Researchers fromStanford Universityhave conducted a study on microfabrication using additive manufacturing, which increases the emerging paradigm shift of building microstructures with AM to revolutionize device design in fields such as medicine and energy storage.
The study,最近在科学进步上发表，描述了工程师在AM中解决多个微加工问题的一种新方法，并启用3D印刷对象，其特性小至1.5微米，这是红细胞的大小的五分之一。The new single-digit-micron resolution technology, dubbed micro-CLIP, allows for 50X smaller part features than commercial CLIP printers while retaining the commercial printers’ high print speed, which is more than 100X quicker than other “state-of-art” high-resolution 3D printing methods suited for microfabrication.
研究强调什么？
The researchers developed and implemented a custom projection lens system consisting of a tube lens and microscope objectives to attain the single-digit-micrometer resolution. Furthermore, due to the extremely narrow depth of field (tens of micrometers) of the high-magnification microscope objectives, the team used a focused algorithm that included an in-line beam splitter and a customizable tube lens to visualize the projection pattern with a CCD camera.
为了找到最佳的焦平面位置，该团队采用了基于对比度的算法和数字设计的网格模式。该团队引用了最佳清晰度位置，并通过400μm的深度进行扫描并评估了对焦点投射的图像堆栈后的实际打印结果确认了性能。根据团队的说法，这种基于对比的聚焦系统解决了专注于高磁化投影光学的狭窄景深的挑战，并使它们能够轻松地重新调整理想焦点平面。
使用孔和线模式从4.5到135μm不等的孔和线模式，评估了具有单位千分尺分辨率的基于夹的3D打印机的分辨率性能。尽管光学分辨率开发为1.5μm，但反复并成功打印的最小特征是18μm孔和6μm线。已经发现，树脂配方，设计模式，光学分辨率，打印策略以及清洁策略对打印机的分辨率和印刷性能有很大的影响。
Following that, the team created a simulation model to offer a deeper understanding of the CLIP printing process as well as directions for creating optimal printing strategies for different designs and materials. The model includes an optical simulation of projection optics through a PSF estimated with a Gaussian distribution, and a lubrication theory prediction of momentum transport and flow field. It also consists of cured height, oxygen concentration gradient, and photopolymerization kinetics modeling to assess dead-zone thickness.
The model offers insights into how to enhance the printing process, such as using a step-by-step printing strategy (for instance, stop-move-expose) to enable effective resin reflow and estimating the necessary interlayer moment to remove resin convection-induced print artifacts. The model also estimates the parameters (oxygen diffusion coefficient and light intensity) needed to keep a constant dead zone for constant printing. Finally, the team demonstrated 3D printing with single-digit-micrometer-resolution CLIP-based 3D printers and the capability to print with viscous elastomeric material.
微分辨率3D打印
之前，Nanofabrica是基于特拉维夫的精确增材制造技术的开发人员，引入了两台工业3D打印机雷电竞充值雷电竞app下载micron-level resolution，即车间系统和工业系统。两种系统都纳入了公司的专利流程，该过程基于数字光处理(DLP) engine, along with自适应光学器件(AO), a technology used to enhance image discrepancies in optical devices like telescopes. This technology is intended for use in the medical, automotive, aerospace, optics, and semiconductor industries to develop parts with micron and sub-micron resolution and surface finishes.
此外，法国超高分辨率3D打印机制造商Microlight3Dreleased the Altraspin sub-micron 3D printer. The machine has a resolution of 0.2µm, which is 100 times smaller than the thickness of human hair. Altraspin 3D printer, which is useful in the fields of micro-robotics, bioengineering, and microsensors, is developed to meet the increasing demand forsub-micron fabrication。The company’s CEO, Denis Barbier, comments, “Microlight3D designed Altraspin to respond to manufacturing demands for more customization and the rapid prototyping of submicron parts that are not constrained by their geometric or organic shape.”
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Feature image shows Single-digit-micrometer-resolution CLIP-based 3D printer setup schematic and printing process. Image via Stanford University.
