Constrained Window Design in Projection Stereolithography for Continuous Three-Dimensional Printing

Abstract

Although continuous projection Stereolithography (SL) printing is one of the next-generation ultra-fast additive manufacturing (AM) processes, its current constrained window design of the resin vat is suffering from many challenges, such as the complex control mechanism and limited hardware lifetime. In this article, we investigate a novel constrained window design, namely Island Window (IW), for the continuous three-dimensional (3D) printing by using the projection SL process. The proposed IW window has a highly oxygen-permeable polydimethylsiloxane membrane onto the laser-machined acrylic vat frame, which allows the formation of an effective liquid interface (>200 lm oxygen inhibition layer) to enable the continuous projection SL process. Experimental results verified the feasibility of the window design for extending the maximum printing time (increased by up to 73%) due to the enhanced oxygen concentration. It was also found that the maximum printing speed for producing parts with a smooth surface (Rz <30 lm) can be as high as 90 mm/h, which is comparable to the speeds in recently reported continuous SL processes. In addition, a variety of parts were successfully fabricated through continuous 3D printing by using the proposed IW design, implying tremendous promise for future low-cost, high-resolution, easy-controlled, and ultra-fast AM processes.

Overflow Control for Sustainable Development by Superwetting Surface with Biomimetic Structure

“…Compared to the general DLP printing, the vertical printing speed increased by 2 orders of magnitude, reaching hundreds of millimeters per hour through applying the CLIP technology. Jiang et al prepared an oxygen-permeable window (Island window) via laser-processed acrylic resin sheets and a highly oxygen-permeable polydimethylsiloxy membrane, which formed an oxygen-containing zone with thickness larger than 200 μm . Continuous photocuring printing was achieved with the fastest printing speed of 90 mm·h –1 .…”

“…Jiang et al prepared an oxygen-permeable window (Island window) via laser-processed acrylic resin sheets and a highly oxygen-permeable polydimethylsiloxy membrane, which formed an oxygen-containing zone with thickness larger than 200 μm. 333 Continuous photocuring printing was achieved with the fastest printing speed of 90 mm•h −1 . The photoinitiated radical polymerization released a large amount of heat in the printing process.…”

Next Evolution in Organ‐Scale Biofabrication: Bioresin Design for Rapid High‐Resolution Vat Polymerization

“…Jiang and co-workers have recently advanced the CLIP process using a novel constrained window design, namely, Island Window (IW), which allows the formation of an effective oxygen inhibition layer of greater than 200 µm. [49] One of the key factors to the success of continuous printing is a proper continuous elevation speed, [50] which can allow for print speeds of to 500 mm h −1 compared to few millimeters per hour for DLP. [46]…”

“…Copyright 2015, American Association for the Advancement of Science (AAAS) c) Printed parts by using IW technique: i) Artichoke model, 60 mm tall, ii) Turbo shell model, 30 mm tall, iii) Vase model, 70 mm tall, and iv) Cage model, 22 mm diameter. Reproduced with open access [49]. Copyright 2020, Elsevier.…”

Comprehensive performance of a low-cost spring-assisted mechanism for digital light processing

“…There are many ways to reduce the separation force, such as optimizing the experimental parameters [9][10][11], changing the contact area between the bottom of the resin tank and the cured layer [12][13][14], or adding materials [15][16][17]. Developing an innovative separation mechanism is a practical approach that may realize additional benefits.…”