Fast Speed, Multi-Scale Additive Manufacturing Process based on Dynamic Resolution Control Approach

Additive Manufacturing (AM) is a class of technologies that possess formation of 3D parts in a layer-by-layer fashion. Mask Image Projection Stereolithography (MIP-SL) is a sub-branch of AM in which parts are fabricated by curing photopolymer liquid resin using sliced digital mask images. In a typical MIP-SL system, it is critical to make a trade-off between the resolution and build area for applications in which varied dimensional sizes, feature sizes, and accuracies are desired. The lack of the capability in adjusting resolution dynamically during building processes limits the use of AM in fabricating complex structures with big layer areas and small features. In this paper, a novel AM system with dynamic resolution control by integrating a compact laser projector in vat photo-polymerization process is presented. Theoretical models and parameter characterizations are presented for the developed AM system. Accordingly, the process planning and mask image planning approaches for fabricating models with varied dimensional sizes and feature sizes have been developed. Multiple test cases based on various types of structures have been performed. Moreover, to fully utilize the benefits of the compact laser projector, a portable, compact size, and low-cost 3D printing setup with an added feature of using a smart phone has been designed and constructed. The dimension of the prototype machine is 7.8 x 7.0 inch, smaller than the paper size. An IPhone is used as the source to transfer the sliced images to the laser projector in the modified hardware setup.