Mask Video Projection-Based Stereolithography With Continuous Resin Flow

Abstract

The mask image projection-based stereolithography (MIP-SL) is a low-cost and high-resolution additive manufacturing (AM) process. However, the slow speed of part separation and resin refilling is the primary bottleneck that limits the fabrication speed of the MIP-SL process. In addition, the stair-stepping effect due to the layer-based fabrication process limits the surface quality of built parts. To address the critical issues in the MIP-SL process related to resin refilling and layer-based fabrication, we present a mask video projection-based stereolithography (MVP-SL) process with continuous resin flow and light exposure. The newly developed AM process enables the continuous fabrication of three-dimensional (3D) objects with ultra-high fabrication speed. In the paper, the system design to achieve mask video projection and the process settings to achieve ultrafast fabrication speed are presented. The relationship between process parameters and the surface quality of the built parts is discussed. Test results illustrate that the MVP-SL process with a continuous resin flow can build three-dimensional objects within minutes, and the surface quality of the fabricated objects is significantly improved.

Sequential process optimization for a digital light processing system to minimize trial and error

“…The resin flow between the two plates is an incompressible laminar flow, and the velocity distribution V r of the resin is expressed by Eq. ( 5 ) 55 : where z is the vertical distance from the vat, L is the x -direction length of the curing area, and μ is the viscosity of the resin. The maximum velocity V max occurs at point h/2 , and is expressed by Eq.…”

Vat-Photopolymerization-Based Ceramic Manufacturing

“…In general, VPP is an enhanced AM method for ceramic fabrication with major advantages in its multiscale capability and printing speed ( Ref 3,[45][46][47][48]. Scalewise, VPP is versatile for fabrication ranging from as large as a few meters to as small as several micrometers (Ref 23,[25][26][27][28][29][30][31][32][33]. Throughout the span of its dimensional capabilities, VPP also maintains relatively fast printing speed, whereas other methods, such as SLS or binder jetting, may sacrifice building speed for large cross-sectional parts due to traversing of the tool bit and time-consuming material spreading over a large area ( Ref 30,31).…”

Aliphatic silicone‐epoxy based hybrid photopolymers applied in stereolithography 3D printing

“…Depending on different printing principles, there have been over 50 printing technologies and can be classified into seven categories: powder bed fusion, vat photopolymerization, material jetting, material extrusion, binder jetting, sheet lamination and energy deposition 7,9‐15 . As one of the major group of these techniques, Vat photopolymerization uses laser beam or UV light as light source to induce photopolymer curing in vat to form the target entity and it has become increasing popular because of high printing speed and accuracy comparing with many other 3D technologies 4,9,16‐19 . Stereolithography (SLA) is the earliest developed vat photopolymerization method.…”