Roll-to-Roll Axial Lithography for Continuous 3D Web Patterning

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Solution Overview

Problem

Current computed axial lithography systems are limited to printing three-dimensional objects within a container of photosensitive material, lacking flexibility in producing three-dimensional objects through alternative systems.

Innovation Solution

A roll-to-roll computed axial lithography system that includes an optical illumination system, an optical modulation system, and a web-handling system to process a web coated with photosensitive material, using spatially and temporally modulated illumination patterns to create three-dimensional structures through exposure and development, with optional liquid processing and heating systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If computed axial lithography is performed in a container of photosensitive material, then three-dimensional objects can be printed, but the system lacks flexibility and cannot process continuous webs

Engineering Contradiction:

Improvesystem flexibilityVSAvoidsystem configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system transitions from a static container-based configuration to a dynamic roll-to-roll web processing system. The web moves continuously through the exposure zone while the illumination system dynamically modulates light patterns in space and time to create three-dimensional structures on the moving substrate, enabling flexible processing of continuous materials.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the fundamental operating parameters from batch processing in a container to continuous processing on a moving web. Key parameters including material state (contained liquid to coated web), processing mode (static to dynamic), and geometry (container volume to surface area) are transformed to achieve versatility in producing three-dimensional objects on flexible substrates.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If a web is processed at high speed through the optical modulation system, then productivity increases, but the exposure precision and resolution of three-dimensional structures deteriorate

Engineering Contradiction:

Improveweb processing speedVSAvoidexposure precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The optical modulation system employs periodic pulsed illumination synchronized with web motion. By delivering light in precisely timed pulses that correspond to the web's periodic movement, the system maintains exposure precision at high speeds, with each pulse creating a specific three-dimensional pattern that is accurately positioned on the moving web.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent replaces mechanical positioning systems with optical field-based positioning. Instead of physically moving components to achieve precision, the system uses computationally controlled light fields that can be dynamically adjusted to maintain manufacturing precision regardless of web processing speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If the optical modulation system uses a high refresh rate to match web speed, then continuous three-dimensional patterning is achieved, but energy consumption increases

Engineering Contradiction:

Improvecontinuous patterning capabilityVSAvoidoptical system energy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The system achieves continuous three-dimensional patterning by maintaining uninterrupted optical modulation synchronized with web motion. The illumination system operates continuously with dynamically modulated patterns rather than intermittent exposure, ensuring seamless three-dimensional structure formation across the entire web surface without energy-intensive repositioning.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent employs efficient light utilization where unexposed portions of the light field are dynamically redirected or shut off, and the illumination system recovers and reuses optical energy through synchronized pulsed operation. This reduces wasted energy while maintaining continuous patterning capability at high refresh rates.

Inventive Principle:

Principle #34Discarding and recovering

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 three-dimensional structures with submillimeter or submicrometer features on flexible substrates, facilitating applications in mechanical metamaterials, microfluidics, and 3D tissue culturing, and desalination by patterning photosensitive materials on a web rather than in a container.

Implementation Method 1

The spatially and temporally modulated illumination pattern of light provides predetermined three-dimensional regions within a bulk of the layer of photosensitive material that are exposed beyond a photo-responsive threshold for the photosensitive material

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

The development module removes one of regions of the layer of the photosensitive material that are exposed beyond the photo-responsive threshold or regions of the layer of photosensitive material that are not exposed beyond the photo-responsive threshold

Methodology Applied

Scientific EffectChemical development:

Implementation Method 3

the development module includes a liquid processing system to at least one of rinse or spray the layer of photosensitive material with a developer solvent

Methodology Applied

Scientific EffectLiquid processing:

Implementation Method 4

the development module includes a heating system to apply heat to the layer of photosensitive material after being exposed to the spatially and temporally modulated illumination pattern of light

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS12529961B2Roll-to-roll based 3D printing through computed axial lithography

Publication Date: 2026.01.20 RGT UNIV OF CALIFORNIA

AI summary

A roll-to-roll computed axial lithography system includes an optical illumination system; an optical modulation system to receive light from the optical illumination system and to output an illumination pattern of light; and a web-handling system to receive and transport a web having a photosensitive material layer such that a portion of the web will be in an optical path of the modulation system. The web-handling system includes a development module to render three-dimensional structures from the layer exposed to the illumination pattern of light. The illumination pattern of light provides predetermined three-dimensional regions within a bulk of the layer that are exposed beyond a photo-responsive threshold for the photosensitive material providing volumetric patterning. The development module removes one of regions of the layer exposed beyond the photo-responsive threshold or regions of the layer that are not exposed beyond the photo-responsive threshold to provide a three-dimensional structure from the layer.