Deconvolution volumetric additive manufacturing

Antony Orth (), Daniel Webber (), Yujie Zhang, Kathleen L. Sampson, Hendrick W. Haan, Thomas Lacelle, Rene Lam, Daphene Solis, Shyamaleeswari Dayanandan, Taylor Waddell, Tasha Lewis, Hayden K. Taylor, Jonathan Boisvert and Chantal Paquet
Additional contact information
Antony Orth: National Research Council of Canada
Daniel Webber: National Research Council of Canada
Yujie Zhang: National Research Council of Canada
Kathleen L. Sampson: National Research Council of Canada
Hendrick W. Haan: Ontario Tech University
Thomas Lacelle: National Research Council of Canada
Rene Lam: National Research Council of Canada
Daphene Solis: National Research Council of Canada
Shyamaleeswari Dayanandan: National Research Council of Canada
Taylor Waddell: University of California Berkeley
Tasha Lewis: University of California Berkeley
Hayden K. Taylor: University of California Berkeley
Jonathan Boisvert: National Research Council of Canada
Chantal Paquet: National Research Council of Canada

Nature Communications, 2023, vol. 14, issue 1, 1-11

Abstract: Abstract Volumetric additive manufacturing techniques are a promising pathway to ultra-rapid light-based 3D fabrication. Their widespread adoption, however, demands significant improvement in print fidelity. Currently, volumetric additive manufacturing prints suffer from systematic undercuring of fine features, making it impossible to print objects containing a wide range of feature sizes, precluding effective adoption in many applications. Here, we uncover the reason for this limitation: light dose spread in the resin due to chemical diffusion and optical blurring, which becomes significant for features ⪅0.5 mm. We develop a model that quantitatively predicts the variation of print time with feature size and demonstrate a deconvolution method to correct for this error. This enables prints previously beyond the capabilities of volumetric additive manufacturing, such as a complex gyroid structure with variable thickness and a fine-toothed gear. These results position volumetric additive manufacturing as a mature 3D printing method, all but eliminating the gap to industry-standard print fidelity.

Date: 2023
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DOI: 10.1038/s41467-023-39886-4

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