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Continuous Volumetric 3D Printing: Xolography in Flow.

Lucas Stüwe1, Matthias Geiger1, Franz Röllgen1

  • 1Chemical Process Engineering, RWTH Aachen University, Forckenbeckstr. 51, 52074, Aachen, Germany.

Advanced Materials (Deerfield Beach, Fla.)
|August 11, 2023
PubMed
Summary

Continuous volumetric 3D printing using xolography overcomes the speed-resolution trade-off. This novel approach enables high-resolution, high-throughput additive manufacturing with flowing photopolymers.

Keywords:
continuous printingflow profile shapingvolumetric 3D printingxolography

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Area of Science:

  • Additive Manufacturing
  • Polymer Science
  • Optical Engineering

Background:

  • Established 3D printing methods face a resolution-speed trade-off due to layer-by-layer processes.
  • Volumetric 3D printing offers high resolution and speed by polymerizing entire volumes simultaneously.
  • Xolography is a volumetric 3D printing technique requiring advancement for continuous production.

Purpose of the Study:

  • To develop a continuous volumetric 3D printing process based on xolography.
  • To enhance production rates and maintain high resolution in light-based additive manufacturing.
  • To address limitations of existing photopolymerization techniques.

Main Methods:

  • Implemented dual-color photopolymerization in a continuously flowing resin within a custom flow cell.
  • Utilized simulations to optimize flow profiles, flattening the printing area and increasing wall velocities.
  • Minimized unwanted polymerization caused by laser sheet-induced curing.

Main Results:

  • Successfully printed various objects continuously with high fidelity and smooth surfaces.
  • Achieved production rates up to 1.75 mm³ s⁻¹ in the developed flow cell.
  • Demonstrated parallel object printing for scalable manufacturing.

Conclusions:

  • Continuous xolography in flow represents a significant advancement in volumetric 3D printing.
  • This method has the potential to resolve the long-standing trade-off between production speed and resolution.
  • Opens new avenues for high-throughput, high-resolution additive manufacturing applications.