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Updated: May 15, 2025

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Non-Sticky Display Eliminates Surface Roughness and Interface Adhesion: Enabling Large-Scale LCD-Based 3D Printing.

Sandeep Kumar Paral1,2, Jeng-Ywan Jeng1,2,3,4, Guan-Wei Lin2

  • 1Taiwan High Speed 3D Printing Research Center, National Taiwan University of Science and Technology, No. 43, Sec. 4, Keelung Rd., Taipei, 106, Taiwan.

Small (Weinheim an Der Bergstrasse, Germany)
|April 11, 2025
PubMed
Summary

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This study introduces a non-sticky display (NSD) using structured PDMS film to overcome surface roughness and adhesion issues in liquid crystal display (LCD)-based vat photopolymerization (VPP). The NSD approach significantly reduces surface roughness and separation forces, enabling high-resolution printing of complex parts.

Area of Science:

  • Materials Science
  • Additive Manufacturing
  • Polymer Chemistry

Background:

  • Liquid crystal display (LCD)-based vat photopolymerization (VPP) offers high resolution and cost-effectiveness for polymer 3D printing.
  • Key challenges hindering LCD-VPP adoption include surface roughness from the LCD's black matrix and interface adhesion issues.
  • Existing methods struggle to simultaneously address both surface texture and interfacial bonding.

Purpose of the Study:

  • To develop a novel non-sticky display (NSD) approach to mitigate surface roughness and interface adhesion in LCD-VPP.
  • To investigate the efficacy of sub-micron structured polydimethylsiloxane (PDMS) film for improving print quality and material compatibility.
  • To demonstrate the potential of the NSD approach for printing large-scale, complex geometries with enhanced properties.
Keywords:
3D printingLCD VPPelectrostatic chargeinterface adhesionpixelated effectsub‐micron roughness

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Main Methods:

  • A non-sticky display (NSD) was engineered by laminating a sub-micron structured polydimethylsiloxane (PDMS) film onto an LCD panel.
  • The structured PDMS surface was optimized to create a stable Cassie state, trapping air for hydrophobicity and low adhesion.
  • Electrostatic interactions between the LCD panel and printing interface were eliminated using the PDMS layer.

Main Results:

  • The optimized NSD 2000 configuration reduced surface roughness by 82.5% while maintaining print resolution.
  • The structured surface imparted hydrophobic properties and significantly lowered the work of adhesion.
  • Separation energy was reduced by up to 52% for high-viscosity foam resin, and separation force decreased 8-fold for acrylate resin.
  • Successful printing of large-scale, complex geometries using challenging materials was achieved.

Conclusions:

  • The NSD approach effectively addresses critical challenges in LCD-VPP, namely surface roughness and interface adhesion.
  • The sub-micron structured PDMS film enables controlled light diffusion and stable air-trapping for improved printing performance.
  • This advancement facilitates the development of functional parts with enhanced mechanical and optical properties via LCD-VPP.