Vibration-assisted vat photopolymerization for pixelated-aliasing-free surface fabrication
Mask image projection-based vat photopolymerization (MIP-VPP) offers advantages like low cost, high resolution, and a wide material range, making it popular in industry and education. Recently, MIP-VPP employing liquid crystal displays (LCDs) has gained traction, increasingly replacing digital micro...
| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | English |
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IOP Publishing
2024-01-01
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| Series: | International Journal of Extreme Manufacturing |
| Subjects: | |
| Online Access: | https://doi.org/10.1088/2631-7990/ad2e14 |
| _version_ | 1797249030430916608 |
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| author | Han Xu Renzhi Hu Shuai Chen Junhong Zhu Chi Zhou Yong Chen |
| author_facet | Han Xu Renzhi Hu Shuai Chen Junhong Zhu Chi Zhou Yong Chen |
| author_sort | Han Xu |
| collection | DOAJ |
| description | Mask image projection-based vat photopolymerization (MIP-VPP) offers advantages like low cost, high resolution, and a wide material range, making it popular in industry and education. Recently, MIP-VPP employing liquid crystal displays (LCDs) has gained traction, increasingly replacing digital micromirror devices, particularly among hobbyists and in educational settings, and is now beginning to be used in industrial environments. However, LCD-based MIP-VPP suffers from pronounced pixelated aliasing arising from LCD’s discrete image pixels and its direct-contact configuration in MIP-VPP machines, leading to rough surfaces on the 3D-printed parts. Here, we propose a vibration-assisted MIP-VPP method that utilizes a microscale vibration to uniformize the light intensity distribution of the LCD-based mask image on VPP’s building platform. By maintaining the same fabrication speed, our technique generates a smoother, non-pixelated mask image, reducing the roughness on flat surfaces and boundary segments of 3D-printed parts. Through light intensity modeling and simulation, we derived an optimal vibration pattern for LCD mask images, subsequently validated by experiments. We assessed the surface texture, boundary integrity, and dimensional accuracy of components produced using the vibration-assisted approach. The notably smoother surfaces and improved boundary roughness enhance the printing quality of MIP-VPP, enabling its promising applications in sectors like the production of 3D-printed optical devices and others. |
| first_indexed | 2024-04-24T20:24:00Z |
| format | Article |
| id | doaj.art-abaa93fa45d54442ae14f81086458a9b |
| institution | Directory Open Access Journal |
| issn | 2631-7990 |
| language | English |
| last_indexed | 2024-04-24T20:24:00Z |
| publishDate | 2024-01-01 |
| publisher | IOP Publishing |
| record_format | Article |
| series | International Journal of Extreme Manufacturing |
| spelling | doaj.art-abaa93fa45d54442ae14f81086458a9b2024-03-22T06:05:25ZengIOP PublishingInternational Journal of Extreme Manufacturing2631-79902024-01-016303500410.1088/2631-7990/ad2e14Vibration-assisted vat photopolymerization for pixelated-aliasing-free surface fabricationHan Xu0Renzhi Hu1Shuai Chen2Junhong Zhu3Chi Zhou4https://orcid.org/0000-0001-7230-3754Yong Chen5https://orcid.org/0000-0002-8377-5914Center for Advanced Manufacturing, University of Southern California , Los Angeles, CA 90007, United States of America; Daniel J. Epstein Department of Industrial and Systems Engineering, University of Southern California , Los Angeles, CA 90089, United States of AmericaDepartment of Aerospace and Mechanical Engineering, University of Southern California , Los Angeles, CA 90089, United States of AmericaDepartment of Aerospace and Mechanical Engineering, University of Southern California , Los Angeles, CA 90089, United States of AmericaDepartment of Aerospace and Mechanical Engineering, University of Southern California , Los Angeles, CA 90089, United States of AmericaDepartment of Industrial and Systems Engineering, University of Buffalo , Buffalo, NY 14260, United States of AmericaCenter for Advanced Manufacturing, University of Southern California , Los Angeles, CA 90007, United States of America; Daniel J. Epstein Department of Industrial and Systems Engineering, University of Southern California , Los Angeles, CA 90089, United States of America; Department of Aerospace and Mechanical Engineering, University of Southern California , Los Angeles, CA 90089, United States of AmericaMask image projection-based vat photopolymerization (MIP-VPP) offers advantages like low cost, high resolution, and a wide material range, making it popular in industry and education. Recently, MIP-VPP employing liquid crystal displays (LCDs) has gained traction, increasingly replacing digital micromirror devices, particularly among hobbyists and in educational settings, and is now beginning to be used in industrial environments. However, LCD-based MIP-VPP suffers from pronounced pixelated aliasing arising from LCD’s discrete image pixels and its direct-contact configuration in MIP-VPP machines, leading to rough surfaces on the 3D-printed parts. Here, we propose a vibration-assisted MIP-VPP method that utilizes a microscale vibration to uniformize the light intensity distribution of the LCD-based mask image on VPP’s building platform. By maintaining the same fabrication speed, our technique generates a smoother, non-pixelated mask image, reducing the roughness on flat surfaces and boundary segments of 3D-printed parts. Through light intensity modeling and simulation, we derived an optimal vibration pattern for LCD mask images, subsequently validated by experiments. We assessed the surface texture, boundary integrity, and dimensional accuracy of components produced using the vibration-assisted approach. The notably smoother surfaces and improved boundary roughness enhance the printing quality of MIP-VPP, enabling its promising applications in sectors like the production of 3D-printed optical devices and others.https://doi.org/10.1088/2631-7990/ad2e14additive manufacturingvat photopolymerizationpiezo vibrationsub-pixel resolutionaliasing |
| spellingShingle | Han Xu Renzhi Hu Shuai Chen Junhong Zhu Chi Zhou Yong Chen Vibration-assisted vat photopolymerization for pixelated-aliasing-free surface fabrication International Journal of Extreme Manufacturing additive manufacturing vat photopolymerization piezo vibration sub-pixel resolution aliasing |
| title | Vibration-assisted vat photopolymerization for pixelated-aliasing-free surface fabrication |
| title_full | Vibration-assisted vat photopolymerization for pixelated-aliasing-free surface fabrication |
| title_fullStr | Vibration-assisted vat photopolymerization for pixelated-aliasing-free surface fabrication |
| title_full_unstemmed | Vibration-assisted vat photopolymerization for pixelated-aliasing-free surface fabrication |
| title_short | Vibration-assisted vat photopolymerization for pixelated-aliasing-free surface fabrication |
| title_sort | vibration assisted vat photopolymerization for pixelated aliasing free surface fabrication |
| topic | additive manufacturing vat photopolymerization piezo vibration sub-pixel resolution aliasing |
| url | https://doi.org/10.1088/2631-7990/ad2e14 |
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