Three-Dimensional Printing of Large Objects with High Resolution by Dynamic Projection Scanning Lithography

Abstract

Due to the development of printing materials, light-cured 3D printing is playing an increasingly important role in industrial and consumer markets for prototype manufacturing and conceptual design due to its advantages in high-precision and high-surface finish. Despite its widespread use, it is still difficult to achieve the 3D printing requirements of large volume, high resolution, and high speed. Currently, traditional light-cured 3D printing technologies based on stereolithography, such as regular DLP and SLA, can no longer meet the requirements of the processing size and processing rate. This paper introduces a dynamic projection of 3D printing technology utilizing a digital micro-mirror device (DMD). By projecting the ultraviolet light pattern in the form of “animation”, the printing resin is continuously cured in the exposure process to form the required three-dimensional structure. To print large-size objects, the three-dimensional model is sliced into high-resolution sectional images, and each layer of the sectional image is further divided into sub-regional images. These images are dynamically exposed to the light-curing material and are synchronized with the scanning motion of the projection lens to form a static exposure pattern in the construction area. Combined with the digital super-resolution, this system can achieve the layering and fine printing of large-size objects up to 400 × 400 × 200 mm, with a minimum feature size of 45 μm. This technology can achieve large-size, high-precision structural printing in industrial fields such as automobiles and aviation, promoting structural design, performance verification, product pre-production, and final part processing. Its printing speed and material bending characteristics are superior to existing DLP light-curing 3D printing methods.

Research on the large-format splicing method for stamping-type digital light processing 3D printing

“…Lin Chunbo and others designed a dynamic projection scanning 3D printing exposure system, realizing two-dimensional directional scanning exposure, namely, a printing method where lines form surfaces [25]. By intermittently displaying maskless images through Digital Micromirror Device (DMD), the 3D printing of large-area microfluidic devices has been achieved [26].…”

The Feature Resolution and Dimensional Control in Freeform Solidification of Alumina Systems by Stereolithography

“…In another study, the cure depth and width were examined as a function of energy dose using a fixed compositional variable that was chosen based on its desirable rheological properties [26]. Additionally, the feature resolution, printing scale, and speed were also shown to be improved by developing a printer that uses a dynamic projection scanning lithography technique with digital super resolution [27]. In our previous study, the impact of layer thickness and energy dose on interlayer adhesion and dimensional control was examined using commercial feedstock with fixed compositional variables and a limited energy dose range [28].…”

Cost-Effective Laboratory Matrix Projection Micro-Lithography System

“…Maskless projection lithography seems very promising, as it allows drawing arbitrary patterns similar to laser lithography. Projection lithography technologies, utilizing DMD (digital micro-mirror device) matrices, have changed various fields, ranging from 3D printing and sensors to microfluidics and medicine [ 6 , 7 , 8 , 9 , 10 , 11 ]. Generally, lithography in the laboratory should be performed on relatively tiny substrates (∼1 cm × 1 cm or even less) and does not need to be aligned over a 2–4 inch wafer size.…”