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    Tomographic Volumetric Additive Manufacturing (TVAM) can now achieve sub-20µm resolution. A new wave-based optical optimization scheme overcomes limitations of current ray optics for high-resolution 3D printing.

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    Area of Science:

    • Additive Manufacturing
    • Optical Engineering
    • Materials Science

    Background:

    • Tomographic Volumetric Additive Manufacturing (TVAM) enables rapid 3D printing of mesoscopic objects.
    • Current TVAM relies on ray optics for pattern optimization, limiting resolution to approximately 20 µm and causing variations within the printed volume.

    Purpose of the Study:

    • To introduce a rigorous wave-based optical amplitude optimization scheme for TVAM.
    • To demonstrate the theoretical possibility of achieving high-resolution printing throughout the entire volume of 3D objects using TVAM.

    Main Methods:

    • Developed an efficient angular spectrum method of plane waves for wave optical optimization.
    • Implemented custom memory-efficient gradients for optimizing realistic TVAM volumes (e.g., (100 µm)³ or (10 mm)³ with 550³ voxels and 600 angles).

    Main Results:

    • Simulations revealed that ray optics produce artifacts for features 20 µm and below.
    • The amplitude-modulated TVAM, optimized using the full wave model, can achieve sub-20 µm features.

    Conclusions:

    • Wave-based optical optimization significantly enhances resolution in TVAM compared to ray optics.
    • This advanced method enables high-fidelity 3D printing of intricate structures with sub-20 µm resolution across the entire printed volume.