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Voxel-Scale Conversion Mapping Informs Intrinsic Resolution in Stereolithographic Additive Manufacturing
Tobin E Brown1, Veruska Malavé1, Callie I Higgins2
1Applied Chemicals and Materials Division, National Institute of Standards and Technology, Boulder, Colorado 80305, United States.
ACS Applied Polymer Materials
|May 22, 2026
Summary
High-resolution 3D printing accuracy is limited by polymerization and diffusion. Controlling these processes is key to achieving dimensionally accurate, mechanically uniform parts in stereolithography.
Area of Science:
- Materials Science
- Chemical Engineering
- Polymer Chemistry
Background:
- High-resolution stereolithography (HSL) often produces printed parts with significant geometric deviations from the intended design.
- These inaccuracies stem from complex reaction dynamics occurring at the voxel scale during the photopolymerization process.
Purpose of the Study:
- To develop and apply a novel technique for measuring local photopolymerization rates.
- To investigate the interplay between polymerization kinetics and oligomer diffusion in thiol-ene resins during HSL.
Main Methods:
- Utilized a nanocylinder-tipped atomic force microscope (AFM) cantilever to measure local photopolymerization rates.
- Correlated cantilever drag force during oscillation to resin viscosity and reaction extent.
- Employed fluid dynamics simulations for micrometer-scale measurement localization and resonance-based detection for submillisecond temporal resolution.
Main Results:
- Oligomer diffusion length scales were found to be significant relative to printed structure sizes in thiol-ene resins.
- Part resolution was determined to be a balance between polymerization rate and diffusion.
- Increased light intensity at a constant dose reduced local conversion and increased geometric aberrations in printed test structures.
Conclusions:
- The competition between polymerization and diffusion critically impacts dimensional accuracy in stereolithography.
- Radical polymerization mechanisms lead to counterintuitive effects of light intensity on conversion and diffusion.
- Enhanced control over both polymerization and diffusion is essential for producing dimensionally accurate and mechanically homogeneous 3D printed parts.
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