"On-Axis" Linear Focused Spot Scanning Microstereolithography System: Optomechatronic Design, Analysis and Development

Abstract

Microstereolithography (MSL) is technology of fabrication of three-dimensional (3D) components by using layer-by-layer photopolymerization. Typical design goals of MSL system are: small features, high resolution, high speed of fabrication, and large overall size of component. This paper focuses on design and development of such a system to meet these optomechatronic requirements. We first analyze various optical scanning schemes used for MSL systems along with the proposed scheme via optical simulations and experiments. Next, selection criteria for various subsystems are laid down and appropriate design decisions for the proposed system are made. Further, mechanical design of the scanning mechanism is carried out to meet requirements of high speed and resolution. Finally, system integration and investigation in process parameters is carried out and fabrication of large microcomponent with high resolution is demonstrated. The proposed system would be useful for fabrication of multiple/large microcomponents with high production rate in various applications.