Experimental and numerical investigations on microstereolithography of ceramics

Abstract

Microstereolithography (μSL) uses laser light to solidify UV-curable resin mixed with concentrated ceramic powders. During the μSL process, the light scattering from the particle suspension is found to significantly influence the fabrication resolution in both lateral and depth dimensions which are critical for the complex three-dimensional (3D) microfabrication. In this work, we performed Monte Carlo simulations and experimental studies to understand the detailed microscale optical scattering, chemical reaction (polymerization), and their influence on critical fabrication parameters. As a result, it was found that due to the scattering, the fabricated line is wider in width and smaller in depth compared with polymeric fabrication at the same condition. The doping technique that we used substantially reduced the light scattering, which in turn enhanced the fabrication precision and control. In addition, the experimental values of curing depth and radius agreed reasonably well with the theoretical modeling. When a laser beam was focused to the diffraction limit, an ultimate linewidth resolution with ceramic μSL was found at about 2.6 μm.

Digital micromirror device (DMD)-based 3D printing of poly(propylene fumarate) scaffolds

“…The logarithmic response of the area is similar to that of C d and may be modeled as such [26]. Other investigators have applied Mie Theory for design purposes to compensate for the scattering-induced loss of accuracy [16]. However, in cases such as ours, where high ceramic loading is unnecessary, the elimination of dark cure is desirable.…”

“…Also, TiO 2 is a pigment rather than a dye, as it does not dissolve and will fall out of solution over time. Other authors report similar complications when using ceramic particles [14, 15, 16, 17, 6]. These disadvantages suggest a solution: replacing TiO 2 with a UV-filter that is a strong UV absorber, while causing little UV scattering, as well as being a dye (dissolving in the resin) rather than a pigment (suspending in the resin).…”

Projection Microstereolithography as a Micro-Additive Manufacturing Technology: Processes, Materials, and Applications

“…Ronca et al 134 also embedded nanosized hydroxyapatite (Nano HAP) particles into synthesized poly(d,l-lactide) oligomers to fabricate porous structures. Yasui et al 115 25 Jiang et al, 35 Zissi et al, 80 Provin and Monneret, 81 Baker et al, 82 Goswami et al, 83 Ibrahim et al, 84 Gandhi and Bhole 85 Poly(ethylene glycol) diacrylate Leigh et al, 86 Lee and Fang, 87 Lee et al, 88 6 Choi et al, 8,67 Goswami et al, 83 Sun and Zhang, 91 Thomas et al 92 2,2-Dimethoxy-2-phenylacetophenone (DMPA) Lu and Chen, 75 Zissi et al, 80 Bertsch et al, 93 Park et al, 94 Jariwala et al 95 Irgacure ® series (2959, a 784, 819 a ) Stampfl et al, 48 Heller et al, 49 Lu et al, 72 Provin and Monneret, 81 Baker et al, 82 Gauvin et al, 96 Wu et al, 97 25 Provin and Monneret, 81 Bertsch et al, 93 Monneret et al, 98 Sun and Zhang, 102 Kirihara, 103 Noritoshi et al, 104 113 has been investigated as a means to introduce the desired material properties to 3D microstructures.…”

Investigation of Aberration for Optical System in Integral Stereolithography System

“…SL process is the most widely used rapid prototyping process with highprecision and good surface quality [1], So SL process was mostly adopted in the research of rapid prototyping technology for fabricating micro-structures .SL can be classified into laser scanning SL process and integral SL process according to resin solidifying mode [2]. In laser scanning SL process, laser beam is focused to a light point, and the light point cures liquid photo curable resin into solid resin during the laser light point scanning process [3][4]. In integral SL process, photo-sensitive resin is solidified with an image mask, which irradiates on resin surface during the building process, and the image mask is produced by a dynamic mask generator [5].…”