vat .
  • the array of pixels may be arranged so as to face a base plate of the vat, the base plate being transparent for electromagnetic radiation emitted by the LEDs.
  • the array of pixels may be arranged so as to face an inner portion of the vat.
  • the array of optical elements may be implemented by a micro lens array.
  • the array of optical elements is formed so that each of the optical elements encapsulates a corresponding one of the LEDs.
  • the photo-polymerization system may further comprise a second optical element assigned to the array of pixels.
  • the base plate of the vat may be patterned in accordance with the array of optical elements.
  • a pitch between adjacent pixels is larger than 8* (a lateral size of an LED) .
  • the photo-polymerization system may further comprise an optical blocking element between adjacent pixels.
  • the optical elements or the second optical element are configured to collimate incident radiation emitted by a corresponding pixel.
  • each of the optical elements may comprise a reflector and a lens.
  • each of the pixels may be configured to emit electromagnetic radiation having two di f ferent wavelengths .
  • the photo-polymeri zation system may further comprise a control device configured to individually address any of the pixels .
  • an illumination device comprises an array of pixels comprising a plurality of pixels .
  • Each of the pixels comprises an LED .
  • the illumination device further comprises an array of optical elements comprising a plurality of optical elements .
  • Each of the pixels is assigned to a corresponding one of the optical elements , respectively .
  • a method for producing a three- dimensional obj ect comprises placing a photo-curable polymer in the vat of the photo-polymeri zation system as described above , placing a stamp in the vat , activating the array of pixels in accordance with the three-dimensional obj ect to be produced, and moving the stamp in a vertical direction .
  • the stamp may be moved in a direction opposite to a base plate of the vat .
  • the stamp may be moved in a direction to a base plate of the vat .
  • Fig. 1A shows a cross-sectional view of a photo-polymerization system according to embodiments.
  • Fig. IB shows an enlarged cross-sectional view of a portion of the photo-polymerization system including an illumination device .
  • Fig. 1C shows a cross-sectional view of a photo-polymerization system according to further embodiments.
  • Fig. ID shows an enlarged cross-sectional view of a portion of the photo-polymerization system.
  • Figs. 2A to 2E show cross-sectional views of a portion of a photo-polymerization system according to embodiments.
  • Fig. 2F shows a cross-sectional view of a portion of a photopolymerization system according to embodiments.
  • Fig. 3A shows an example of a setup of a pixel according to embodiments .
  • Fig. 3B shows a further example of a setup of a pixel according to embodiments.
  • Fig. 4A shows a top view of an illuminated portion using the illumination device described.
  • the polymerization takes place at the interface between the photo- curable polymer 122 and an ambient atmosphere, e.g. air.
  • the projection takes place from the top to the interface between the ambient atmosphere, e.g. air, and the photo-curable polymer 122.
  • Fig. ID shows an enlarged cross-sectional view of a portion of the photo-polymerization system 10 including the illumination device 15.
  • the single elements of the illumination device 15 may be similar or identical with those illustrated in Fig. IB.
  • the pixels 102 and the LEDs 106 may be arranged so that electromagnetic radiation emitted by the illumination device 15 enters the interior 126 of the vat and the photo-curable polymer 122.
  • the array 105 of optical elements is arranged between the LEDs 106 and the photocurable polymer 122.
  • the illumination device may further comprise a first optical layer 107 .
  • the first optical layer may comprise a plurality of optical layer elements 108 .
  • the optical layer 107 may be implemented as a micro-lens array .
  • the illumination device 15 may comprise further optical layers .
  • the array of optical elements may include optional primary optics , which may be formed by the LED encapsulant which establi shes one optical surface .
  • the optical system may further comprise secondary optics in the form of a micro-lens array so that two optical surfaces may be generated .
  • the optical system may comprise a secondary optics in another micro-lens array so that 4 optical surfaces are generated .
  • Each of the optical surfaces described herein may be di f fractive , refractive , holographic or may include meta-optical structures .
  • the pixels 103 and the corresponding optical elements may be arranged in arbitrary arrangements, e.g. in rectangular arrays comprising rows and columns, in hexagonal arrays, in non-rectangular arrays, in periodic arrays and in non-periodic arrays.
  • Fig. 3A is a schematic drawing illustrating a pixel 102 comprising an LED 106 which is arranged at a distance Pi from an optical element 104 which may be implemented as a convex lens.
  • a distance Pi may be less than 15 pm.
  • the distance Pi may be larger than 5 pm, e.g. approximately 10 pm.
  • the pixels 102 may be arranged at a pixel pitch d which may be larger than 10 pm and less than 200 pm, e.g. approximately 50 pm.
  • the LED 106 has a small size s which may be smaller than 10 pm.
  • a size s of the LEDs 106 may be larger than 2 pm, e.g. approximately 5 pm.
  • a ratio of size s to pitch d may be less than 1:8, e.g. approximately 1:10. Accordingly, the LED array may have a low fill factor of less than 1:64, e.g. approximately 1:100.
  • the LEDs may be implemented to emit electromagnetic radiation having a wavelength so as to cure a photo-curable polymer. For example, the wavelength may be larger than 350 nm. Moreover, the wavelength may be less than 500 nm.
  • the optical element 104 may be configured to collimate electromagnetic radiation emitted by the LED 106. As a result, parallel beams 22 will impinge on the base plate 124 of the vat. Further, the parallel beams 22 will be transmitted by the base plate 124.
  • a height of the optical element 104 P 2 may be less than 50 pm, e.g. more than 20 pm, e.g. approximately 30 pm.
  • a distance P3 between the optical element 104 and the base plate 124 of the vat 120 may be larger than 5 pm, e.g. approximately 10 pm.
  • Fig . 3B is a schematic drawing illustrating a further example of a pixel 102 .
  • the pixel 102 compri ses an LED 106 and an optical element 104 for collimating electromagnetic radiation 21 emitted by the LED 106 .
  • the optical element 104 comprises a reflector 115 and a lens 116 .
  • the reflector 115 may be implemented as a pre-collimating reflector .
  • an exit angle range of emitted electromagnetic radiation 21 may be reduced by the reflector 115 .
  • the electromagnetic radiation is collimated by the lens 116 .
  • Fig . 4A shows an example of an area which is illuminated by a pixel which forms a component of the illumination device 15 that has been described herein above .
  • the single pixel generates a homogeneous radiation pattern having a rectangular shape .
  • Fig . 4B shows a radiation intensity depending on a position .
  • the radiation intensity has a value which is above the limit for photo-curable the polymer .
  • the light intensity is strong enough so as to accomplish curing of the photo-polymer .
  • a method for producing a three-dimensional obj ect comprises placing ( S 100 ) a photo-curable polymer in the vat of the photo- polymerization system as described above.
  • the method further comprises placing (S110) a stamp in the vat, activating (S120) the array of pixels in accordance with the three-dimensional object to be produced, and moving (S130) the stamp in a vertical direction.
  • the stamp may be moved in a direction opposite to a base plate of the vat.
  • the stamp may be moved in a direction towards the base plate of the vat.
  • activating the array of pixels may comprise selectively addressing selected ones of the LEDs in accordance with the three-dimensional object. For example, this may be accomplished using a control device.
  • micro-projection optical element is provided for each pixel.
  • the use of LEDs 106, for example micro LEDs 106, results in a higher system efficiency compared to known systems. As a result, a higher printing speed may be achieved. Further, due to the reduced area of the LEDs 106, reduced cost of the system in terms of power per area may be obtained.

