Three-Dimensional Printing of Large Objects with High Resolution by Dynamic Projection Scanning Lithography

Area of Science:

• Additive Manufacturing
• Materials Science
• Optical Engineering

Background:

• Light-cured 3D printing, including DLP and SLA, is crucial for prototypes but struggles with large volumes, high resolution, and speed.
• Existing stereolithography-based methods face limitations in processing size and rate, hindering industrial adoption for large components.

Purpose of the Study:

• To introduce a dynamic projection 3D printing technology using a digital micro-mirror device (DMD).
• To address the limitations of traditional methods in achieving large-size, high-resolution, and high-speed 3D printing.
• To enable advanced applications in industrial sectors like automotive and aviation.

Main Methods:

• Utilizes a digital micro-mirror device (DMD) to project ultraviolet light patterns dynamically, curing resin in an "animation"-like process.
• Slices 3D models into high-resolution sectional and sub-regional images, dynamically exposing them.
• Synchronizes image projection with scanning lens motion to create static exposure patterns, incorporating digital super-resolution.

Main Results:

• Achieves layering and fine printing of large objects up to 400 × 400 × 200 mm.
• Attains a minimum feature size of 45 μm, demonstrating high precision.
• Exhibits superior printing speed and material bending characteristics compared to existing DLP methods.

Conclusions:

• The dynamic projection 3D printing technology effectively enables large-size, high-precision structural printing.
• This advancement supports industrial fields such as automotive and aviation for design, verification, and production.
• The technology offers significant improvements over traditional DLP light-curing methods in speed and material properties.