来自斯坦福大学have conducted a study on microfabrication using additive manufacturing, which increases the emerging paradigm shift of building microstructures with AM to revolutionize device design in fields such as medicine and energy storage.
研究，published recently in Science Advances, describes a new approach by engineers to addressing multiple microfabrication issues in AM and enabling 3D printed objects with characteristics as small as 1.5 microns—one-fifth the size of a red blood cell. The new single-digit-micron resolution technology, dubbed micro-CLIP, allows for 50X smaller part features than commercial CLIP printers while retaining the commercial printers’ high print speed, which is more than 100X quicker than other “state-of-art” high-resolution 3D printing methods suited for microfabrication.
What does the research highlight?
研究人员开发并实施了一个自定义投影镜头系统，该系统由管透镜和显微镜目标组成，以实现单位微观计分辨率。此外，由于高磁化显微镜目标的极度狭窄（数十微米），该团队使用了一个重点算法，其中包括在线束分配器和可自定义的管镜来可视化投影图案，以CCD可视化投影模式。相机。
To find the optimal focal plane position, the team employed a contrast-based algorithm and digitally designed mesh pattern. The team cited the optimum sharpness location and confirmed the performance with actual print results after scanning through a depth of 400 μm and assessing the through-focus projected image stacks. This contrast-based focusing system, according to the team, solves the challenge of focusing on the narrow depth of field from high-magnification projection optics and enables them to effortlessly readjust to the ideal focal plane.
The resolution performance of the CLIP-based 3D printer with single-digit micrometer resolution was assessed utilizing hole and line patterns with dimensions varying from 4.5 to 135 μm. Although the optical resolution was developed to be 1.5 μm, the smallest features which were repeatedly and successfully printed were 18-μm holes and 6-μm lines. It has been discovered that resin formulation, design patterns, optical resolution, printing strategies, and finally, cleaning strategies have a strong influence on printer resolution and print performance.
在此之后，团队创建了一个模拟模型，以更深入地了解剪辑打印过程以及为不同设计和材料创建最佳打印策略的方向。该模型包括通过高斯分布估计的PSF进行投影光学的光学模拟，以及动量传输和流场的润滑理论预测。它还包括固化的高度，氧浓度梯度和光聚合动力学建模，以评估死区厚度。
该模型提供了有关如何增强打印过程的见解，例如使用分步打印策略（例如，定格式曝光）启用有效的树脂反射并估算必要的室内层矩矩来删除树脂对流诱导的诱导。打印工件。该模型还估算了保持恒定死区以进行恒定打印所需的参数（氧扩散系数和光强度）。最终，该团队展示了具有单位微米计分辨率的3D打印机的3D打印，并具有使用粘性弹性体材料打印的能力。
Micron resolution 3D printing
Previously,纳米, a Tel Aviv-based developer of precision additive manufacturing technologies, introduced two industrial 3D printers withmicron-level resolution, namely, the Workshop System and the Industrial System. Both systems incorporate the company’s patented process, which is based on aDigital Light Processing（DLP）引擎，以及Adaptive Optics(AO), a technology used to enhance image discrepancies in optical devices like telescopes. This technology is intended for use in the medical, automotive, aerospace, optics, and semiconductor industries to develop parts with micron and sub-micron resolution and surface finishes.
Furthermore, French ultra-high-resolution 3D printer manufacturerMicrolight3d释放了altraspin子微米3D打印机。该机器的分辨率为0.2µm，比人头发的厚度小100倍。Altraspin 3D打印机在微型机制，生物工程和微传感器的领域很有用，以满足对日益增长的需求亚微米制造. The company’s CEO, Denis Barbier, comments, “Microlight3D designed Altraspin to respond to manufacturing demands for more customization and the rapid prototyping of submicron parts that are not constrained by their geometric or organic shape.”
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Feature image shows Single-digit-micrometer-resolution CLIP-based 3D printer setup schematic and printing process. Image via Stanford University.