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

Abstract

L'invention concerne un système de photopolymérisation (10) comprenant une cuve (120) pour loger un polymère photodurcissable (122), un réseau (103) de pixels (102), comprenant une pluralité de pixels (102), chacun des pixels (102) comprenant une DEL (106). Le réseau (103) est agencé de manière à faire face à la cuve (120). Le système de photopolymérisation (10) comprend en outre un réseau (105) d'éléments optiques (104) comprenant une pluralité d'éléments optiques (104). Chacun des pixels (102) est attribué à un élément optique correspondant parmi les éléments optiques (104), respectivement. Le réseau (105) d'éléments optiques est disposé entre le réseau (103) de pixels et la cuve (120).
PCT/EP2024/073182 2023-08-24 2024-08-19 Système de photopolymérisation, dispositif d'éclairage et procédé de production d'un objet tridimensionnel Pending WO2025040610A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102023122752 2023-08-24
DE102023122752.1 2023-08-24

Publications (1)

Publication Number Publication Date
WO2025040610A1 true WO2025040610A1 (fr) 2025-02-27

Family

ID=92503558

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2024/073182 Pending WO2025040610A1 (fr) 2023-08-24 2024-08-19 Système de photopolymérisation, dispositif d'éclairage et procédé de production d'un objet tridimensionnel

Country Status (1)

Country Link
WO (1) WO2025040610A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2218571A1 (fr) * 2009-01-30 2010-08-18 Nederlandse Organisatie voor toegepast -natuurwetenschappelijk onderzoek TNO Système d'éclairage pour une utilisation dans un appareil de stéréolithographie
EP3158583B1 (fr) * 2014-06-18 2022-01-26 X Display Company Technology Limited Unités d'affichage à led micro-assemblées

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2218571A1 (fr) * 2009-01-30 2010-08-18 Nederlandse Organisatie voor toegepast -natuurwetenschappelijk onderzoek TNO Système d'éclairage pour une utilisation dans un appareil de stéréolithographie
EP3158583B1 (fr) * 2014-06-18 2022-01-26 X Display Company Technology Limited Unités d'affichage à led micro-assemblées

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