Multi-Scale Projection Micro-Stereolithography for Faster Printing
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Solution Overview
Problem
Existing micro-stereolithography technologies face a conflict between high resolution and large-area printing, as the pixel size reduction for higher resolution significantly reduces printing speed.
Innovation Solution
A dual-projection lens system with different pixel sizes (2 μm and 10 μm) and a precision translation stage are combined to enable faster and more accurate printing over a larger area, using optical shutter control and multi-scale exposure modes to adapt resolution based on local details.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pixel size is reduced to increase resolution, then manufacturing precision is improved, but printing speed deteriorates
Solution Approach 1:
The patent divides the printing area into multiple regions, each handled by projection lenses with different pixel sizes. High-resolution lenses (2 μm pixels) are used for regions requiring fine detail, while lower-resolution lenses (10 μm pixels) handle larger areas where fine detail is not critical. This segmentation allows the system to maintain high resolution where needed while improving overall printing speed by using faster, lower-resolution lenses for the remainder of the printing area.
2Manufacturing precision
If pixel size is reduced to increase resolution, then manufacturing precision is improved, but printing area deteriorates
Solution Approach 1:
The patent employs a multi-projection lens system where each lens serves multiple functions: high-resolution lenses (2 μm pixels) provide fine detail capability, while lower-resolution lenses (10 μm pixels) provide broader coverage. By coordinating multiple lenses with different capabilities, the system achieves both high resolution and large printing area (up to 10 cm×10 cm) simultaneously, making the system universally capable of handling diverse printing requirements.
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
The method achieves precise control and increased speed in printing larger areas (e.g., 10 cm×10 cm) with 2 μm optical resolution, maintaining dimensional accuracy and improving printing efficiency by adapting resolution as needed.
Implementation Method 1
optical shutter control, which quickly switches the image projection between individual lenses of the dual-projection lens system
Implementation Method 2
dual-projection lens system of 2 μm and 10 μm pixels
Implementation Method 3
combined with a precision translation stage system
Data Source
AI summary
Fast 3D printing with high resolution is made possible by projecting light and an image from optical light engine comprises a micro display chip and a light source, through a projection lens of a multi-projection lens system onto printing material, e.g., a curable resin, wherein the multi-projection lens system comprises two or more projection lenses each with different imaging ratios wherein the image and light are projected through only one projection lens of the multi-projection lens system at a time.