title: Design and optimization of a light-emitting diode projection micro-stereolithography three-dimensional manufacturing system.
abstract: The rapid manufacture of complex three-dimensional micro-scale components has eluded researchers for decades. Several additive manufacturing options have been limited by either speed or the ability to fabricate true three-dimensional structures. Projection micro-stereolithography (PμSL) is a low cost, high throughput additive fabrication technique capable of generating three-dimensional microstructures in a bottom-up, layer by layer fashion. The PμSL system is reliable and capable of manufacturing a variety of highly complex, three-dimensional structures from micro- to meso-scales with micro-scale architecture and submicron precision. Our PμSL system utilizes a reconfigurable digital mask and a 395 nm light-emitting diode (LED) array to polymerize a liquid monomer in a layer-by-layer manufacturing process. This paper discusses the critical process parameters that influence polymerization depth and structure quality. Experimental characterization and performance of the LED-based PμSL system for fabricating highly complex three-dimensional structures for a large range of applications is presented.
authors.affiliation: Lawrence Livermore National Laboratory, Livermore, California 94550, USA.
authors.forename: Xiaoyu
authors.initials: X
authors.lastname: Zheng
authors.forename: Joshua
authors.initials: J
authors.lastname: Deotte
authors.forename: Matthew P
authors.initials: MP
authors.lastname: Alonso
authors.forename: George R
authors.initials: GR
authors.lastname: Farquar
authors.forename: Todd H
authors.initials: TH
authors.lastname: Weisgraber
authors.forename: Steven
authors.initials: S
authors.lastname: Gemberling
authors.forename: Howon
authors.initials: H
authors.lastname: Lee
authors.forename: Nicholas
authors.initials: N
authors.lastname: Fang
authors.forename: Christopher M
authors.initials: CM
authors.lastname: Spadaccini