Hybrid 3D Printing Optics for High-Resolution and High Throughput
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Solution Overview
Problem
Current 3D printing technologies, such as stereolithography, polyjet modeling, and two-photon polymerization, face limitations in achieving high-resolution, high-speed printing of complex macrostructures due to inherent limitations in resolution, speed, and material constraints, making them unsuitable for many current and future applications.
Innovation Solution
A hybrid system combining two-photon polymerization (TPP) and projection microstereolithography (PμSL) techniques, utilizing a dichroic mirror to integrate a TPP subsystem with a PμSL subsystem, allowing simultaneous or sequential illumination of the target material with different light sources for high-resolution and high-speed printing of large, complex components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fabrication methods such as diamond turning, photolithography, electron-beam lithography, or femtosecond laser lithography are used, then high manufacturing precision can be achieved, but the productivity is low and the cost is high
Solution Approach 1:
The patent combines two-photon polymerization (TPP) technology with projection microstereolithography (PμSL) technology into a hybrid system. The TPP subsystem provides high-resolution printing for critical features, while the PμSL subsystem enables high-speed printing for bulk material deposition. This merging of two complementary technologies allows the system to achieve both high manufacturing precision and high productivity simultaneously, overcoming the limitations of using either technology alone.
2Productivity
If stereolithography, polyjet modeling, or multijet modeling is used, then productivity can be improved, but the manufacturing precision is insufficient for high-resolution applications
Solution Approach 1:
The hybrid system applies different printing technologies to different regions of the target material based on local requirements. The TPP subsystem is used for regions requiring high resolution (such as external surfaces or critical features), while the PμSL subsystem is used for regions where high speed is more important (such as internal bulk structures). This local quality approach allows the system to optimize both resolution and speed in different areas of the same component.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of high-resolution, high-speed printed components with improved multi-scale capability, multi-material handling, and in-situ metrology, overcoming the limitations of existing systems by achieving resolutions from 100 nm to 100 μm and printing dimensions from micrometers to centimeters with precise control over material properties and curing processes.
Implementation Method 1
a dichroic mirror positioned to receive light corresponding to the first light source from the scanning optical device and to receive light corresponding to the second light source from the projection device, and an objective lens positioned to provide illumination to a target material for 3D printing. In this system, the dichroic mirror is configured to allow one of the light corresponding to the first light source or the light corresponding to the second light source to pass therethrough to the objective lens, and to allow the other of the light corresponding to the first light source or the light corresponding to the second light source to be reflected towards the objective lens
Implementation Method 2
The disclosed embodiments, among other features and benefits, address the above problems through the disclosed methods, devices and systems to provide versatile, high resolution, and high-speed three-dimensional (3D) printing
Data Source
AI summary
Methods, devices and systems that allow three-dimensional printing of material with high resolution are described. One example system includes a two-photon polymerization (TPP) subsystem including a first light source coupled to an optical fiber positioned to deliver a first laser light to a scanning optical device, and an optical projection subsystem comprising a second light source configured to provide a second light to a digital projection device. A dichroic mirror is positioned to receive light corresponding to the first and the second light source, and an objective lens positioned to provide illumination to a target material for 3D printing. The dichroic mirror is configured to allow light from one of the light sources to pass therethrough to the objective lens, and to allow light corresponding to the other light source to be reflected towards the objective lens to enable simultaneous illumination of the target material.