Multi-Scale Stereolithography Using Shaped Beams

[+] Author and Article Information
Yong Chen

3715 McClintock Avenue, GER240 Los Angeles, CA 90089

Huachao Mao

2676 Ellendale Place Los Angeles, CA 90007

Yuen-Shan Leung

3715 McClintock Ave, GER240 Los Angeles, CA 90089

Yuanrui Li

3740 McClintock Ave Los Angeles, CA 90089

Pan Hu

3740 McClintock Ave Los Angeles, CA 90089

Wei Wu

3740 McClintock Ave Los Angeles, CA 90089

1Corresponding author.

ASME doi:10.1115/1.4037832 History: Received June 13, 2017; Revised August 28, 2017


Current Stereolithography (SL) can fabricate three-dimensional (3D) objects in a single scale level, e.g. printing macro-scale or micro-scale objects. However, it is difficult for the SL printers to fabricate a 3D macro-scale object with micro-scale features. In the paper a novel SL-based multi-scale fabrication method is presented to address such a problem. The developed SL process can fabricate multi-scale features by dynamically changing the shape and size of a laser beam. Different shaped beams are realized by switching apertures with different micro-patterns. The laser beam without using micro-patterns is used to fabricate macro-scale features, while the shaped laser beams based on small apertures are used to fabricate micro-patterned features. Accordingly, a tool path planning method for the multi-scale fabrication process is presented to build macro-scale and micro-scale features using different layer thicknesses, laser exposure time, and scanning paths. Compared with the conventional SL process using a fixed laser beam size, our process can manufacture multi-scale features in a 3D object with fast fabrication speed and good surface quality.

Copyright (c) 2017 by ASME
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