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Paral SK, Lin DZ, Cheng YL, Lin SC, Jeng JY. A Review of Critical Issues in High-Speed Vat Photopolymerization. Polymers (Basel) 2023; 15:2716. [PMID: 37376363 DOI: 10.3390/polym15122716] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/14/2023] [Revised: 06/14/2023] [Accepted: 06/15/2023] [Indexed: 06/29/2023] Open
Abstract
Vat photopolymerization (VPP) is an effective additive manufacturing (AM) process known for its high dimensional accuracy and excellent surface finish. It employs vector scanning and mask projection techniques to cure photopolymer resin at a specific wavelength. Among the mask projection methods, digital light processing (DLP) and liquid crystal display (LCD) VPP have gained significant popularity in various industries. To upgrade DLP and LCC VPP into a high-speed process, increasing both the printing speed and projection area in terms of the volumetric print rate is crucial. However, challenges arise, such as the high separation force between the cured part and the interface and a longer resin refilling time. Additionally, the divergence of the light-emitting diode (LED) makes controlling the irradiance homogeneity of large-sized LCD panels difficult, while low transmission rates of near ultraviolet (NUV) impact the processing time of LCD VPP. Furthermore, limitations in light intensity and fixed pixel ratios of digital micromirror devices (DMDs) constrain the increase in the projection area of DLP VPP. This paper identifies these critical issues and provides detailed reviews of available solutions, aiming to guide future research towards developing a more productive and cost-effective high-speed VPP in terms of the high volumetric print rate.
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Affiliation(s)
- Sandeep Kumar Paral
- High Speed 3D Printing Research Center, National Taiwan University of Science and Technology, No. 43, Sec. 4, Keelung Rd., Taipei 106, Taiwan
- Department of Mechanical Engineering, National Taiwan University of Science and Technology, No. 43, Sec. 4, Keelung Rd., Taipei 106, Taiwan
| | - Ding-Zheng Lin
- Department of Mechanical Engineering, National Taiwan University of Science and Technology, No. 43, Sec. 4, Keelung Rd., Taipei 106, Taiwan
| | - Yih-Lin Cheng
- Department of Mechanical Engineering, National Taiwan University of Science and Technology, No. 43, Sec. 4, Keelung Rd., Taipei 106, Taiwan
| | - Shang-Chih Lin
- High Speed 3D Printing Research Center, National Taiwan University of Science and Technology, No. 43, Sec. 4, Keelung Rd., Taipei 106, Taiwan
- Graduate Institute of Biomedical Engineering, National Taiwan University of Science and Technology, No. 43, Sec. 4, Keelung Rd., Taipei 106, Taiwan
| | - Jeng-Ywan Jeng
- High Speed 3D Printing Research Center, National Taiwan University of Science and Technology, No. 43, Sec. 4, Keelung Rd., Taipei 106, Taiwan
- Department of Mechanical Engineering, National Taiwan University of Science and Technology, No. 43, Sec. 4, Keelung Rd., Taipei 106, Taiwan
- Academy of Innovative Semiconductor and Sustainable Manufacturing, National Cheng Kung University, No. 1, University Rd., Tainan 701, Taiwan
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Zhou S, Jiang L, Dong Z. Overflow Control for Sustainable Development by Superwetting Surface with Biomimetic Structure. Chem Rev 2023; 123:2276-2310. [PMID: 35522923 DOI: 10.1021/acs.chemrev.1c00976] [Citation(s) in RCA: 19] [Impact Index Per Article: 19.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Abstract
Liquid flowing around a solid edge, i.e., overflow, is a commonly observed flow behavior. Recent research into surface wetting properties and microstructure-controlled overflow behavior has attracted much attention. Achieving controllable macroscale liquid dynamics by manipulating the micro-nanoscale liquid overflow has stimulated diverse scientific interest and fostered widespread use in practical applications. In this review, we outline the evolution of overflow and present a critical survey of the mechanism of surface wetting properties and microstructure-controlled liquid overflow in multilength scales ranging from centimeter to micro and even nanoscale. We summarize the latest progress in utilizing the mechanisms to manipulate liquid overflow and achieve macroscale liquid dynamics and in emerging applications to manipulate overflow for sustainable development in various fields, along with challenges and perspectives.
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Affiliation(s)
- Shan Zhou
- CAS Key Laboratory of Bio-inspired Materials and Interfacial Science, Technical Institute of Physics and Chemistry, Chinese Academy of Sciences, Beijing 100190, P. R. China.,School of Future Technology, University of Chinese Academy of Sciences, Beijing 100049, P. R. China
| | - Lei Jiang
- CAS Key Laboratory of Bio-inspired Materials and Interfacial Science, Technical Institute of Physics and Chemistry, Chinese Academy of Sciences, Beijing 100190, P. R. China.,School of Future Technology, University of Chinese Academy of Sciences, Beijing 100049, P. R. China
| | - Zhichao Dong
- CAS Key Laboratory of Bio-inspired Materials and Interfacial Science, Technical Institute of Physics and Chemistry, Chinese Academy of Sciences, Beijing 100190, P. R. China.,School of Future Technology, University of Chinese Academy of Sciences, Beijing 100049, P. R. China
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Hu M, Cheng H, Feng Y. Rotation-Assisted Separation Model of Constrained-Surface Stereolithography. 3D PRINTING AND ADDITIVE MANUFACTURING 2023; 10:146-155. [PMID: 36998802 PMCID: PMC10049864 DOI: 10.1089/3dp.2021.0001] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 05/17/2023]
Abstract
Among a variety of additive manufacturing technologies, constrained-surface image-projection-based stereolithography (SLA) technology has unique advantages in printing precision and commercial maturity. For the constrained-surface SLA process, separating the cured layer from the constrained surface is a crucial step that enables the fabrication of the current layer to accomplish. The separation process limits the accuracy of vertical printing and affects the reliability of fabricating. To reduce the separation force, current existing methods include coating nonsticky film, tilting the tank, sliding the tank, and vibrating the constrained glass. Compared with the above methods, the rotation-assisted separation method presented in this article has the advantages of simple structure and inexpensive equipment. The results of the simulation show that the pulling separation with rotating can reduce the separation force and shorten the separation time effectively. Besides, the timing of rotating is also crucial. A customized rotatable resin tank is used in the commercial liquid crystal display-based three-dimensional printer to reduce the separation force by breaking the vacuum environment between the cured layer and the fluorinated ethylene propylene film in advance. The analyzed results have demonstrated that this method can reduce the maximum separation force and the ultimate separation distance, and the reduction is related to the edge profile of the pattern.
