Single-digit-micrometer-resolution continuous liquid interface production

Abstract

To date, a compromise between resolution and print speed has rendered most high-resolution additive manufacturing technologies unscalable with limited applications. By combining a reduction lens optics system for single-digit-micrometer resolution, an in-line camera system for contrast-based sharpness optimization, and continuous liquid interface production (CLIP) technology for high scalability, we introduce a single-digit-micrometer-resolution CLIP-based 3D printer that can create millimeter-scale 3D prints with single-digit-micrometer-resolution features in just a few minutes. A simulation model is developed in parallel to probe the fundamental governing principles in optics, chemical kinetics, and mass transport in the 3D printing process. A print strategy with tunable parameters informed by the simulation model is adopted to achieve both the optimal resolution and the maximum print speed. Together, the high-resolution 3D CLIP printer has opened the door to various applications including, but not limited to, biomedical, MEMS, and microelectronics.

Droplet interface in additive manufacturing: From process to application

“…confinement by controlling the liquid-solid interface. 64,65 The liquid film adhering to the cured structure was drawn into the steps between cured layers, and the excess resin adhering to the cured structure was scraped off, eliminating the step effect and the need for postprinting washing. 61 To overcome the adhesion of the cured layer to the printing interface, a smooth surface inspired by the pitcher plant was proposed (Figure 5b).…”

“…A variation of vat photopolymerization uses a surface tension‐controlled droplet pool instead of a vat to contain the resin (Figure 5a). This approach was used for continuous liquid confinement by controlling the liquid–solid interface 64,65 . The liquid film adhering to the cured structure was drawn into the steps between cured layers, and the excess resin adhering to the cured structure was scraped off, eliminating the step effect and the need for postprinting washing 61 .…”

Advanced Fabrication of Mechanical Metamaterials Based on Micro/Nanoscale Technology

“…Figure 9h displays instances of the porous material (left) and the lattice block (right), both of them are produced using CLIP. [168,169] The resins used in CLIP provide a range of mechanical, thermal, and chemical properties, making it possible to print parts with the desired qualities for specific applications. In addition, CLIP has advantages such as high printing speed and isotropic printed parts.…”

“…Reproduced with permission [168]. Copyright 2015, American Association for the Advancement of Science; Reproduced with permission [169]. Copyright 2022, American Association for the Advancement of Science.…”

Repeatedly Recyclable 3D Printing Catalyst‐Free Dynamic Thermosetting Photopolymers

“…3D printing, alias additive manufacturing (AM), is a technology platform for highly specialized model manufacturing and rapid prototyping, which has been widely used in myriad of areas, such as lightweight engineering, [ 4 ] sensors, [ 5 ] the biomedical, [ 6 ] flexible electronics [ 7 ] and others. [ 8 ] Recently, photocuring based 3D printing technologies, which include stereolithography (SLA), [ 9 ] digital light processing (DLP), [ 10 ] continuous liquid interface production (CLIP), [ 11 ] high‐area rapid printing (HARP) [ 12 ] and two‐photon polymerization (TPP), [ 13 ] have been drawing great attention in many fields due to their high resolution and printing efficiency properties. [ 14 ] Photopolymers, which combine the on‐demand, light‐triggered fabrication and the robust properties of crosslinked structures, are key materials for 3D printing technologies, especially for photo‐curing based 3D printing technology.…”