0
Technical Brief

Fast Mask Image Projection-Based Micro-Stereolithography Process for Complex Geometry

[+] Author and Article Information
Yayue Pan

Mem. ASME
Department of Mechanical and Industrial Engineering,
University of Illinois at Chicago,
842 W. Taylor Street,
ERF 2039,
Chicago, IL 60607
e-mail: yayuepan@uic.edu

Yong Chen

Mem. ASME
Epstein Department of Industrial and Systems Engineering,
University of Southern California,
3715 McClintock Avenue,
GER 201,
Los Angeles, CA 90089
e-mail: yongchen@usc.edu

Zuyao Yu

School of Ship and Ocean Engineering,
Huazhong University of Science and Technology,
1037 Luoyu Road,
East Building 2-118,
Wuhan 430074, Hubei
e-mail: yuzuyao@163.com

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO- AND NANO-MANUFACTURING. Manuscript received April 19, 2016; final manuscript received November 30, 2016; published online January 6, 2017. Assoc. Editor: Cheryl Xu.

J. Micro Nano-Manuf 5(1), 014501 (Jan 06, 2017) (6 pages) Paper No: JMNM-16-1013; doi: 10.1115/1.4035388 History: Received April 19, 2016; Revised November 30, 2016

In micro-stereolithograhy (μSL), high-speed fabrication is a critical challenge due to the long delay time for refreshing resin and retaining printed microfeatures. Thus, the mask-image-projection-based micro-stereolithograhy (MIP-μSL) using the constrained surface technique is investigated in this paper for quickly recoating liquid resin. It was reported in the literature that severe damages frequently happen in the part separation process in the constrained-surface-based MIP-μSL system. To conquer this problem, a single-layer movement separation approach was adopted, and the minimum delay time for refreshing resin was experimentally characterized. The experimental results verify that, compared with the existing MIP-μSL processes, the MIP-μSL process with single-layer movement separation method developed in this paper can build microstructures with complex geometry, with a faster build speed.

FIGURES IN THIS ARTICLE
<>
Copyright © 2017 by ASME
Your Session has timed out. Please sign back in to continue.