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Affiliation(s)
- Min Hu
- Joint Research Center for Optomechatronics Design and Engineering, School of Optics and Photonic, Beijing Institute of Technology, Beijing, China
| | - Haobo Cheng
- Joint Research Center for Optomechatronics Design and Engineering, School of Optics and Photonic, Beijing Institute of Technology, Beijing, China
- Shenzhen Research Institute, Beijing Institute of Technology, Shenzhen, China
| | - Yunpeng Feng
- Joint Research Center for Optomechatronics Design and Engineering, School of Optics and Photonic, Beijing Institute of Technology, Beijing, China
- Shenzhen Research Institute, Beijing Institute of Technology, Shenzhen, China
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The Effect of Acceleration on the Separation Force in Constrained-Surface Stereolithography. APPLIED SCIENCES-BASEL 2022. [DOI: 10.3390/app12010442] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/04/2023]
Abstract
Constrained-surface-based stereolithography has recently attracted much attention from both academic and industrial communities. Despite numerous experimental, numerical and theoretical efforts, the fundamental need to reduce the separation force between the newly cured part and constrained surface has not yet been completely solved. In this paper, we develop a fluid dynamics approach, proposed in our previous work, to theoretically model the separation force in 3D printing of a cylindrical part for flat and patterned windows. We demonstrate the possibility of separation force reduction with an accelerated movement of the printing platform. In particular, we investigate behaviors of transient parameter, its reduction rate, and separation force reduction with respect to elevation speed and time. The proposed approach involves deceleration and acceleration stages and allows to achieve the force reduction for the entire printing process. Finally, we provide implicit analytical solutions for time moments when switching between the stages can be done without noticeable increase of separation force and explicit expression for separation force in case of patterned window.
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Tseytlin O, O'Connell R, Sivashankar V, Bobko AA, Tseytlin M. Rapid Scan EPR Oxygen Imaging in Photoactivated Resin Used for Stereolithographic 3D Printing. 3D PRINTING AND ADDITIVE MANUFACTURING 2021; 8:358-365. [PMID: 34977276 PMCID: PMC8713732 DOI: 10.1089/3dp.2020.0170] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/14/2023]
Abstract
Oxygen plays a critical role in the photopolymerization process resulting in the formation of solid structures from liquid resins during three-dimensional (3D) printing: it acts as a polymerization inhibitor. Upon exposure to light, oxygen is depleted. As a result, the polymerization process becomes activated. Electron paramagnetic resonance (EPR) imaging is described as a tool to visualize changes in oxygen distribution caused by light exposure. This nondestructive method uses radio waves and, therefore, is not constrained by optical opacity offering greater penetrating depth. Three proof-of-principle imaging experiments were demonstrated: (1) spatial propagation of the photopolymerization process; (2) oxygen depletion as a result of postcuring; and (3) oxygen visualization in a 3D printed spiral model. Commercial stereolithography (SLA) resin was used in these experiments. Lithium octa-n-butoxynaphthalocyanine (LiNc-BuO) probe was mixed with the resin to permit oxygen imaging. Li-naphthalocyanine probes are routinely used in various EPR applications because of their long-term stability and high functional sensitivity to oxygen. In this study, we demonstrate that EPR imaging has the potential to become a powerful visualization tool in the development of 3D printing technology, including bioprinting and tissue engineering.
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Affiliation(s)
- Oxana Tseytlin
- Biochemistry Department, West Virginia University, Morgantown, West Virginia, USA
- In Vivo Multifunctional Magnetic Resonance Center at Robert C. Byrd Health Sciences Center, and West Virginia University, Morgantown, West Virginia, USA
| | - Ryan O'Connell
- Biochemistry Department, West Virginia University, Morgantown, West Virginia, USA
- In Vivo Multifunctional Magnetic Resonance Center at Robert C. Byrd Health Sciences Center, and West Virginia University, Morgantown, West Virginia, USA
| | - Vignesh Sivashankar
- Statler College of Engineering and Mineral Resources, West Virginia University, Morgantown, West Virginia, USA
| | - Andrey A. Bobko
- Biochemistry Department, West Virginia University, Morgantown, West Virginia, USA
- In Vivo Multifunctional Magnetic Resonance Center at Robert C. Byrd Health Sciences Center, and West Virginia University, Morgantown, West Virginia, USA
| | - Mark Tseytlin
- Biochemistry Department, West Virginia University, Morgantown, West Virginia, USA
- In Vivo Multifunctional Magnetic Resonance Center at Robert C. Byrd Health Sciences Center, and West Virginia University, Morgantown, West Virginia, USA
- West Virginia University Cancer Institute, Morgantown, West Virginia, USA
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