Volumetric Additive Manufacturing of Polymer Structures by Holographically Projected Light Fields

Abstract

The experience of completing this doctoral dissertation has been akin to the effort of climbing a tall mountain peakreaching the top, you look around with satisfaction and a sense of accomplishment (and possibly also fatigue), and see all the others who made the climb with you. Just as the tallest peaks are virtually impossible to climb without a team, this PhD is not something that I did alone, and the accomplishment belongs as much to my family, friends, and colleagues as it does to me. Most prominently, I owe an enormous debt of gratitude to my wife Tamar. Thank you for supporting and encouraging this slightly foolish endeavor of a PhD all the way through, in the myriad ways that you did (and the ways I didn't even notice), though I was already prone to bouts of working a little too hard even before I started. Мама и папа, вам я вечно благодарен за прочное основание знаний и любви к учёбe. Вы научили меня что такое старание до последних усилий, и зародили во мне безграничноe любопытство, без которых никакой исследователь из меня не мог бы выйтидоктор или нет. И конечно за тот месяц, что вы провели у нас, позволив мне сделать последний рывок к финишу. To my brother Sasha, thank you for putting me up for every visit to Boston to meet with my committee, and for always keeping me humble. To my kids, thank you for being a constant reminder that life is more than work; I hope one day this thesis might serve as a measure of inspiration to climb your own mountain. Thank you to all the friends who cheered, needled, heckled, commiserated, and cheered again along the way, especially Jessica Blazer, and Dr. Dave Sopchak. In the professional realm, thank you foremost to Chris Spadaccini, my friend and unfailingly supportive center lead, for the trust you place in those who work for you, and the example you set as a leader. To my thesis supervisor Prof. Nick Fang, our longtime collaborator, for being willing to take on a grad student with a very weird arrangement, and to my other committee members Profs. Karl Berggren and Jeff Lang for your guidance and mentorship throughout. To the staff of the MIT EECS Graduate Office, who enabled me to thread the administrative and bureaucratic needles needed to get to this point. The reason I could carry out this research at all is because I'm highly fortunate to work with the additive manufacturing team at LLNL, a truly exceptional group of people. When talking about my job, I always tell people how lucky I am to be able to learn something literally every single day; my generous, creative, and knowledgeable colleagues are the reason why. Thanks especially to Allie Browar for the Kingdom of Cubes, and to James Oakdale and Todd Weisgraber for giving me a framework which allowed me to start filling in the yawning gaps in my understanding of photopolymerization. Thank you to my other colleagues, who are too many to nameyour kindness and advice, technical and otherwise, and good humor most of all give me the real reasons that I like coming in to work every day. To those of my managers who s...

Scalable 3D printing of aperiodic cellular structures by rotational stacking of integral image formation

“…These are challenges that need to be addressed, both to achieve the necessary uniformity for generating desired geometric features and to ensure good printing quality. Advanced lens array technologies [e.g., the aspheric lens design (61) or immersion method (62) and the computational correction procedure by inverse image function obtained after measuring nonuniformity of intensity distribution (12,63,64)] would be possible approaches to the aberration or vignetting issue, but further investigation in this area should be required. Furthermore, we expect that the integral lithographic approach would expand their potentials and flexibility via combining with the functional lens array such as tunable lens (65), multifocal lens (66), or various arrangements of lens array (e.g., hexagonal or nonperiodic) (24,67).…”

Preliminary study on volumetric 3D printing using visible light

“…In recent years AM has shown excellent accuracy with resin polymers as the media for generating components with good tolerance [2]. AM has grown to many different variations that are out in the market, including the 0D method (e.g., Fused Deposition Modeling & Stereolithography), 1D method (e.g., Binder Jetting), 2D (e.g., Digital Light Processing) [3] & 3D (e.g., Volumetric 3D Printing) [4]. All these methods have unique characteristics that make the nal part more usable in different situations based on additives & surface nish.…”

“…Volumetric 3D Printing (V3DP) has focused on the use of light that was near the 400 nm wavelength or less since it has a strong research background for free-radical polymerization with stereolithography-like platforms [4]. Using wavelengths of light in the visible range would help understand better the opportunities of diverting from the UV spectrum of light.…”