Stereolithography Sub-Resolution Patterning via Overlapping Light Regions
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Solution Overview
Problem
Stereolithography is limited in manufacturing objects with patterns smaller than the resolution of the irradiation optical system, as the minimum dimension of a photo-curable resin that can be cured is dependent on the resolution of the light irradiation system, which restricts the creation of finer patterns.
Innovation Solution
A method involving the irradiation of multiple overlapping regions of a photo-curable resin with light, where parts of each region coincide to form a common cured area, allowing for the creation of finer patterns beyond the resolution limits of the optical system by controlling the overlap and light dosage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional stereolithography is used with a single irradiation region, then the manufacturing process is simple, but the minimum pattern dimension is limited by the optical system resolution
Solution Approach 1:
The patent divides the irradiation process into multiple steps, where each step irradiates a different region (R1 to Rn) of the photo-curable resin. By segmenting the irradiation into multiple regions that partially overlap, the system can cure the resin in the common overlap region to achieve pattern dimensions smaller than the optical system's resolution limit.
Solution Approach 2:
The patent introduces a temporal dimension to the irradiation process by performing multiple irradiation steps at different times. Each step targets a different spatial region, and the cumulative effect in the overlap region over time enables sub-resolution patterning, effectively adding a time dimension to overcome spatial resolution limits.
2Manufacturing precision
If multiple overlapping regions are irradiated to achieve finer patterns, then the pattern resolution improves, but the irradiation process complexity increases
Solution Approach 1:
The patent performs preliminary irradiation of specific regions (R1 to Rn) in a planned sequence, where each irradiation step is pre-configured to contribute to the final pattern in the common overlap region. This preliminary action approach allows the system to build up the required energy distribution over time, achieving fine patterns while managing the total irradiation time through strategic region selection.
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 manufacturing of stereolithographically fabricated objects with finer patterns compared to the resolution of the irradiation optical system, effectively overcoming the size limitations imposed by existing stereolithography techniques.
Implementation Method 1
a photo-curable resin to be cured by exposure to light
Data Source
AI summary
A method for manufacturing a stereolithographically fabricated object includes separately irradiating, with light, respective n regions R1 to Rn of a photo-curable resin, where n is an integer of not less than 2. An overlap area of the region Ri overlaps a part of the region Rj, where i is an integer that satisfies 1≤i≤n and j is an integer that satisfies 1≤j≤n and j≠i. The photo-curable resin is cured in a part or an entirety of the overlap area by irradiating the region Ri with the light.