References

Varadan, V. K. , Jiang, X. , and Varadan, V. V. , 2001, Microstereolithography and Other Fabrication Techniques for 3D MEMS, Wiley, DeKalb, IL, Chap. 1.
Hirata, Y. , 2003, “ LIGA Process–Micromachining Technique Using Synchrotron Radiation Lithography–and Some Industrial Applications,” Nucl. Instrum. Methods Phys. Res. Sect. B, 208, pp. 21–26. [CrossRef]
Ikuta, K. , and Hirowatari, K. , 1993, “ Real Three Dimensional Micro Fabrication Using Stereo Lithography and Metal Molding,” An Investigation of Micro Structures, Sensors, Actuators, Machines and Systems, IEEE, Fort Lauderdale, FL, pp. 42–47.
Ikuta, K. , Ogata, T. , Tsubio, M. , and Kojima, S. , 1996, “ Development of Mass Productive Micro Stereo Lithography (Mass-IH Process),” An Investigation of Micro Structures, Sensors, Actuators, Machines and Systems, IEEE, San Diego, CA, pp. 301–306.
Zhang, X. , Jiang, X. N. , and Sun, C. , 1999, “ Micro-Stereolithography of Polymeric and Ceramic Microstructures,” Sens. Actuators A, 77(2), pp. 149–156. [CrossRef]
Saxena, I. , Malhotra, R. , Ehmann, K. , and Cao, J. , 2015, “ High-Speed Fabrication of Microchannels Using Line-Based Laser Induced Plasma Micromachining,” J. Micro Nano Manuf., 3(2), p. 021006. [CrossRef]
Saxena, I. , Wolff, S. , and Cao, J. , 2015, “ Unidirectional Magnetic Field Assisted Laser Induced Plasma Micro-Machining,” Manuf. Lett., 3, pp. 1–4. [CrossRef]
Cheng, Y. L. , and Lee, M. L. , 2009, “ Development of Dynamic Masking Rapid Prototyping System for Application in Tissue Engineering,” Rapid Prototyping J., 15(1), pp. 29–41. [CrossRef]
Choi, J. , Wicker, R. , Lee, S. , Choi, K. , Ha, C. , and Chung, I. , 2009, “ Fabrication of 3D Biocompatible/Biodegradable Micro-Scaffolds Using Dynamic Mask Projection Microstereolithography,” J. Mater. Process. Technol., 209(15), pp. 5494–5503. [CrossRef]
Ikuta, K. , Hirowatari, K. , and Ogata, T. , 1994, “ Three Dimensional Micro Integrated Fluid Systems (MIFS) Fabricated by Stereo Lithography,” IEEE Workshop on Micro Electro Mechanical Systems, IEEE, Oiso, Japan, Jan. 25–28.
Sun, C. , Fang, N. , Wu, D. M. , and Zhang, X. , 2005, “ Projection Micro-Stereolithography Using Digital Micro-Mirror Dynamic Mask,” Sens. Actuators A: Phys., 121(1), pp. 113–120. [CrossRef]
Choi, J. S. , Kang, H. W. , Lee, I. H. , Ko, T. J. , and Cho, D. W. , 2009, “ Development of Micro-Stereolithography Technology Using a UV Lamp and Optical Fiber,” Int. J. Adv. Manuf. Technol., 41(3–4), pp. 281–286. [CrossRef]
Xu, G. , Zhao, W. , Tang, Y. , and Lu, B. , 2006, “ Novel Stereolithography System for Small Size Objects,” Rapid Prototyping J., 12(1), pp. 12–17. [CrossRef]
Bártolo, P. J. , ed., 2011, Stereolithography: Materials, Processes and Applications, Springer Science & Business Media, Berlin, Germany, Chap. 1.
Hadipoespito, G. W. , 2004, “ Digital Micromirror Device (DMD) Based Integral Microstereolithography,” Ph.D. thesis, University of Wisconsin-Madison, Madison, WI.
Dendukuri, D. , Pregibon, D. C. , Collins, J. , Hatton, T. A. , and Doyle, P. S. , 2006, “ Continuous-Flow Lithography for High-Throughput Microparticle Synthesis,” Nat. Mater., 5(5), pp. 365–369. [CrossRef] [PubMed]
Pan, Y. , Zhou, C. , and Chen, Y. , 2012, “ A Fast Mask Projection Stereolithography Process for Fabricating Digital Models in Minutes,” ASME J. Manuf. Sci. Eng., 134(5), p. 051011. [CrossRef]
Limaye, A. S. , and Rosen, D. W. , 2007, “ Process Planning Method for Mask Projection Micro-Stereolithography,” Rapid Prototyping J., 13(2), pp. 76–84. [CrossRef]
Choi, J. W. , Ha, Y. M. , Lee, S. H. , and Choi, K. H. , 2006, “ Design of Microstereolithography System Based on Dynamic Image Projection for Fabrication of Three-Dimensional Microstructures,” J. Mech. Sci. Technol., 20(12), pp. 2094–2104. [CrossRef]
Takagi, T. , and Nakajima, N. , 1994, “ Architecture Combination by Micro Photoforming Process,” IEEE Workshop on Micro Electro Mechanical Systems, IEEE, Oiso, Japan, pp. 211–216.
Bertsch, A. , Bernhard, P. , Vogt, C. , and Renaud, P. , 2000, “ Rapid Prototyping of Small Size Objects,” Rapid Prototyping J., 6(4), pp. 259–266. [CrossRef]
Monneret, S. , Loubere, V. , and Corbel, S. , 1999, “ Microstereolithography Using a Dynamic Mask Generator and a Noncoherent Visible Light Source,” Design, Test, and Microfabrication of MEMS/MOEMS, International Society for Optics and Photonics, Paris, France, pp. 553–561.
Monneret, S. , Provin, C. , and Le Gall, H. , 2001, “ Micro-Scale Rapid Prototyping by Stereolithography,” 8th IEEE International Conference on Emerging Technologies and Factory Automation, Juan les Pins, France, Vol. 2, pp. 299–304.

Figures

Grahic Jump Location
Fig. 6

Software setup of the developed fast micro-stereolithography and the related process flowchart

Grahic Jump Location
Fig. 5

Hardware setup of the developed MIP-μSL testbed

Grahic Jump Location
Fig. 4

Build time of a layer in a constrained-surface MIP-μSL process with the proposed single-layer movement approach

Grahic Jump Location
Fig. 3

The flow-filling time with different Z movement distance

Grahic Jump Location
Fig. 2

Test results for identifying the minimum gap size and waiting time: (a) CAD model; (b) built part with insufficient waiting time; (c) void-free parts; (d) surface with a hole; (e) shadows due to incomplete filling; and (f) void-free surface

Grahic Jump Location
Fig. 1

Schematic of MIP-μSL systems based on the top–down projection method (a) and the bottom–up projection method (b)

Grahic Jump Location
Fig. 7 A

microgear: (a) CAD model; (b) built part; and (c) microscopic image

Grahic Jump Location
Fig. 8

A turbofan: (a) CAD model and (b) microscopic image of the built part

Grahic Jump Location
Fig. 9

A hearing-aid: (a) CAD model with added supports; (b) built physical object; and (c) microscopic image of the built part (top view)

Grahic Jump Location
Fig. 10

A threaded pipe: (a) CAD model of the pipe and (b)–(e) built physical object

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In