Scalable 3D printing of aperiodic cellular structures by rotational stacking of integral image formation

Abstract

The limitation of projection microstereolithography in additive manufacturing methods is that they typically use a single-aperture imaging configuration, which restricts their ability to produce microstructures in large volumes owing to the trade-off between image resolution and image field area. Here, we propose an integral lithography based on integral image reconstruction coupled with a planar lens array. The individual microlenses maintain a high numerical aperture and are used to create digital light patterns that can expand the printable area by the number of microlenses (10 3 to 10 4 ), thereby allowing for the scalable stereolithographic fabrication of 3D features that surpass the resolution-to-area scaling limit. We extend the capability of integral lithography for programmable printing of deterministic nonperiodic structures through the rotational overlapping or stacking of multiple exposures with controlled angular offsets. This printing platform provides new possibilities for producing periodic and aperiodic microarchitectures spanning four orders of magnitude from micrometers to centimeters.

Single-digit-micrometer-resolution continuous liquid interface production

“…Although the overall print area while conserving the high resolution, the overall manufacturing process is slowed down by either the translation stage speed or the postprocessing steps and could introduce additional alignment errors. Recent advances with scanning lens projection methods (41) and introduction of lens array (68) in PSL have notably increased the build area and scalability.…”

High‐Throughput Metal 3D Printing Pen Enabled by a Continuous Molten Droplet Transfer

“…[22][23][24][25] However, the path generation in the arc-based metal AM is still based on a point-by-point or layer-by-layer manufacturing approach. [26][27][28] Thus, their print speed is limited by stepwise material deposition due to the time of solidification and cooling of molten metals during the printing process. [29][30][31][32] This is because conventional arc-based metal 3D printing processes typically require solidified beads as supporting material to attach the molten metal droplet and to form a stable structure.…”

Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns

“…The increasing demand for nanopatterned functional surfaces in numerous emerging applications, such as optical 1,2 , biological [3][4][5][6][7] , energy harvesting 8 , lithographic systems 9 , and environmental devices 10 , has stimulated thelarge-area micro-and need for scalable manufacturing technologies 2,[11][12][13] . Functional surfaces are commonly composed of a two-dimensional (2D) or quasi-three-dimensional (3D) array of micro-and nano-scale structures with periodic or aperiodic arrangements 11,13,14 .…”

“…The increasing demand for nanopatterned functional surfaces in numerous emerging applications, such as optical 1,2 , biological [3][4][5][6][7] , energy harvesting 8 , lithographic systems 9 , and environmental devices 10 , has stimulated thelarge-area micro-and need for scalable manufacturing technologies 2,[11][12][13] . Functional surfaces are commonly composed of a two-dimensional (2D) or quasi-three-dimensional (3D) array of micro-and nano-scale structures with periodic or aperiodic arrangements 11,13,14 . As these arrayed structures must have precise dimensions and arrangements to realize high performance according to specific design intents in the required surface area 2 , an elaborate fabrication technique is essential.…”